Nested Porous Tubes for Tubular Medical Implant Manufacturing
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Solution Overview
Problem
Current methods for manufacturing tubular medical implants with complex porous structures are limited by material constraints, labor intensity, and the risk of altering pore sizes, particularly in implants with high thickness and variable pore patterns throughout.
Innovation Solution
The method involves sliding and bonding portions of one porous tube within another to create overlapped areas, allowing for precise control of pore size and distribution, using a combination of tubes with varying diameters and pore patterns to form a complex three-dimensional structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If elastic porous graft material is stretched over a stent, then the graft material forms a snug fit on the stent, but the pore sizes on the graft material are permanently changed during stretching
Solution Approach 1:
The patent applies nesting by placing multiple porous tubes of different diameters inside one another to create a multi-layered tubular implant. Each tube maintains its original pore structure without deformation, and the nested arrangement allows the implant to achieve the desired shape and fit without stretching that would alter pore sizes.
Solution Approach 2:
The patent segments the implant into multiple separate porous tubes that are assembled together. Each tube can be manufactured with precise pore characteristics independently, and they are joined via overlapped and bonded areas, avoiding the need to stretch a single graft material which would permanently change its pore structure.
2Ease of manufacture
If graft material is stretched to fit over the stent, then proper positioning is achieved, but the process is labor intensive
Solution Approach 1:
The patent applies preliminary action by pre-forming multiple porous tubes with their final dimensions and pore structures before assembly. The tubes are manufactured to precise specifications and then simply slid into position within one another, eliminating the need for labor-intensive stretching and positioning operations during assembly.
Solution Approach 2:
The nested arrangement of pre-formed tubes allows for straightforward assembly where each tube is simply inserted into the next larger tube, achieving proper positioning without the complex stretching and sewing operations required by conventional methods.
3Adaptability or versatility
If current production methods are used, then simple pore patterns can be produced, but complex porous structures with variable pore patterns throughout the implant thickness cannot be achieved
Solution Approach 1:
The patent applies local quality by using different porous tubes with different pore patterns at different locations and depths within the implant structure. Each tube can have unique pore characteristics, and by selectively combining tubes with different pore patterns, the implant achieves spatially variable pore distribution throughout its thickness, allowing different regions to have optimized properties for specific functions.
Solution Approach 2:
The segmentation of the implant into multiple independent tubes allows each tube to be manufactured with its own specific pore pattern and characteristics. This enables the assembly of complex variable pore structures by combining simpler individual tube designs, achieving high adaptability while maintaining manufacturing precision for each component.
4Adaptability or versatility
If multiple tubes with varying diameters and pore patterns are combined, then complex three-dimensional porous structures are created, but the device complexity increases
Solution Approach 1:
The nested configuration of multiple tubes creates complex three-dimensional porous structures while maintaining a relatively simple overall architecture. The tubes are arranged concentrically, which simplifies the bonding process to primarily end-to-end connections at overlapped areas, rather than requiring complex lateral bonding between numerous separate components.
Solution Approach 2:
The patent applies universality by using the same basic construction approach (multiple porous tubes with overlapped and bonded areas) to achieve multiple functions and complex structures. The same methodology can be used regardless of the number of tubes or variations in pore patterns, providing a universal manufacturing approach that scales from simple to complex configurations without fundamentally changing the process.
Data Source
AI summary
A method of manufacturing a tubular medical implant is provided. The method includes forming a hollow first tube with a first diameter and a first plurality of pores formed thereon and a hollow second tube with a second unstretched diameter and a second plurality of pores formed thereon. The second unstretched diameter is greater than the first diameter. At least a portion of the first tube slides within the second tube to create an overlapped area of the first tube and the second tube. The first tube and second tube are then bonded together in the overlapped area.