Stent Strand-End Coupling Structure for Reliable Laser Welding
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Solution Overview
Problem
Existing medical devices, such as stents and occluders, face challenges in securely joining strand ends made of nickel-titanium materials, particularly in maintaining structural integrity and consistency during insertion and expansion within anatomical structures.
Innovation Solution
The use of coupling structures, which are welded to the strand end portions using laser welding, to secure and align the ends of devices like stents, ensuring axial alignment or offset positioning, and maintaining structural consistency through precise welding techniques and material composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If coupling structures are welded to strand end portions using laser welding, then the structural integrity and alignment of device ends are improved, but the manufacturing complexity and precision requirements increase
Solution Approach 1:
The coupling structure serves as an intermediary component between strand end portions, facilitating reliable joining while accommodating manufacturing tolerances. The coupling structure's design allows it to bridge gaps and misalignments that would otherwise prevent successful welding, thus maintaining structural integrity without requiring extremely precise manufacturing.
Solution Approach 2:
The patent employs laser welding parameters (energy density, pulse duration, focal point) to achieve strong joints. By optimizing these parameters, the process achieves high-strength bonds while managing the precision requirements through controlled energy input and localized heating that compensates for minor alignment variations.
2Reliability
If coupling structures are used to secure strand ends, then the reliability of device insertion and expansion is improved, but the device complexity increases
Solution Approach 1:
The device is segmented into distinct functional components: the main body structure and the separate coupling structures at the ends. This segmentation allows the coupling structures to be optimized specifically for joining and alignment functions, improving reliability of insertion and expansion, while the modular nature helps manage overall device complexity by separating concerns.
Solution Approach 2:
The coupling structures are designed to perform multiple functions: securing strand ends, providing alignment features, and serving as attachment points for deployment mechanisms. This multi-functionality reduces the need for additional separate components, thereby managing device complexity while maintaining high reliability.
3Stability of the object's composition
If strand end portions are precisely aligned and welded, then the structural consistency of the device is improved, but the manufacturing time and energy consumption increase
Solution Approach 1:
Alignment features such as protrusions and recesses are pre-formed on the coupling structures and strand ends before the welding process. This preliminary alignment action reduces the precision requirements during welding, allowing for faster, lower-energy welding processes while maintaining structural consistency. The pre-formed features guide the components into proper alignment, reducing the energy needed for precise positioning and welding.
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 method effectively secures strand ends, maintaining the structural integrity and consistency of devices like stents, allowing for reliable insertion and expansion within anatomical structures, while ensuring precise alignment and material compatibility.
Implementation Method 1
The securing may be accomplished by welding (e.g., laser welding) the coupling structure to the first strand end portion to create a first welded region and by welding the coupling structure to the second strand end portion to create a second welded region.
Implementation Method 2
welding (e.g., laser welding) the coupling structure to the first strand end portion to create a first welded region
Data Source
AI summary
A woven, self-expanding stent device has one or more strands and is configured for insertion into an anatomical structure. The device includes a coupling structure secured to two different strand end portions that are substantially aligned with each other. The two different strand end portions include nickel and titanium. The coupling structure is not a strand of the device.