Irrigated Catheter Tip Electrode With Segmented Support Member

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Solution Overview

Problem

Conventional electrophysiology catheters with irrigated tip electrodes are costly due to the use of precious metal alloys and intricate micro-machining for complex geometries, which increases manufacturing costs and complexity.

Innovation Solution

The catheter tip electrode features a support member with a conductive interface portion made of precious metal alloy and an insert-molded portion made of less-expensive plastic, configured to support irrigation, force sensing, and temperature sensing, reducing material and manufacturing costs while maintaining functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional catheters use precious metal alloys for the entire insert support member, then electrical conductivity and structural integrity are maintained, but manufacturing cost increases significantly

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insert support member is divided into two distinct portions: a distal portion made of precious metal alloy for electrical conductivity during ablation, and a proximal portion made of less expensive material for structural support. This segmentation allows each portion to be optimized for its specific function while reducing overall manufacturing cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different materials are applied to different portions of the insert support member based on local functional requirements. The distal portion requires high electrical conductivity for RF ablation, while the proximal portion requires structural integrity for supporting components. This local quality approach ensures optimal performance where needed while minimizing cost elsewhere.

Inventive Principle:

Principle #3Local quality

2Device complexity

If conventional catheters use intricate micro-machining to produce complex geometry, then component integration is achieved, but manufacturing cost and production time increase

Engineering Contradiction:

Improvecomponent integrationVSAvoidmanufacturing cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

Multiple components including the insert support member, irrigation system, and temperature sensor are integrated into a single molded structure. This merging of components eliminates the need for separate assembly steps and intricate micro-machining, reducing both manufacturing cost and production time while maintaining functional integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The catheter tip employs composite construction with the insert support member made from less expensive material combined with precious metal alloy only where electrical conductivity is required. This composite approach allows complex geometry to be achieved through molding rather than costly micro-machining operations.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional catheters minimize the precious metal alloy portion, then manufacturing cost is reduced, but electrical connection reliability may be compromised

Engineering Contradiction:

Improvemanufacturing costVSAvoidelectrical connection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The precious metal alloy is pre-positioned in the distal portion of the insert support member where electrical connection is critical, while less expensive material is used in the proximal portion. This preliminary allocation of materials ensures electrical connection reliability is maintained at the critical interface while reducing overall cost.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The precious metal alloy is extracted from the entire insert support member and concentrated only in the distal portion where it is most needed for electrical conductivity during ablation. This extraction of the expensive material to only where necessary maintains electrical connection reliability while minimizing manufacturing cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12588944B2Method of manufacturing a tip electrode of an electrophysiology catheter

Publication Date: 2026.03.31 BIOSENSE WEBSTER (ISRAEL) LTD

AI summary

An irrigated electrophysiology catheter has a tip electrode having a shell, and a support member configured to plug the shell and support one or more tip components and/or facilitate their functions. Advantageously, the support member has an electrically-conductive interface portion and an insert-molded portion, wherein the interface portion, typically constructed of a precious metal alloy, is structurally minimized, yet still configured for electrical connection with the shell and the lead wire, so as to reduce the amount and hence the cost of its manufacture, whereas the insert-molded portion is constructed of a significantly less-costly material and is readily configured with micro-complex 3-D geometry adapted to support tip structure and functions including irrigation, force sensing and temperature sensing, as a further cost savings in the manufacturing of the tip electrode by reducing materials, labor and time.