Medical Device Wire Connection Using Hook and Bore Interface
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Solution Overview
Problem
Conventional methods for connecting components in medical devices, such as catheters, face challenges in achieving strong connections between dissimilar metals and geometries, particularly between flat and round elements, which can lead to inadequate strength under applied forces.
Innovation Solution
The use of a connection device that includes an elongate planarity wire with a passage for an activation wire, featuring a bonding agent and interfaces like hooks, detents, or metallurgical connections to securely join the flat wire and activation wire, enhancing the structural integrity by utilizing the strength of both materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional soldering methods are used to join dissimilar metals and geometries, then the connection process is simple, but the connection strength is inadequate under applied forces
Solution Approach 1:
The patent combines multiple connection mechanisms into a single integrated connection device: a mechanical interface (hook and bore) provides structural interlocking, while a metallurgical interface (brazing or soldering) provides material-level bonding. This merging of mechanical and metallurgical connection methods achieves superior connection strength that neither method could achieve alone, while the integrated design prevents the complexity that would result from separate connection components.
Solution Approach 2:
The connection device utilizes composite connection approaches by joining dissimilar metals (e.g., nitinol wire to stainless steel tube) through combined mechanical interlocking and metallurgical bonding. The interface combines the geometric compatibility of mechanical fitting with the material compatibility of metallurgical bonding, creating a composite connection structure that accommodates both dissimilar geometries and materials simultaneously.
2Strength
If crimping is used to join dissimilar metals, then metallurgical connection is achieved, but connection between dissimilar geometries (flat and round elements) is not improved
Solution Approach 1:
The connection interface is segmented into two distinct functional zones: a mechanical interface portion that handles geometric adaptation between flat and round elements through hook-and-bore interlocking, and a metallurgical interface portion that provides material-level bonding. This segmentation allows each interface type to optimize for its specific function—mechanical for geometric compatibility, metallurgical for bond strength—without compromising either aspect.
3Ease of operation
If flat wires are used in deflectable catheters, then deflection control is achieved, but connection strength between flat wire and round activation wire is insufficient
Solution Approach 1:
The connection device employs a nested structure where the round activation wire is inserted through a bore in the flat planarity wire, creating a nested arrangement. The mechanical interface (hook on one element engaging with bore in the other) provides structural interlocking that maintains connection strength, while the nested geometry allows the flat wire to maintain its deflection control functionality. The activation wire passes through the flat wire's bore, enabling both elements to perform their respective functions without compromising connection integrity.
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 solution provides significantly stronger connections than conventional solder-only joints, capable of withstanding higher loads and maintaining stability under tensile forces, effectively addressing the limitations of existing connection methods.
Implementation Method 1
a bonding agent joining the activation wire to the flat wire at the passage
Data Source
AI summary
A connection device for a deflectable medical device, such as a catheter, comprises an elongate planarity wire having a proximal end and a distal end, an elongate activation wire having a proximal end a distal end, a passage and an interface. The passage extends through the planarity wire near the distal end of the planarity wire. The distal end of the activation wire extends through the passage. The interface is between the passage and the activation wire, and may comprise one or more of the following: a hook and bore interface, a detent interface, a mechanical interface, or a metallurgical interface.