Laser Welded Coupler for Dissimilar Wire Joining
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Solution Overview
Problem
Joining dissimilar materials, particularly in the context of intravascular guidewires with varying stiffness and flexibility requirements, is challenging due to limitations in existing approaches, especially when the sections are small in diameter and made of different materials.
Innovation Solution
The use of a coupler with laser-induced indents to securely join dissimilar wire sections by melting the coupler material and allowing it to penetrate into the adjacent wire sections, creating a strong mechanical connection while minimizing intermetallic phase formation and maintaining the structural integrity of the materials used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining methods are used to connect dissimilar wire sections, then the joining process is simple, but the joint strength is insufficient and brittle intermetallic phases form
Solution Approach 1:
A coupler made of a specific alloy composition serves as an intermediary between dissimilar wire sections. The coupler's composition is designed to minimize intermetallic phase formation while providing strong mechanical bonding to both wire materials, resolving the contradiction between achieving strong joints and avoiding brittle phases.
Solution Approach 2:
The invention changes the material parameters by selecting a coupler alloy with specific compositional ranges that optimize both strength and compatibility with dissimilar wires. By controlling the coupler's chemical composition, the process achieves strong joints while minimizing harmful intermetallic phase formation.
2Strength
If laser welding is used to join dissimilar materials, then joint strength is improved, but the complexity of the joining process increases
Solution Approach 1:
The coupler is pre-designed with specific material properties and geometric features that facilitate the joining process. The preliminary selection of coupler material composition and structure simplifies the subsequent laser welding process while ensuring strong joints, reducing overall process complexity.
3Adaptability or versatility
If the guidewire uses sections of different materials to achieve varying stiffness, then the flexibility characteristics are improved, but the difficulty of joining sections increases
Solution Approach 1:
The coupler acts as a universal intermediary component that can join different wire materials (e.g., stainless steel, nitinol, cobalt-chromium) with varying stiffness characteristics. This standardizes the joining process across dissimilar materials, maintaining ease of manufacture while enabling flexible guidewire designs.
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 method provides a secure and strong mechanical connection between dissimilar wire sections, ensuring the desired stiffness and flexibility characteristics for intravascular devices, while limiting the formation of brittle intermetallic phases that could weaken the guidewire.
Implementation Method 1
a laser is used to weld into the coupler such that indents are created from the coupler and penetrate into the adjacent wire sections
Implementation Method 2
melting the coupler material and allowing it to penetrate into the adjacent wire sections
Data Source
AI summary
A method of forming a wire includes providing a first wire segment and a second wire segment. The first and second wire segments are inserted into opposite ends of a coupling segment. The coupling segment is laser welded such that the laser creates an indent in the coupling segment that penetrates into at least one of the first and second wire segments.