Catheter Electrode Assembly Using Localized Heating Contacts
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Solution Overview
Problem
The production of catheters with multiple electrodes is complex due to the use of electrically insulated wires, which occupy space, require a larger diameter, are difficult to handle, and are time-consuming to assemble, and the electrical connection of flexible circuit boards to catheter electrodes is challenging due to low mechanical and thermal stability of other components.
Innovation Solution
A method involving a catheter body with a hollow cylindrical inner liner, outer insulation, and a flexible circuit board wound in spiral turns, where contact openings are created for electrodes, and electrodes are secured to electrical conductors using a contact means through targeted heating, such as electromagnetic radiation or induction, to ensure electrical conductivity and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically insulated wires are used to connect electrodes, then electrical connections can be established, but the catheter diameter increases and assembly becomes time-consuming
Solution Approach 1:
The patent combines multiple electrical conductors into a single flexible circuit board that spirally winds around the inner liner. This integration eliminates the need for separate insulated wires for each electrode, reducing assembly steps and time while maintaining reliable electrical connections between all electrodes and the control unit.
Solution Approach 2:
The flexible circuit board serves multiple functions simultaneously: it provides electrical connections for multiple electrodes, maintains mechanical flexibility of the catheter, and enables signal transmission between electrodes and the control unit through its spiral configuration around the inner liner.
2Reliability
If electrically insulated wires are used, then electrical connections are established, but the catheter requires a larger diameter
Solution Approach 1:
The flexible circuit board is nested within the catheter structure by spirally winding it around the inner liner, similar to a nested doll configuration. This allows multiple electrical conductors to be compactly arranged within the existing catheter diameter without requiring additional space for separate insulated wires.
Solution Approach 2:
The patent transitions from a linear arrangement of separate wires to a spiral three-dimensional configuration of the flexible circuit board around the inner liner. This dimensional change allows efficient use of space within the catheter, reducing the required diameter while maintaining all necessary electrical connections.
3Reliability
If conventional heating is used to secure electrodes, then electrical connections are established, but thermal stress deforms other catheter components
Solution Approach 1:
The heating process is applied locally only at the contact points where electrodes meet the flexible circuit board, rather than heating the entire catheter assembly. This localized heating establishes reliable electrical connections while preventing thermal stress and deformation of other temperature-sensitive catheter components.
Solution Approach 2:
The flexible circuit board acts as an intermediary that can withstand localized heating at contact points without transmitting excessive thermal stress to other components. Its material properties and spiral configuration allow it to serve as a thermal buffer, protecting the inner liner and outer insulation from deformation.
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 method simplifies the assembly of catheters with flexible circuit boards, reduces thermal stress on components, and ensures reliable electrical connections without undesirable deformations, making the process more efficient and cost-effective.
Implementation Method 1
targeted heating of the electrode and of the contact means in order to secure the electrode to the electrical conductor via the contact means in an electrically conductive manner
Implementation Method 2
targeted heating of the electrode and of the contact means in order to secure the electrode to the electrical conductor via the contact means in an electrically conductive manner
Data Source
AI summary
The present invention relates to a method for producing a catheter, comprising the method steps of providing a catheter body, creating at least one contact opening in the vicinity of the distal catheter body end, wherein, to create the contact opening, parts of the outer insulation and of any insulating layers of the flexible circuit board are removed so that the at least one electrical conductor can be selectively electrically contacted via the contact opening; providing a contact means; applying the contact means into the at least one contact opening; providing at least one electrode; positioning the electrode at the position of the contact opening in contact with the contact means in the contact opening; and, targeted heating of the electrode and of the contact means in order to secure the electrode to the electrical conductor via the contact means in an electrically conductive manner.