Laser-Welded Catheter Tip Guide Rings for Precise Bending
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Solution Overview
Problem
Bendable medical devices with small diameters and high curvature requirements face challenges due to the rigidity added by inner and outer liners, and the inconsistent bonding of guide rings using adhesives, which affects the device's flexibility and functionality.
Innovation Solution
The use of laser welding to attach guide rings to the inner and outer liners, or extrusions, without altering the lumen sections, ensuring precise spacing and strong bonding, replacing traditional adhesive methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to attach guide rings to inner liner, then guide rings can be attached to the device, but the adhesive acts like a lubricant causing components to move and spacing becomes inconsistent
Solution Approach 1:
The patent replaces the chemical bonding mechanism of adhesives with a mechanical/thermal bonding mechanism using laser welding. The laser welder melts and fuses the guide ring to the inner liner, creating a permanent mechanical bond that prevents guide ring movement and maintains precise spacing during the bonding process and throughout device operation.
Solution Approach 2:
The patent utilizes the phase transition of the thermoplastic material from solid to molten state during laser welding. The laser energy heats the guide ring and inner liner material to its melting point, allowing the materials to fuse together upon cooling. This phase transition enables strong, permanent bonding without the lubricating effect of adhesives.
2Ease of manufacture
If adhesive is applied manually to attach guide rings, then guide rings can be attached to the device, but the bond strength is inconsistent and lower than required for catheter durability
Solution Approach 1:
The patent replaces manual adhesive application with an automated laser welding process. The laser welder systematically moves along the guide ring, providing consistent energy input and controlled melting. This automation eliminates the variability of manual application and ensures uniform bond strength around the entire guide ring, meeting the durability requirements for catheter operation.
Solution Approach 2:
The patent incorporates preliminary positioning of the guide ring on the inner liner before the laser welding process begins. This preliminary action ensures correct spacing and alignment are established before bonding, and the laser welding then secures this positioning permanently. The process includes preliminary clamping or fixation to maintain position during the welding operation.
3Strength
If adhesive is placed between guide rings or blocks lumens, then guide rings are attached, but the bendable medical device loses bending degrees of freedom
Solution Approach 1:
The patent replaces adhesive bonding with laser welding, which creates a localized fusion zone only at the interface between the guide ring and inner liner. This localized bonding method does not require adhesive material that could spill into or block the lumens, thereby preserving the bending degrees of freedom of the catheter while still achieving strong attachment.
Solution Approach 2:
The laser welding process applies energy locally at the bonding interface, creating a concentrated heat zone that fuses only the contact surfaces of the guide ring and inner liner. This localized action ensures strong attachment without affecting the lumens or surrounding areas, maintaining the device's flexibility and bending capabilities.
4Strength
If non-additive methods like ultrasonic or heat welding are used to attach components, then components can be attached, but the process deforms surrounding material and is not localized, making it difficult to use on small diameter devices
Solution Approach 1:
The patent utilizes ultrasonic vibration as the mechanism for laser welding. The high-frequency vibration of the laser beam creates localized friction and heat at the bonding interface, enabling fusion without the need for extensive heat zones. This vibrational mechanism allows precise attachment on small diameter catheter components while minimizing deformation of surrounding materials.
Solution Approach 2:
The laser welding process induces a localized phase transition from solid to molten state at the bonding interface, then back to solid upon cooling. This controlled phase transition creates a strong bond between components while the rapid heating and cooling cycles prevent heat from spreading to and deforming surrounding materials, enabling precise work on small diameter devices.
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
This approach enhances the flexibility and durability of bendable medical devices by maintaining the integrity of lumen sections and achieving consistent, strong welds, improving the range of bending motion and reducing the risk of guide ring displacement.
Implementation Method 1
The guide ring is attached to the inner liner using a laser welder
Implementation Method 2
The laser welder melts and fuses the guide ring to the inner liner
Implementation Method 3
The laser welder heats the guide ring and inner liner material to its melting point
Implementation Method 4
The laser energy heats the guide ring and inner liner material
Data Source
AI summary
The present disclosure relates to methods of manufacture, apparatus, and fixtures. An apparatus comprising an inner liner having a hollow chamber extending the length of the inner liner, at least two guide rings disposed collectively along the inner liner, and at least one lumen portion extending through each of the at least two guide rings and being parallel with the hollow chamber, wherein the at least two components are fixed by welding is provided. Further provided is a fixture and a method of manufacture.