Vascular Access Port MIM Design for Flow Path and Snap Fit
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Solution Overview
Problem
Conventional manufacturing methods for vascular access ports are costly and limit design flexibility, making it difficult to incorporate complex features and efficient fluid flow paths.
Innovation Solution
Metal powder injection molding (MIM) is used to create vascular access ports with molded metal snap fits and sacrificial cores, allowing for design innovations such as non-tangential non-radial flow paths, snap fit connections, and complex geometries that reduce manufacturing costs and improve functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods (machining and assembly) are used, then manufacturing precision is maintained, but manufacturing cost increases and design flexibility is limited
Solution Approach 1:
The patent combines multiple manufacturing operations (machining, assembly, welding) into a single metal powder injection molding process. The port body, flow path, and features are formed in one operation, eliminating the need for separate machining and assembly steps, thereby reducing manufacturing cost while maintaining precision through controlled molding parameters
Solution Approach 2:
The invention changes the manufacturing approach from subtractive machining to additive injection molding. By controlling parameters such as powder particle size, binder composition, injection pressure, and temperature, the process achieves both cost reduction and design flexibility while maintaining the required manufacturing precision for medical devices
2Ease of manufacture
If conventional manufacturing methods are used, then manufacturing cost is controlled, but design flexibility is limited
Solution Approach 1:
The patent uses segmented mold cavities and modular core inserts that can be independently designed and configured. This allows different port configurations, flow path geometries, and feature arrangements to be produced using the same basic molding process, enabling design flexibility without increasing manufacturing cost
Solution Approach 2:
The invention employs sacrificial core inserts as intermediaries during the molding process. These removable inserts define complex internal geometries and flow paths that would be difficult to machine. The cores are inserted into the mold, the powder is molded around them, and then the cores are removed to leave the desired complex features, enabling design flexibility at low cost
3Ease of manufacture
If simple flow paths are used, then manufacturing is easier, but fluid flow efficiency is reduced
Solution Approach 1:
The patent incorporates the optimal flow path geometry directly into the mold design before manufacturing. By pre-forming the flow path with appropriate curvature, cross-section, and orientation during injection molding, the device achieves efficient fluid flow without requiring post-manufacturing modifications or complex assembly steps
4Adaptability or versatility
If snap fit connections are used instead of press fits, then design flexibility improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent integrates the snap fit features directly into the molded port body, combining the connection mechanism with the main structure in a single operation. This eliminates the need for separate precision machining of mating surfaces, as the snap fit geometries are formed directly during injection molding with controlled tolerances
Solution Approach 2:
The invention changes the joining method from mechanical press fits requiring high precision to molded snap fits where the geometry is formed by molding parameters. By controlling injection pressure, temperature, and mold closure forces, the process achieves the necessary precision for snap fit connections while maintaining design flexibility
Data Source
AI summary
A vascular access port includes a base with a floor. A cap is engaged with the base to form a reservoir above the floor as a septum seals the reservoir in a fluid-tight manner. An outlet is in fluid communication with the reservoir. At least one of the base and cap is formed by metal injection molding. The cap and base may be engaged with a snap fit connection or a rotatable connection. The fluid communication may be along a non-tangential non-radial flow path. The flow path may be asymmetrical and may also include textured walls.