Stent Strand-End Coupling Structure for Consistent Laser Welding
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Solution Overview
Problem
Existing techniques for securing the ends of strands in woven, self-expanding stents are inefficient, particularly in ensuring consistent alignment and secure bonding of coupling structures, which affects the stent's structural integrity and expansion characteristics.
Innovation Solution
The method involves securing a coupling structure to aligned strand end portions of a stent using laser welding, where the coupling structure is not a strand itself, and is made of nickel-titanium, with the length of the coupling structure being a fraction of the stent's length, and positioned either axially aligned or offset, to ensure secure bonding without direct contact between all strand end portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding or sleeve methods are used to join strand ends, then structural integrity is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent extracts the coupling function from the strand ends themselves by introducing separate coupling structures. These coupling structures are positioned at the ends of the stent and engage with the strand ends, thereby separating the joining function from the structural strands and simplifying the overall manufacturing process while maintaining strength
Solution Approach 2:
The coupling structures are pre-positioned and secured to the strand ends before final stent assembly. This preliminary action ensures proper alignment and reduces the complexity of final assembly, as the coupling structures are already in place to receive and secure the strand ends
2Reliability
If coupling structures are made longer to ensure secure bonding, then bonding reliability improves, but device length and material usage increase
Solution Approach 1:
The coupling structures are designed with localized bonding features at specific positions rather than requiring extended length throughout. The coupling structures have specific engagement zones that provide secure bonding through localized interactions, allowing short overall length while maintaining reliability
Solution Approach 2:
The coupling structures engage with only the essential portions of the strand ends rather than requiring full-length engagement. This partial action approach provides sufficient bonding reliability through targeted engagement zones without the need for excessive coupling structure length
3Manufacturing precision
If all strand end portions are brought into direct contact for welding, then bonding consistency improves, but alignment precision requirements increase
Solution Approach 1:
The coupling structures serve as intermediary elements between the welding process and the strand ends. They provide a standardized interface that facilitates consistent bonding without requiring precise direct alignment of all strand end portions, as the coupling structures themselves are designed to accommodate variations in strand end positioning
4Strength
If multiple coupling structures are used to secure all strand ends, then structural integrity improves, but device complexity and material usage increase
Solution Approach 1:
The stent structure is divided into segments that are secured by discrete coupling structures at strategic locations rather than requiring continuous coupling along all strand ends. This segmentation approach maintains structural integrity at critical joints while reducing overall material usage
Solution Approach 2:
Multiple strand ends are combined and secured together through shared coupling structures. The coupling structures engage with multiple strands simultaneously, providing structural integrity for bundled strand ends while using a single coupling component rather than separate couplings for each strand
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 structural integrity and self-expansion properties of the stent by ensuring consistent and secure bonding of strand ends, maintaining the stent's shape and functionality.
Implementation Method 1
The coupling structure may be secured to the first strand end portion by a weld that forms a first welded region, the coupling structure is secured to the second strand end portion by a weld that forms a second welded region
Implementation Method 2
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 3
the device includes one or more strands that include nickel and titanium
Data Source
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AI summary
Methods for securing strand ends of devices configured for insertion into an anatomical structure, and the resulting devices.