Medical Stent Lattice Adhesion via Substrate Indentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing medical devices with lattice structures face challenges in achieving a strong and consistent connection between the lattice structure and the cover, particularly due to contour fluctuations and irregular edges, which affect adhesion and radial force distribution.
Innovation Solution
The method involves pressing the lattice structure into a substrate to reproduce its contours, filling the interstices with a sacrificial material, and then applying a cover layer, ensuring complete contact and adhesion independent of edge irregularities, with adjustable indentation depth for optimal radial force transmission and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lattice structure is applied flat on the substrate without pressing, then the production process is simpler, but the contact between the lattice elements and substrate is incomplete due to contour fluctuations and rounded edges
Solution Approach 1:
The lattice structure is pressed into the substrate before applying the sacrificial material and cover layer. This preliminary pressing action creates accurate imprints of the lattice element contours in the substrate, ensuring complete contact areas are established before subsequent coating steps. The pressing action compensates for rounded edges and contour fluctuations by forcing the lattice elements into full contact with the substrate surface.
2Reliability
If the lattice structure is pressed into the substrate to improve contact, then the adhesion between lattice structure and cover is improved, but the production process becomes more complex
Solution Approach 1:
A sacrificial material layer is applied as an intermediary between the pressed lattice structure and the final cover layer. This sacrificial material fills the interstices of the lattice structure and provides a uniform bonding surface for the cover layer, while also protecting the lattice structure during subsequent processing steps. The intermediary layer simplifies the overall process by decoupling the pressing operation from the coating operation.
3Force
If the wall thickness of lattice elements is increased to improve radial force distribution, then the radial force transmission is improved, but the flexibility and crimpability of the stent deteriorates
Solution Approach 1:
The stent is constructed as a composite structure combining a lattice framework with an additional cover layer. The lattice structure provides the primary mechanical support and radial force distribution, while the cover layer applied over the lattice elements enhances the radial force transmission to the vessel wall without significantly increasing the overall wall thickness of the lattice elements themselves. This composite approach maintains flexibility and crimpability while improving radial force distribution.
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 approach enhances the adhesion between the lattice structure and the cover, maintaining flexibility and radial force distribution while avoiding contour-related issues, resulting in a more reliable and effective medical device.
Implementation Method 1
The lattice structure is at least partially pressed into the substrate with the side arranged on the substrate
Implementation Method 2
The lattice structure is coated with a first layer of a sacrificial material, so that at least part of the interstices of the lattice structure are covered with the first layer
Implementation Method 3
A second layer to form the cover is applied to the side of the lattice structure previously pressed into the substrate
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
The invention relates to a method for producing a medical device with a lattice structure (10), which is connected at least in some areas to a cover (11), in which the lattice structure (10) is arranged on a substrate (12) via the side (13a) that is to be connected to the cover (11), the lattice structure (10) has the side (13a) arranged on the substrate (12) pressed at least partially into the substrate (12), the lattice structure (10) is coated with a first layer (14) of a sacrificial material, such that at least some (19a, 19b) of the interstices (15) of the lattice structure (10) are covered by the first layer (14), and the first layer (14) with the lattice structure (10) on the side (13a) to be connected to the cover (11) forms a substantially closed surface (16), the substrate (12) is removed, such that the side (13a) of the lattice structure (10) is accessible that is to be connected to the cover (11), a second layer (17) for forming the cover (11) is applied to the side (13a) of the lattice structure (10) previously pressed into the substrate (12), and the sacrificial material is removed.