Basket Catheter Electrode Retainers Using Strut Friction Fit
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Solution Overview
Problem
Current methods for attaching electrodes to spines of basket catheters, such as those used for irreversible electroporation (IRE), are challenging due to the small size and require soldering, welding, or adhesives, leading to increased manufacturing time and risk of improper bonding or misalignment.
Innovation Solution
A medical probe with a mechanical retainer system that secures electrodes to spines without soldering, welding, or adhesives, using struts with protrusions and bends to form a friction fit, preventing slippage and ensuring stable attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering, welding, or adhesives are used to attach electrodes to spines, then the electrodes can be secured to the spines, but the manufacturing time and cost increase and the risk of improper bonding or misalignment increases
Solution Approach 1:
The patent replaces thermal/chemical bonding methods (soldering, welding, adhesives) with a purely mechanical retention system. The strut includes a mechanical retainer with protrusions that engage with the electrode, allowing the electrode to be secured to the spine through mechanical interlocking rather than thermal or chemical processes, thereby reducing manufacturing time and eliminating the risks associated with improper bonding.
Solution Approach 2:
The mechanical retainer is divided into multiple protrusions distributed along the strut. These segmented protrusions work together to provide reliable retention while allowing for easier assembly compared to monolithic bonding methods. The segmentation enables the retainer to engage with the electrode at multiple points, ensuring stable attachment without requiring time-consuming soldering or welding operations.
2Reliability
If soldering, welding, or adhesives are used to attach electrodes to spines, then the electrodes can be secured to the spines, but the manufacturing cost increases
Solution Approach 1:
The patent replaces expensive thermal and chemical processes (soldering, welding, adhesive application) with a simple mechanical interlocking mechanism. The protrusions on the strut engage with the electrode through pure mechanical means, eliminating the need for specialized equipment and materials required for thermal or chemical bonding, thereby reducing manufacturing costs while maintaining reliable electrode attachment.
3Reliability
If soldering, welding, or adhesives are used to attach electrodes to spines, then the electrodes can be secured to the spines, but the chances that the electrode fails due to improper bond or misalignment increases
Solution Approach 1:
The mechanical retainer system provides inherent alignment guidance through the protrusions that engage with the electrode. This mechanical interlocking mechanism ensures precise positioning of the electrode on the spine, eliminating the misalignment risks associated with thermal or chemical bonding methods where precise alignment is difficult to achieve and control.
4Productivity
If a mechanical retainer system is used to attach electrodes to spines, then the manufacturing time and cost are reduced, but the device complexity increases
Solution Approach 1:
The mechanical retainer is segmented into multiple simple protrusions that are easily manufactured as integral parts of the strut. This segmentation allows for simple, modular construction that can be manufactured efficiently while providing reliable electrode retention. The simplicity of the individual protrusion elements keeps the overall device complexity manageable despite the functional complexity of the retention mechanism.
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
The mechanical retainer system provides a secure and efficient method for attaching electrodes, reducing manufacturing time and costs while ensuring reliable electrode positioning and functionality.
Implementation Method 1
The strut can include a bend forming a spring bias in the strut to cause the strut to form a friction fit with the electrode and prevent the electrode from sliding proximally or distally along a length of the spine
Data Source
AI summary
The disclosed technology includes a medical probe comprising a tubular shaft having a proximal end and a distal end, the tubular shaft extending along a longitudinal axis. The medical probe further comprises an expandable basket assembly coupled to the distal end of the tubular shaft. The basket assembly includes a plurality of electrodes with each electrode of the plurality of electrodes having a lumen therethrough. The basket assembly further includes a plurality of spines extending along the longitudinal axis and configured to bow radially outward from the longitudinal axis when the expandable basket assembly is transitioned from a collapsed form to an expanded form. Each spine includes a proximal and a distal end and a strut passing through the lumen of an electrode. The strut includes a mechanical retainer disposed on the strut to prevent the electrode from sliding proximally or distally along a length of the spine.