Multilumen Catheter Heat-Bonding Process

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Solution Overview

Problem

Current methods for manufacturing multilumen catheters are time-consuming, costly, and can compromise the integrity of the catheter due to the use of chemical solvents, extrusion processes, and platen molds, which can lead to surface finish issues and material degradation.

Innovation Solution

A heat-bonding process that joins catheter tubes longitudinally without external sleeves or solvents, allowing for adjustable bond strength and incorporation of different materials, while maintaining a smooth outer surface finish and enabling various catheter configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If chemical solvents or adhesives are used to bond catheter tubes, then the tubes can be joined together, but the physical properties of the catheter tube materials are adversely affected or altered, and the tubes may degrade

Engineering Contradiction:

Improvebond strengthVSAvoidcatheter tube integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces chemical bonding systems (solvents, adhesives) with a mechanical/thermal bonding system. The catheter tubes are heated to a temperature where the material becomes pliable and bonds to itself when pressed together, eliminating the need for chemical agents that degrade the material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the temperature parameter of the catheter tube material during bonding. By heating the tubes to a specific temperature range, the material transitions to a bonding state where it fuses to itself, then cools to form a strong bond without chemical degradation.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If extrusion processes are used to manufacture multilumen catheters, then catheters can be produced, but the process is time-consuming and more costly compared to single lumen extrusion

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent segments the manufacturing process into two distinct steps: first extruding individual single-lumen catheter tubes using standard single-lumen extrusion equipment, then bonding multiple tubes together to form multilumen catheters. This avoids the complexity of extruding multiple lumens simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary action by extruding and preparing individual catheter tubes before bonding them together. This allows each tube to be manufactured using optimized single-lumen processes, and the multilumen configuration is created in a subsequent bonding step.

Inventive Principle:

Principle #10Preliminary action

3Shape

If platen molds are used to heat and shape catheter shafts, then the desired shape can be conferred, but the outer surface finish is destroyed due to re-heating

Engineering Contradiction:

Improvecatheter shaft shapeVSAvoidsurface finish quality

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent applies local quality by heating only the specific regions of the catheter tubes that require bonding, rather than heating the entire catheter shaft. This localized heating approach allows shaping and bonding without subjecting the outer surface to temperatures that would destroy the finish.

Inventive Principle:

Principle #3Local quality

4Stability of the object's composition

If outer sleeves are used to hold multiple catheter tubes together, then the tubes can be fixed within the sleeve, but additional bulk is added and more manufacturing steps are required

Engineering Contradiction:

Improvetube positioning stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges the catheter tubes directly together through heat bonding, eliminating the need for separate outer sleeves. The tubes are bonded to each other at their interfaces, creating a unified structure without additional components that would add bulk or complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces manufacturing time and costs, enhances catheter reliability, and produces a stronger bond compared to traditional methods, with the ability to create catheters with diverse properties such as different durometers and radiopacity.

Implementation Method 1

at least a portion of the inner surface of each of the two catheter tubes are selectively heated

Methodology Applied

Scientific EffectConduction (thermal): Conduction (thermal)

Implementation Method 2

contacting the selectively heated portion of at least the first tube with at least a portion of a second tube to form a multilumen catheter shaft that is bonded or joined together

Methodology Applied

Scientific EffectHeat bonding: Welding

Data Source

PatentUS9901704B2Multilumen catheters and method of manufacturing

Publication Date: 2018.02.27 MERIT MEDICAL SYSTEMS INC

AI summary

A multilumen catheter assembly and method of making the catheter assembly is provided that involves providing a plurality of tubes, each tube having a first end, a second end, at least one lumen, and at least one surface, selectively heating at least a portion of the surface of at least a first tube of the plurality of tubes, and contacting the selectively heated portion of the tube with a portion of the surface of a second tube to form a multilumen catheter shaft that is joined together along at least a portion of the length of the catheter shaft.