Balloon Guide Catheter Reflow Bonding for Minimal Outer Profiles
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Solution Overview
Problem
Existing balloon guide catheters face challenges in achieving optimal bond strength and integrity while minimizing the outer profile or diameter at the bonding interface between the balloon and the catheter shaft.
Innovation Solution
The catheter design incorporates features such as reflow jackets, apertures or recesses, inverted and skived bond interface areas, and vent tubes to secure the balloon to the catheter shaft, enhancing bond strength and minimizing the outer diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the balloon is bonded to the catheter shaft with a larger bonding interface area, then bond strength and integrity are improved, but the outer profile or outer diameter at the bonding interface area increases
Solution Approach 1:
The bonding interface is divided into multiple discrete bonding zones along the catheter shaft rather than a continuous large-area bond. This segmentation allows the balloon to be securely attached at specific points while maintaining a minimized outer profile in the regions between bonding zones, thus resolving the contradiction between bond strength and outer profile dimensions
Solution Approach 2:
The bonding interface transitions from a two-dimensional surface area approach to a three-dimensional structure utilizing the radial dimension. The balloon is bonded to the catheter shaft in a manner that creates a tapered or angled interface, allowing the bond to extend radially outward rather than only axially, thereby achieving strong bonding without increasing the axial outer profile
2Area of stationary object
If the bonding interface area is minimized, then the outer profile is reduced, but bond strength and integrity may be compromised
Solution Approach 1:
The bonding interface incorporates localized features such as bonding ridges, grooves, or textured surfaces at specific bonding zones that concentrate adhesive material and mechanical interlocking properties. These local quality enhancements provide high bond strength at minimal interface areas, allowing the outer profile to remain minimized while maintaining integrity
Solution Approach 2:
The bonding interface utilizes composite construction combining the balloon material, catheter shaft material, and adhesive material with complementary properties. This composite approach creates a multi-layered bonding structure that achieves superior bond strength at reduced interface areas compared to single-material bonds, thereby minimizing the outer profile while maintaining 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
The design ensures a secure bond between the balloon and catheter shaft with minimal increase in outer diameter, preventing peel back during inflation and improving the catheter's performance in procedures like thrombectomy.
Implementation Method 1
At least one reflow jacket made of a material reflowable into the braid secures the balloon to the catheter shaft
Data Source
AI summary
Balloon guide catheter with a balloon bonded thereto maximizing bonding strength and integrity while minimizing outer profile. Reflow jacket(s) is melted to/embedded within a braid supporting structure of the catheter securing beneath the balloon. Radially arranged apertures and/or recesses may be defined in the balloon through which adhesive is seepable upwards when secured about the catheter shaft. Proximal and distal bond interface areas of the balloon may be skived at right angles into two sections each extending radially 180°. Proximal and/or distal edges of the balloon may be flipped inwards prior to securing to the catheter shaft to form respective proximal and/or inverted bonds. During prepping of the catheter, residual air may be purged from the balloon via an exhaust hole defined in the compliant balloon or an exhaust tube secured between the exterior surface of the catheter shaft and the balloon.