3D-Printed Magnetic Field Sensor Coils for Compact Catheters
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Solution Overview
Problem
Existing catheter technologies face challenges in fitting accurate location and force sensors within the narrow body of catheters, which requires efficient, cost-effective, and automated fabrication techniques for small, high-sensitivity coils.
Innovation Solution
The development of a novel positioning sensory system using 3D printed magnetic field sensors with open magnetic circuit coils, fabricated by multi-material 3D printing of magnetic, conductive, and dielectric materials, allowing for the integration of longitudinally and transversely oriented coils within a monolithic body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wire-winded coils with ferrite cores are manually inserted and soldered, then the coils can be fabricated with adequate sensitivity, but the manufacturing process becomes complex, time-consuming, and costly
Solution Approach 1:
The patent combines the ferrite core and conductive windings into a single integrated component fabricated by 3D printing. The conductive channel is printed directly onto the ferrite core, eliminating the need for separate manual insertion and soldering operations. This merging of components resolves the technical contradiction by maintaining sensitivity while dramatically simplifying the manufacturing process.
Solution Approach 2:
The patent replaces manual mechanical assembly operations (inserting ferrite cores into coil forms and soldering windings to cables) with automated 3D printing technology. The 3D printing process deposits conductive material directly onto the ferrite core in a controlled, automated manner, eliminating the need for complex manual assembly and reducing manufacturing complexity.
2Measurement precision
If wire-winded coils are manually assembled, then the coils can be fabricated with adequate sensitivity, but the production time and cost increase
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated 3D printing technology. The 3D printing process can fabricate multiple coils simultaneously or in rapid succession without the time-consuming manual steps of inserting ferrite cores and soldering windings, thereby dramatically improving production efficiency while maintaining coil sensitivity.
Solution Approach 2:
The patent performs preliminary integration of the ferrite core and conductive windings during the 3D printing process itself. By printing the conductive channel directly onto the ferrite core before final assembly, the patent eliminates subsequent time-consuming assembly steps, thereby improving productivity.
3Manufacturing precision
If conventional fabrication techniques are used, then the coils can be assembled with manual precision, but mass production becomes difficult and variability increases
Solution Approach 1:
The patent replaces manual assembly operations with automated 3D printing technology, which provides consistent, repeatable fabrication of coils. The automated deposition process ensures uniform coil geometry and electrical properties across大批量 production, reducing variability while maintaining high precision that is difficult to achieve consistently through manual assembly.
Solution Approach 2:
The patent changes the fabrication method from manual mechanical assembly to automated 3D printing, fundamentally altering the manufacturing parameters. This parameter change enables mass production capability while maintaining or improving manufacturing precision through controlled material deposition and automated process repeatability.
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 enables the creation of compact, sensitive magnetic field sensors with high induced voltage, suitable for accurate position sensing and force measurement in catheters, while facilitating mass production with reduced variability and improved sensitivity.
Implementation Method 1
magnetic field sensor 100... suitable for magnetic-field-based position sensing... capable of providing accurate feedback on the location of the catheter in the body, and the contact interface between the catheter and the tissue and the force (e.g., vector) applied between them
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~1E
AI summary
Magnetic field sensors and methods for 3D-printing of the same are disclosed. The magnetic field sensor includes a monolithic body with a plurality of coils 3D-printed therein by successive printing of layers along a printing direction; the coils include longitudinally oriented coil(s) whose magnetic axe(s) are parallel to the printing direction and transversely oriented coil(s) whose magnetic axe(s) are perpendicular to the printing direction. The transversely oriented coil(s) is each 3D-printed with a magnetic channel that curves between a pair of opposite flux collection facets being perpendicular to its magnetic axis, such that it includes a magnetic core section extending along the printing direction. Each of the longitudinally and transversely oriented coils is 3D-printed with respective arrangement of conductive windings including a plurality of turns 3D-printed in planes of the 3D-printed layers. The turns of transversely oriented coil surround the magnetic core section to the magnetic channel thereof.