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Efficient Thermobonding Process Forming a Polyurethane Based Diagnostic Catheter with Liquid Crystal Polymer.
Summary
This study introduces a new method for manufacturing medical catheters using liquid crystal polymer (LCP) and thermoplastic polyurethane (TPU). This innovative thermobonding process enhances durability and electrode density for minimally invasive procedures.
Area of Science:
- Materials Science
- Biomedical Engineering
- Medical Device Manufacturing
Background:
- Standard catheters have limitations in transducer density and manufacturing complexity.
- Minimally invasive medical procedures rely heavily on advanced catheter technology.
Purpose of the Study:
- To develop a novel catheter design and manufacturing method.
- To improve transducer density and reduce production efforts for medical catheters.
Main Methods:
- Utilized a liquid crystal polymer (LCP)-based flexible printed circuit board (FPCB) bonded with a thermoplastic polyurethane (TPU) elastomer tube.
- Employed a low-cost, additive-free lamination process at 250°C, enhanced with laser welding and microholes to prevent delamination.
- Conducted standardized mechanical tests to characterize the bonding.
Main Results:
- Achieved a peel strength of up to 8.5 N in the radial direction.
- Demonstrated non-plastic elongation of 10% in the axial direction.
- Validated the suitability of the thermobonding process for durable catheter production.
Conclusions:
- The proposed thermobonding process is effective for producing flexible and mechanically robust medical catheters.
- This method enables high electrode densities, advancing diagnostic and therapeutic catheter capabilities.
- The LCP-FPCB and TPU elastomer combination offers a cost-effective solution for next-generation catheters.
