Flexible Catheter Circuit Assembly for Magnetic Interference Control
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Solution Overview
Problem
Current methods for manufacturing catheter shafts are labor-intensive and prone to human error due to the cumbersome process of soldering dozens of wires, which complicates the assembly and increases the risk of improper termination.
Innovation Solution
A flexible substrate with printed conductive wires is used, which is environmentally protected and inserted into the catheter, with connectors attached to both ends for connection to sensors and electronics, and a reference layer for magnetic interference cancellation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire soldering methods are used for catheter shaft assembly, then the catheter can be manufactured with functional wiring, but the assembly process becomes labor-intensive and prone to human error
Solution Approach 1:
The patent replaces the mechanical soldering process with a printed circuit board (PCB) technology where conductive traces are directly printed onto the catheter shaft surface. This substitution eliminates the need for manual wire handling, soldering irons, and flux materials, thereby reducing labor intensity and human error while maintaining reliable electrical connections for sensors and electrodes
Solution Approach 2:
The invention changes the physical state and form of electrical connections from discrete wire-solder-joint structures to continuous printed conductive patterns. By altering the manufacturing parameters from thermal-mechanical soldering to deposition-based printing processes, the system achieves more consistent trace geometry, controlled impedance, and repeatable connection quality without manual intervention
2Productivity
If multiple wires are soldered to create the catheter shaft circuitry, then the catheter achieves functional connectivity, but the manufacturing time and labor requirements increase significantly
Solution Approach 1:
The patent merges multiple discrete wire connections and soldering operations into a single integrated printed circuit board structure. The PCB allows numerous conductive traces to be created simultaneously through printing processes, consolidating what would otherwise require dozens of separate soldering steps into one manufacturing operation, thereby dramatically improving productivity and reducing assembly time
Solution Approach 2:
The invention performs preliminary circuit pattern creation by printing conductive traces directly onto the catheter shaft before final assembly steps. This preliminary action establishes all necessary electrical pathways in advance, eliminating the need for time-consuming wire routing and connection-making during subsequent assembly operations
3Reliability
If traditional wire assembly methods are used, then the catheter can be constructed, but the risk of improper wire termination and human error increases
Solution Approach 1:
The patent replaces error-prone manual wire termination processes with automated printed circuit board fabrication. The printing process uses programmed deposition patterns that ensure consistent trace width, spacing, and connectivity, eliminating human errors such as wrong wire connections, improper soldering, or missed terminations that are common in traditional manual assembly
Solution Approach 2:
The invention uses digital design files to copy and replicate precise circuit patterns onto the catheter shaft through printing. This copying process ensures that each catheter receives identical, pre-verified circuit layouts, maintaining high assembly accuracy and reducing variability caused by manual operations
Data Source
AI summary
A catheter for canceling magnetic interference is disclosed. The catheter includes a catheter shaft having a distal end with sensors and a handle with electronics and non-magnetic sensors. Inside the catheter shaft is at least one flexible substrate having conductive traces. Another flexible substrate is wrapped around a component in the catheter shaft. The catheter further includes a plurality of connectors. A first connector connects the sensors to one end of the at least one flexible substrate. A third connector connects the non-magnetic sensors to one end of the other flexible substrate. A second connector and a fourth connector both connect the electronics to another end of the at least one flexible substrate.