Bipole Catheter Electrode Spacers for Precise Near-Field Detection
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Solution Overview
Problem
Manufacturing and assembling catheters with closely and precisely spaced ring electrodes is challenging, as conventional methods often result in inconsistent spacing and stress on lead wires, making it difficult to achieve accurate electrode placement and signal detection.
Innovation Solution
The use of spacer rings made of biocompatible, electrically-nonconductive material to premeasure and maintain precise spacing between electrodes, simplifying assembly and reducing stress on lead wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional adhesive methods are used to seal ring electrodes, then assembly is simplified, but electrode spacing precision deteriorates (spacing of 1.0 mm or larger can be achieved, but smaller spacing of 0.2 or 0.1 mm is difficult)
Solution Approach 1:
A non-conductive spacer member is introduced as an intermediary component between adjacent ring electrodes. The spacer member includes a body portion positioned between the electrodes and extensions that engage with both electrodes, thereby precisely maintaining the desired spacing (e.g., 0.2 or 0.1 mm) without requiring complex adhesive application techniques. This mediator component resolves the contradiction by providing mechanical positioning accuracy while simplifying the overall assembly process.
Solution Approach 2:
The spacer member is pre-formed with precise dimensions and engagement features before assembly. The extensions of the spacer member are designed to automatically engage with the ring electrodes at the correct spacing when assembled, eliminating the need for complex adhesive application and curing processes. This preliminary preparation of the spacer component enables precise electrode spacing to be achieved through a simplified assembly operation.
2Measurement precision
If electrode pairs are closely spaced to improve signal detection accuracy, then near-field potential detection improves, but manufacturing and assembly difficulty increases
Solution Approach 1:
The non-conductive spacer member acts as a precision intermediary that mechanically enforces the desired spacing between electrode pairs. By designing the spacer body portion and extensions with precise dimensions, consistent spacing (e.g., 0.2 or 0.1 mm) is maintained throughout production, enabling accurate near-field potential detection without the manufacturing complexity that would otherwise be required to achieve such precision.
Solution Approach 2:
The spacer member's physical parameters (dimensions, extension lengths, engagement features) are specifically designed and controlled to achieve the target electrode spacing. By changing and controlling these geometric parameters of the spacer component, precise and consistent electrode spacing is achieved, which directly improves signal detection accuracy while maintaining manufacturing feasibility.
3Reliability
If lead wires are attached at acute angles to reach ring electrodes, then electrode connectivity is achieved, but lead wire stress and breakage risk increase
Solution Approach 1:
The spacer member's extensions serve as intermediary connection points that provide accessible engagement locations for lead wires. Rather than requiring lead wires to reach acute angles to contact the ring electrodes directly, the extensions protrude or are positioned to facilitate easier wire attachment, thereby reducing stress on the lead wires and improving durability while maintaining a relatively simple overall device structure.
4Length of moving object
If adhesive margin is used between adjacent electrodes, then electrode sealing is achieved, but minimum spacing increases (limiting how closely electrodes can be spaced)
Solution Approach 1:
The non-conductive spacer member body portion serves as an intermediary sealing element between adjacent ring electrodes. Instead of relying on adhesive margins that increase the spacing between electrodes, the spacer's body portion directly contacts both electrodes, providing reliable sealing and electrical isolation while maintaining minimal spacing (e.g., 0.2 or 0.1 mm). This mediator approach eliminates the need for adhesive margin space.
Solution Approach 2:
The adhesive layer is extracted or eliminated from the electrode sealing function. The spacer member's body portion directly provides the sealing and isolation function that would otherwise require adhesive, thereby removing the margin space that adhesive requires and enabling closer electrode spacing while maintaining sealing reliability.
Data Source
AI summary
An electrophysiology catheter constructed with assembly and wiring of ring electrodes using spacer rings of electrically-nonconductive material, whose length is predetermined/premeasured, includes a distal section with at least one spine having two electrodes, and a spacer member therebetween, wherein the spacer member configured to provide a separation gap between the two electrodes. The separation gap may span in an axial direction and/or in a circumferential direction. The spacer member may be configured generally as a ring with a center axial opening configured to receive the spine therethrough. The spacer member may include an axial extension providing a first separation gap between a first pair of electrodes in a circumferential direction, and a circumferential providing a second separation gap between a second pair of electrodes in an axial direction