Vessel-Loop Manufacturing via Heat-Sensitive Element
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Solution Overview
Problem
The existing method for manufacturing vessel-loops is labor-intensive, generates metallic debris that contaminates the silicone tubes, requires manual and tedious steps, and is limited to specific needle types, with some countries banning the use of catgut for securing the silicone tube within the steel tube.
Innovation Solution
A method involving a heat-sensitive element within the silicone tubing section, where axial tension and heat are applied to reduce the diameter, forming a conjoined portion that is then cooled and cut to create reduced-diameter ends for secure attachment to a needle, eliminating the need for catgut and reducing exposure to metallic debris during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the silicone tube is attached to the steel tube at an early stage, then the assembly can be processed together, but the silicone tube is exposed to fusels and metallic debris generated during needle formation
Solution Approach 1:
The manufacturing process is divided into two independent stages: first the needle is formed and processed separately, then the silicone tube is attached to the completed needle. This segmentation prevents the silicone tube from being exposed to metallic debris during needle formation, while still achieving secure attachment in the final assembly stage.
Solution Approach 2:
The needle is completely formed and processed (including grinding and polishing of the tip) before the silicone tube is attached. This preliminary completion of the needle ensures that all harmful debris generation steps are finished before the silicone tube enters the process, eliminating contamination risk.
2Manufacturing precision
If manual steps are used to pull, thread and secure the silicone tube in the steel tube, then precise positioning can be achieved, but the procedure becomes tedious and inefficient
Solution Approach 1:
The manual mechanical operations of pulling, threading and securing the silicone tube are replaced by an automated insertion and attachment mechanism. The system automatically feeds the silicone tube into the needle and secures it through the attachment mechanism, maintaining precision while dramatically improving efficiency and eliminating tedious manual steps.
3Reliability
If catgut is used to secure the silicone tube within the steel tube, then secure attachment can be achieved, but some countries have imposed bans on the use of catgut
Solution Approach 1:
The attachment method is changed from using organic catgut material to using a synthetic attachment mechanism (such as adhesive bonding, mechanical interlocking, or thermal attachment). This parameter change maintains the security and reliability of the attachment while eliminating the use of banned materials, ensuring compliance with regional regulations.
4Ease of manufacture
If the silicone tube is attached early in the process, then the needle and tube can be processed together, but the procedure is limited to specific needle types
Solution Approach 1:
The attachment mechanism is designed to be universal and compatible with various needle types and configurations. Rather than being tailored to a specific needle design, the attachment system can accommodate different needle shapes, sizes and materials, making the manufacturing process adaptable and versatile across multiple product variants.
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 simplifies the manufacturing process, prevents contamination by metallic debris, and allows compatibility with various needle types, enhancing efficiency and compliance with good manufacturing practices while eliminating the need for catgut.
Implementation Method 1
applying heat to the heat-sensitive element and the adjacent portion of the tubing section, whereby at least the outer surface of the heat-sensitive element melts and adheres to the adjacent portion of the tubing section
Data Source
AI summary
A vessel-loop having an elastic tube and a needle attached to one end thereof for use in various surgical procedures, and a method for forming same. The method includes the steps of positioning a heat-sensitive element within a section of elastic tubing, applying tensile forces to the opposed ends of the tubing section, and heating the heat-sensitive element and the portion of the tubing adjacent the heat-sensitive element so that the heat-sensitive element adheres to the adjacent tubing portion. The heat-sensitive element and the adjacent tubing portion are allowed to cool until a conjoined reduced-diameter portion is formed. The reduced-diameter portion is cut to form two ends, each having a reduced-diameter end. The reduced-diameter ends are then each secured to a needle, forming two vessel loops.