Hypotubes play an essential role in advanced, minimally-invasive catheters used in the medical device industry. These tubes facilitate the deployment of self- or balloon-expandable medical devices, which are implanted for short or long periods across various medical applications. A hypotube is a metal tube with micro-features along its length, typically covered with a polymer jacket.

The polymer jacket serves multiple purposes. It minimizes tissue damage, reduces friction, and ensures the tube’s flexibility. Common materials for this coating include silicone, polyurethane, or PEBAX. Furthermore, the polymer prevents leaks and seals the hypotube when fluids or gases pass through it. However, metal and polymer typically do not bond easily. Without proper surface activation, the jacket may begin to delaminate over time, particularly at the ends.

Medibrane’s Tie Layer Technology

Bonding metal with polymer can be challenging, as these materials generally do not adhere well to each other. To address this issue, Medibrane’s engineers developed an innovative adhesion platform. The process begins with surface activation, which alters the metal’s chemistry. This modification improves the mechanical bond between the metal and the polymer jacket.

After surface activation, Medibrane applies an encapsulation coating. This forms a thin tie layer that creates a strong connection between the jacket and the encapsulated polymer. By utilizing this process, Medibrane ensures that the polymer remains securely attached to the metal, preventing delamination and ensuring long-term functionality.