Push Connect Catheter Hub Mechanical Locking Design

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Solution Overview

Problem

Current methods for manufacturing catheters with inflatable medical balloons face issues such as leakage, instability, and high manufacturing time due to the use of adhesives, which can be costly and prone to errors.

Innovation Solution

A catheter hub design that uses one or more push connectors to securely connect the catheter shaft without adhesives, featuring a ring with inwardly directed fingers and a retainer to prevent removal, along with seals to prevent leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive is used to bond catheter shaft to hub, then connection can be achieved, but manufacturing time increases due to curing requirement and reliability decreases due to potential leakage

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the chemical bonding system (adhesive) with a mechanical connection system. The hub includes a passage with a retainer that mechanically engages the catheter shaft through friction and geometric interlocking, eliminating the need for adhesive curing time while providing reliable, reversible connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the adhesive bonding step from the manufacturing process. By designing a self-contained mechanical connection system within the hub passage, the solution eliminates the adhesive application and curing steps that cause time loss and potential reliability issues.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If adhesive is used to bond catheter shaft to hub, then connection can be achieved, but manufacturing cost increases and ease of manufacture decreases

Engineering Contradiction:

Improveassembly easeVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent replaces complex adhesive application processes with a simple mechanical insertion process. The catheter shaft is simply inserted into the hub passage where it is automatically retained by the mechanical engagement system, significantly simplifying manufacturing and reducing costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical connection system is self-assembling through the insertion motion itself. The retainer and passage geometry automatically create the connection without requiring additional bonding steps, skill, or materials, making the process inherently easy to manufacture.

Inventive Principle:

Principle #25Self-service

3Reliability

If adhesive is used to bond catheter shaft to hub, then connection stability can be achieved, but leakage risk increases if adhesive is not properly applied

Engineering Contradiction:

Improveconnection stabilityVSAvoidleakage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces chemical adhesive bonding with a mechanical retention system featuring a retainer and passage design that provides stable connection through geometric interlocking and friction. This mechanical system eliminates the leakage risk associated with improper adhesive application while maintaining connection stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250144366A1Push connect catheter hub and related methods

Publication Date: 2025.05.08 BARD PERIPHERAL VASCULAR INC

AI summary

An apparatus for forming a catheter includes a catheter shaft and a hub including at least one connector for irremovably connecting the catheter shaft to the hub. The catheter shaft may engage one or more push connectors captured within a passage in the hub. Related are methods of manufacturing a catheter hub, including connecting first and second generally symmetrical halves of a hub over a connector, and then inserting a catheter shaft into the connector, such as by pushing it through a ring with inwardly directed fingers to form a secure locking engagement.