Rapidly Insertable Central Catheter Distal Tip Merging
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Solution Overview
Problem
Conventional manufacturing techniques for rapidly insertable central catheters (RICCs) result in bumps or ridges at the junctions of different catheter structures, leading to skin catching or guidewire snagging, and require secondary machining to form apertures, increasing complexity and cost.
Innovation Solution
A method of forming RICC catheters with a distal tip structure using a die with multiple mandrels to integrate a dilator section and access section, allowing for tapered apertures to be formed during primary manufacturing, using polymeric materials with varying durometers for smooth surfaces and reduced machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing techniques are used to form RICC catheters with multiple structures, then the catheter can perform multiple functions, but bumps or ridges are formed at the junctions of different structures
Solution Approach 1:
The patent combines multiple catheter structures (catheter body, dilator section, access section) into a single integrated component formed by one continuous extrusion process. This merging eliminates the junctions between separate structures that would otherwise create bumps or ridges, while maintaining the functional versatility of having distinct sections with different mechanical properties.
Solution Approach 2:
The patent uses a single polymeric material with varying durometer (hardness) values at different sections of the catheter. By changing the material parameter (durometer) rather than using different materials or assembly methods, the catheter achieves both functional differentiation and a smooth continuous surface without junctions.
2Ease of manufacture
If conventional manufacturing techniques are used to form apertures after catheter formation, then apertures can be created, but secondary machining procedures are required
Solution Approach 1:
The patent incorporates aperture formation into the primary extrusion process itself. The die used for extrusion is designed with features that create the apertures (such as keyhole apertures or slotted apertures) directly during the initial catheter formation, eliminating the need for secondary machining operations.
Solution Approach 2:
The patent merges the aperture formation operation with the catheter body formation operation into a single extrusion step. By integrating these functions into one process using a specially designed die, the manufacturing complexity is reduced while maintaining the ability to create various aperture configurations.
3Ease of manufacture
If apertures are formed perpendicular to the axis of the lumen in tapered sections, then apertures can be created, but the longitudinal length between apertures and distal tip increases
Solution Approach 1:
The patent employs asymmetric aperture designs such as keyhole apertures or slotted apertures that are oriented at angles to the catheter axis. These asymmetric configurations allow the aperture to be positioned closer to the distal tip while maintaining proper fluid flow characteristics and alignment with the lumen.
Solution Approach 2:
The patent transitions from forming apertures only perpendicular to the axis to forming apertures at various angles and orientations in three-dimensional space. This allows apertures to be positioned more optimally along the longitudinal axis, reducing the distance between apertures and the distal tip while maintaining functional effectiveness.
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 method reduces manufacturing costs and wastage by eliminating secondary machining, ensures smooth surfaces, and improves the efficacy of catheter placement by minimizing skin catching and guidewire obstruction.
Implementation Method 1
melting a polymeric material disposed within a cavity of the die to form a dilator section coupled to the distal tip of the catheter body
Data Source
Figure 1
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Figure 3A~3D
AI summary
A method of forming a rapidly insertable central catheter, comprising: providing a catheter body section (232) having a primary lumen (210), a secondary lumen (212) and a tertiary lumen (213), each extending longitudinally; placing a distal end of the catheter body within a die (300), the die having a first mandrel (310) engaging the primary lumen, a second mandrel (312) engaging the secondary lumen, and a third mandrel (314) engaging the tertiary lumen; melting a polymeric material disposed within a cavity of the die to form a dilator section section (234) coupled to the distal tip of the catheter body, the dilator section defining a tapered out profile and including a secondary lumen aperture (218) disposed in a side wall and communicating with the secondary lumen, and a tertiary lumen aperture (220) disposed in a side wall and communicating with the tertiary lumen.