Catheter Tip Electrode Dual Weld Redundancy
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Solution Overview
Problem
Existing electrophysiologic (EP) catheters with two-piece tip electrodes face challenges in securing the shell and support structure, which can lead to detachment during procedures, necessitating additional safety measures to prevent shell detachment.
Innovation Solution
The catheter employs multiple redundant mechanisms to secure the tip electrode, featuring at least two different welds between the shell and the support structure, including seam welds and penetration welds, with axial and circumferential overlap to provide a dual failure mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a two-piece construction with shell and support structure is used, then uniform fluid flow is improved, but the risk of shell detachment increases
Solution Approach 1:
The tip electrode is divided into two separate pieces: a shell and a support structure, which are then joined together. This segmentation allows each component to be optimized independently for its specific function while creating a plenum chamber for uniform fluid flow distribution.
Solution Approach 2:
The shell and support structure are merged through multiple welding processes (seam welds and penetration welds) to create a secure, integrated assembly. This merging combines the fluid distribution benefits of the two-piece design with the structural integrity of a unified construction.
2Reliability
If multiple welds of different types are used, then attachment reliability is improved, but manufacturing complexity increases
Solution Approach 1:
Different weld types are applied to different locations and aspects of the joint: seam welds provide surface-level bonding for the shell to support structure interface, while penetration welds provide deep structural interlocking. Each weld type is optimized for its specific function in the overall attachment system.
Solution Approach 2:
Multiple redundant welds are applied beforehand to compensate for potential failures in any single weld. The seam welds and penetration welds work together as a redundant system where if one weld path fails, the other welds maintain the structural integrity of the tip electrode assembly.
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 design significantly reduces the risk of tip detachment during procedures by providing a secure attachment mechanism with dual failure modes, ensuring the integrity of the catheter throughout the ablation process.
Implementation Method 1
One weld includes a seam weld and another weld includes a penetration weld
Data Source
AI summary
A catheter has a two-piece tip electrode with a shell and a support structure that are secured to each other by multiple redundant mechanisms in order to reduce the risk of tip detachment during a procedure. The tip electrode includes at least two different welds attaching the shell to the support structure to provide a dual failure mode. One weld includes a seam weld and another weld includes a penetration weld.