Catheter Electrical Connector With Isolated Pin Alignment
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Solution Overview
Problem
Existing electrical connectors for electrophysiology catheters lack adequate isolation between electrodes, leading to reduced effectiveness and safety in ablation therapies, particularly in pulsed field ablation (PFA) procedures.
Innovation Solution
The development of an electrical connector with a cylindrical receptacle body and a flexible electronic circuit featuring conductive contact pads and traces, along with a water-resistant seal, to ensure proper isolation and alignment of connector pins, thereby facilitating effective and safe electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connectors provide isolation between groups of electrodes, then therapy effectiveness is improved, but device complexity increases
Solution Approach 1:
The connector is divided into multiple electrically isolated groups (first group, second group, third group) with distinct contact pads and traces on the flexible circuit board. Each group can be independently connected to different electrodes, enabling isolated electrical connections without requiring a single complex isolated structure.
Solution Approach 2:
The flexible circuit board acts as an intermediary element between the connector pins and the electrodes. It provides the isolation barrier while maintaining electrical connectivity through its conductive traces, separating the high-voltage electrode connections from the low-voltage control connections.
2Reliability
If electrical isolation exists between electrical components and practitioner, then safety is improved, but water resistance requirements increase complexity
Solution Approach 1:
A flexible membrane or diaphragm is incorporated into the connector assembly to provide fluidtight sealing. This flexible barrier prevents fluid infiltration between the connector and the catheter while maintaining electrical isolation, avoiding the need for complex rigid sealing structures.
Solution Approach 2:
The connector assembly combines multiple materials with different properties: conductive materials for electrical contacts, insulating materials for isolation barriers, and flexible sealing materials for fluidtight protection. This composite approach achieves both safety and water resistance through material properties rather than complex structural design.
3Reliability
If connector pins are precisely aligned, then electrical connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connector incorporates flexible elements that allow for slight misalignments and movements during connection. The flexible circuit board and membrane can deform to accommodate variations in assembly tolerance, maintaining reliable electrical contact without requiring extremely precise manufacturing alignment.
Solution Approach 2:
The connector design includes self-aligning features where the flexible membrane and contact pads automatically adjust to achieve proper alignment during the connection process. This self-adjustment mechanism compensates for manufacturing tolerances without requiring external alignment tools or complex positioning systems.
Data Source
AI summary
An electrical connector for a catheter includes a plug portion and a receptacle portion. The plug portion includes a plug body, a plurality of holes formed in the plug body, a plurality of electrically-conductive connector pins recessed within the plurality of holes, and a poka-yoke structure. The receptacle portion includes a receptacle body, a plurality of electrically-insulative hollow posts extending from the receptacle body, a plurality of electrically-conductive connector pins, each being partially disposed within and partially disposed outside of a respective hollow post, and a complementary poka-yoke structure. The poka-yoke structures cooperate to facilitate proper alignment of the electrically-conductive connector pins when the receptacle portion is connected to the plug portion.