Inverted Balloon Bonding For Secure Swappable Earpiece Tips

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Solution Overview

Problem

Inflatable acoustic systems face challenges in maintaining the bonding of a balloon to a stent upon insertion, and there is a lack of pressure management systems designed for inflatable earpieces.

Innovation Solution

The method involves bonding a sheath balloon to a stent with an inverted bond, using a mold to form the bond, and incorporating a pressure management system with a valve, inflation channel, pressure release mechanism, and pump to manage balloon inflation pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional bonding method is used to attach the balloon to the stent, then the bonding process is simple, but the bonding security is insufficient upon insertion

Engineering Contradiction:

Improvebonding securityVSAvoidbonding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The balloon is inverted inside the molding cavity during injection molding, allowing the bonding surface to be formed on the inner surface of the balloon. This inverted configuration enables the bonding adhesive to be applied to the inner surface that contacts the stent, creating a more secure bond that withstands insertion forces while maintaining a relatively simple one-step molding process

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If no pressure management system is used, then the device structure is simpler, but the inflation pressure cannot be maintained optimally

Engineering Contradiction:

Improveinflation pressure maintenanceVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pressure management system incorporates a pressure-sensitive valve integrated into the balloon structure that automatically responds to pressure changes. When inflation pressure reaches a predetermined level, the valve automatically opens to release excess pressure, and when pressure drops, it closes to maintain pressure. This self-regulating mechanism optimizes inflation pressure maintenance without requiring complex external control systems

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses pneumatic principles with a pressure-sensitive valve that utilizes pressure differential to control inflation and deflation. The valve responds to pressure changes within the balloon, allowing automatic pressure regulation through fluid (air) dynamics without mechanical complexity

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Strength

If a standard balloon configuration is used, then the manufacturing process is simpler, but the bonding fails under insertion stress

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The bonding surface is prepared during the injection molding process itself, with the adhesive applied to the inner surface of the balloon before final bonding to the stent. The balloon is pre-formed with the bonding layer in place during manufacturing, so that when the stent is inserted and inflated, the bond is already positioned and configured to withstand insertion stresses without requiring additional bonding steps

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The inverted bond ensures secure attachment of the balloon to the stent, while the pressure management system maintains optimal inflation pressure and releases excess pressure effectively.

Implementation Method 1

a first valve, where the first valve allows air to pass from a first side of the valve to a second side more readily than from the second side to the first side

Methodology Applied

Scientific EffectValve mechanism: Valve

Implementation Method 2

a pump; a stent, where the inflation channel is embedded; and a balloon, where the first valve, the inflation channel, the pressure release mechanism, the pump, and the balloon are operatively connected

Methodology Applied

Scientific EffectCompression: Compression