Laser-Applied Polyurethane Markings for Catheter Imaging
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Solution Overview
Problem
Current medical devices, particularly catheters, face challenges in visibility during ultrasound and radiographic imaging due to their materials' poor echogenicity and radiographic contrast, making precise placement and inspection difficult.
Innovation Solution
A method involving a polyurethane coating with embedded particle films, where specific regions are selectively dried and crosslinked using a laser, allowing for high-geometric-variability markings that enhance visibility in both radiological and sonographic imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radiopaque markers are implemented as solid metal bands or coatings, then radiographic visibility is improved, but device flexibility is worsened and structural integrity deteriorates
Solution Approach 1:
The patent uses composite materials consisting of a polymer matrix combined with radiopaque particles (such as barium sulfate, tungsten, or tantalum) to create markers that maintain both radiographic visibility and device flexibility. This composite approach allows the marker to achieve sufficient X-ray contrast while remaining integrated with and flexible like the catheter shaft material.
Solution Approach 2:
The patent applies radiopaque markers only at specific locations along the catheter (such as at the distal end or at intervals) rather than throughout the entire length. This localized application provides necessary radiographic visibility at critical positions while preserving the overall flexibility and softness of the catheter in non-marked regions.
2Measurement precision
If high volume fractions of radiopaque material are used, then radiographic contrast is improved, but device profile is worsened due to increased wall thickness
Solution Approach 1:
The patent optimizes the parameters of the radiopaque marker including particle size (typically 1-50 micrometers), volume fraction (10-50%), and distribution density to achieve sufficient radiographic contrast with minimal wall thickness. By controlling these parameters, the marker provides adequate X-ray visibility while maintaining a streamlined catheter profile suitable for navigation through blood vessels.
Solution Approach 2:
The patent uses radiopaque particles suspended in a polymer matrix that can be applied as a thin coating or integrated into the catheter wall during manufacturing. This approach creates an effective radiographic marker without requiring thick solid metal layers, as the high-density particles provide sufficient contrast even at low concentrations and thin sections.
3Measurement precision
If metallic markers are used, then radiographic visibility is improved, but manufacturing cost and attachment complexity increase
Solution Approach 1:
The patent combines the radiopaque marker material with the catheter shaft material into a single integrated structure. The radiopaque particles are mixed into the polymer matrix during the extrusion or molding process, creating a unified component that eliminates separate attachment steps. This merging of marker and shaft reduces manufacturing complexity while maintaining effective radiographic visibility.
Solution Approach 2:
The patent employs cost-effective radiopaque particles such as barium sulfate that can be readily incorporated into the catheter manufacturing process. These materials provide sufficient radiographic contrast for their intended use duration and are economically viable for single-use medical devices, reducing overall manufacturing costs compared to precious metal alternatives.
4Measurement precision
If the entire catheter is filled with radiopaque substances, then radiodiagnostics visibility is improved, but device weight and stiffness increase
Solution Approach 1:
The patent applies radiopaque substances only to specific segments or regions of the catheter (such as the distal end or intermediate sections) rather than filling the entire catheter length. This localized radiopacity provides sufficient detectability for tracking catheter position and orientation during procedures while minimizing overall weight and preserving the flexibility needed for navigation through tortuous vasculature.
Solution Approach 2:
The patent uses composite materials with radiopaque particles dispersed in a lightweight polymer matrix, providing radiographic visibility without the density and weight of solid metal construction. This composite approach achieves adequate detectability with minimal weight increase, as the low-density polymer base material keeps the overall catheter mass low.
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 method achieves high radiopacity and echogenicity, allowing for precise imaging and detection of catheter positions and movements, while maintaining the transparency and structural integrity of the catheter.
Implementation Method 1
specific regions are selectively dried and crosslinked using a laser
Implementation Method 2
specific regions are selectively dried
Implementation Method 3
high radiopacity
Implementation Method 4
high echogenicity
Data Source
AI summary
The invention relates to a method for creating visibility-enhancing markers which can be applied onto a wide variety of materials with a very high degree of geometric variability and which can be used both for radiological as well as for sonographic applications. According to the invention, this is achieved substantially by way of novel markings created by means of a polyurethane coating into which a particle film with functional properties and high particle density is embedded. By using a laser, only targeted coating regions in selected areas are dried and chemically cross-linked. Exposed areas are created by subsequently rinsing off non-irradiated coating material. The markings can thus be created in any geometric shape.