Tubular Medical Device Wall Braid and Coil Integration
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Solution Overview
Problem
Current manufacturing methods for tubular bodies in medical delivery devices, such as catheters and electrical leads, are inefficient and require separate assembly of polymer walls and metal coils, which can be improved by integrating assembly steps into a more efficient process.
Innovation Solution
The method involves stranding polymer fibers and metal filars to form a braid matrix and coil, then extruding a polymer material around the tubular wall, which is heated to melt and coalesce the fibers, optionally using a reflow process to ensure integration and maintain the coil pitch, allowing for automated high-volume production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate assembly methods are used for polymer walls and metal coils, then manufacturing flexibility is maintained, but manufacturing efficiency and productivity are reduced
Solution Approach 1:
The patent combines the polymer wall and metal coil into a single integrated tubular body structure. The polymer matrix and metal filaments are stranded together in a planetary stranding process, creating a unified component that eliminates the need for separate assembly operations, thereby improving productivity while reducing process complexity
Solution Approach 2:
The integrated tubular body serves multiple functions simultaneously: the polymer matrix provides structural support and insulation, while the embedded metal filaments provide flexibility and mechanical strength. This multi-functional design allows a single component to replace what would traditionally require multiple separate parts and assembly steps
2Strength
If polymer fibers are melted and coalesced during extrusion, then structural integrity is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent applies controlled thermal parameters during the extrusion process, heating the polymer fibers to their melting point to enable coalescence and bonding. This parameter change transforms the physical state of the polymer from solid to molten and back, creating strong bonds between fibers and the metal filaments, thereby improving structural integrity through a well-controlled thermal process
Solution Approach 2:
The patent replaces traditional mechanical bonding methods with thermal bonding. Instead of using mechanical fasteners or adhesives to bond the polymer and metal components, the process uses heat to melt and coalesce the polymer fibers, creating a strong integral bond. This substitution simplifies the manufacturing process by eliminating secondary bonding operations
3Productivity
If planetary stranding is used to form braid matrix and coil, then manufacturing efficiency is improved, but equipment complexity increases
Solution Approach 1:
The planetary stranding process segments the manufacturing into distinct functional zones: the stationary center mandrel, the rotating planetary carriers that hold the polymer fiber bobbins, and the central take-up spool. This segmentation allows each component to perform its specific function independently, enabling high-speed continuous production while maintaining process control
Solution Approach 2:
The patent employs a planetary motion system where carriers rotate around a central mandrel in circular paths. This curved, orbital motion pattern allows multiple polymer filaments to be stranded simultaneously in a compact configuration, maximizing productivity while maintaining uniform strand geometry and tension throughout the process
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 manufacturing efficiency by integrating assembly steps and improving the structural integrity of tubular bodies for medical devices, enabling more efficient production and flexible designs for medical catheters and electrical leads.
Implementation Method 1
the extrusion process heats the tubular wall, for a sufficient period of time, to a temperature that causes the plurality of polymer fibers to melt and coalesce together with one another
Implementation Method 2
heats the tubular wall... to a temperature that causes the plurality of polymer fibers to melt and coalesce together
Implementation Method 3
a reflow process that follows the extrusion process, causes the plurality of polymer fibers melt and coalesce together with one another
Data Source
AI summary
A tubular wall, which may be employed in a medical catheter or medical electrical lead, is formed by stranding together a plurality of polymer fibers and at least one metal filar, wherein the stranding forms a braid matrix of the polymer fibers and a coil of the metal filar interlaced therewith. Then, while the braid matrix secures a pitch of the coil, a polymer material is extruded around an entire length of the tubular wall, and, in some cases, the extrusion process causes the plurality of polymer fibers to melt and coalesce together with one another, while the pitch of the coil is maintained. Alternately, a reflow process, which follows extrusion, causes the polymer fibers to melt and coalesce along all, or just a discrete length of the tubular wall.