Laser-Cut Catheter Tubes for Variable Stiffness and Torque Transmission
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Solution Overview
Problem
Conventional catheter devices face limitations in achieving a balanced stiffness profile, particularly in micro-machining techniques, which struggle to achieve desired cut parameters and geometries for flexibility, tensile strength, and torque transmission.
Innovation Solution
A catheter device with a tube member featuring distinct cut patterns and parameters, including varying pitches, cut lengths, and uncut lengths in the distal and proximal portions, along with a transition portion, to enhance flexibility and torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-machining techniques are used to create reinforcement layers, then manufacturing precision can be improved, but processing speed and ability to achieve desired cut parameters and geometries deteriorates
Solution Approach 1:
The patent replaces traditional mechanical micro-machining techniques with laser technology. The laser system uses optical energy instead of mechanical cutting elements to create precise cuts in the hypotube. This substitution enables achievement of desired cut parameters and geometries (improving manufacturing precision) while eliminating the speed limitations inherent in mechanical micro-machining (improving productivity).
Solution Approach 2:
The patent changes the fundamental parameter of the cutting process from mechanical force to laser energy. By using laser power, focal spot size, scan speed, and pulse duration as controllable parameters, the system can achieve precise cut geometries while operating at higher speeds than mechanical methods. This parameter change resolves the contradiction between precision and speed.
2Strength
If the metal reinforcement layer is made stiffer to improve torque transmission, then torque transmission is improved, but bending flexibility deteriorates
Solution Approach 1:
The patent applies segmentation by creating multiple discrete cuts in the hypotube wall. These cuts divide the continuous metal reinforcement into segmented sections that can flex independently. The segmentation allows the reinforcement layer to maintain torque transmission capability through the remaining metal bridges while achieving the desired bending flexibility through the cut gaps.
Solution Approach 2:
The patent applies local quality by varying the cut parameters (depth, width, spacing, pattern) at different locations along the hypotube length. The distal portion has different cut characteristics than the proximal portion, allowing each section to have optimized local properties for its specific functional requirements while maintaining overall device performance.
3Ease of operation
If variable stiffness profile is implemented with flexible distal end, then ease of operation in tortuous anatomy is improved, but torque transmission capability deteriorates
Solution Approach 1:
The patent applies dynamics by creating a variable stiffness profile along the length of the hypotube through progressive changes in cut parameters. The transition from fewer/shallower cuts in the proximal portion to more/deeper cuts in the distal portion creates a dynamic stiffness gradient that adapts to different operational requirements at different locations.
Solution Approach 2:
The patent adds the dimensional aspect of axial variation to the cut pattern design. By varying cut parameters along the longitudinal axis in addition to radial and circumferential parameters, the invention creates a three-dimensional optimization of the reinforcement structure that simultaneously achieves flexibility where needed and torque transmission where required.
Data Source
AI summary
A catheter device includes a tube member. The tube member comprises a distal portion and a proximal portion. Each of the distal portion and the proximal portion of the tube member comprises a plurality of cuts circumferentially extending around a longitudinal axis of the tube member. The plurality of cuts of the distal portion of the tube member comprises a first pitch, a first cut length, and a first uncut length, the plurality of cuts of the proximal portion of the tube member comprises a second pitch, a second cut length, and a second uncut length, and the first pitch is less than the second pitch, the first cut length is greater than the second length, and the first uncut length is less than the second uncut length.