Flexible Printed Catheter Substrate for Magnetic Interference Cancellation
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Solution Overview
Problem
Current methods for manufacturing catheter shafts are cumbersome and labor-intensive, requiring dozens of wires to be pulled and soldered, which is prone to human error and time-consuming.
Innovation Solution
A flexible substrate with multiple layers of printed wires is used, which is environmentally protected, rolled or kept straight, and inserted into the catheter. Connectors are attached to each end, connecting sensors at the distal end and electrical components at the proximal end, with a reference layer for magnetic interference cancellation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire-pulling and soldering methods are used for catheter shaft manufacturing, then the catheter can be assembled with functional sensors and electrical components, but the process becomes cumbersome, labor-intensive, and prone to human error
Solution Approach 1:
The patent combines multiple separate wires and electrical connections into a single integrated flexible printed circuit board (FPC). The FPC integrates multiple conductive traces, ground paths, and signal routes that were previously implemented as separate wires requiring individual pulling and soldering operations. This merging eliminates the need for manual wire management and soldering, directly reducing manufacturing complexity while improving assembly accuracy through precise automated placement.
Solution Approach 2:
The patent replaces the mechanical wire-pulling and manual soldering process with a printed circuit board fabrication system. Instead of mechanically inserting and soldering individual wires, the electrical connections are created through printed conductive patterns on the FPC using standard PCB fabrication techniques. This substitution transforms a labor-intensive mechanical assembly process into an automated manufacturing process, improving both reliability and ease of manufacture.
2Productivity
If multiple separate wires are used for sensor connections in the catheter, then functional connectivity can be achieved, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent merges multiple separate wire connections into a single FPC assembly that can be installed as one unit. The FPC contains all necessary conductive traces for sensor connections, power supply, and signal transmission integrated on a single flexible substrate. This reduces the number of discrete assembly steps from dozens of individual wire insertions and soldering operations to a single FPC installation, dramatically improving productivity and eliminating manufacturing time delays.
Solution Approach 2:
The patent performs preliminary action by pre-fabricating the complete electrical connection system on the FPC before catheter assembly. All conductive patterns, connections, and electrical pathways are created in advance during FPC manufacturing, allowing the entire electrical subsystem to be pre-tested and pre-assembled. This preliminary preparation eliminates time-consuming on-site wire pulling and soldering, enabling rapid catheter assembly while maintaining full functional connectivity.
3Reliability
If traditional wire-based electrical connections are used in the catheter, then sensors can be connected to electrical components, but the process is prone to human error in wire termination
Solution Approach 1:
The patent replaces the mechanical wire-termination and soldering process with a printed circuit board system. Electrical connections are established through precisely printed conductive traces on the FPC rather than manual wire stripping, twisting, and soldering. This substitution eliminates human error in wire termination by using automated PCB fabrication processes that ensure consistent, accurate connections, while the standardized FPC interface simplifies the overall assembly process complexity.
Solution Approach 2:
The patent uses the FPC as a precise template or copy of the required electrical connection layout. The conductive patterns on the FPC are designed to exactly match the required sensor connections and electrical component interfaces. This pre-defined pattern copy ensures that each connection point is accurately positioned and connected, eliminating the variability and error potential of manual wire termination while maintaining the necessary device complexity for functional connectivity.
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 catheter assembly process, reduces human error, and enhances efficiency by using printed flexible substrates with conductive traces, allowing for effective magnetic interference cancellation.
Implementation Method 1
a reference layer is used to determine or measure magnetic radiation for interference purposes by connecting and/or shorting two traces in the reference layer at a distal end of the catheter
Implementation Method 2
These measurements are used by a processor or hardware to cancel out the magnetic interference effect on the other layers
Data Source
AI summary
A flexible substrate includes a number of layers, where each layer has a number of printed wires. The printed substrate is environmentally protected. The printed substrate is rolled and inserted into a catheter. Connectors are attached to each end of the rolled substrate. The connectors are connected to sensors at a distal end of the catheter and with electrical cards or a cable connector at a proximate end of the catheter. At least one layer of the substrate is connected to a coil in a magnetic sensor. A layer in which the traces are shorted in the distal end is used to measure a magnetic interference. These measurements are used by a processor or hardware to cancel out the magnetic interference effect on the other layers. Another printed substrate can be wrapped within the catheter shaft and used for non-magnetic type sensors.