Catheter Tip Transducer Array Acoustic Coupling and Thermal Management
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Solution Overview
Problem
Current catheter-based ultrasonic probes face challenges in providing a cost-effective and reliable acoustic transmission medium and effective cooling for transducer arrays, while also being adaptable for use in real-time three-dimensional imaging and mass production for various catheter types.
Innovation Solution
The development of ultrasonic imaging catheter tip assemblies with a movable transducer array, an electromechanical actuator, and alternative methods for acoustic transmission medium management, such as using a solid material, gel, or fluid permeable membrane, to ensure efficient sound transmission and temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a catheter-based ultrasound transducer array is implemented for real-time three-dimensional imaging, then imaging capability and diagnostic accuracy are improved, but the complexity of providing acoustic transmission medium and thermal management increases
Solution Approach 1:
The catheter system is divided into modular components: a reusable catheter body and a disposable catheter tip assembly containing the transducer array. This segmentation simplifies the overall system by allowing the complex transducer assembly to be pre-packaged and pre-filled with acoustic transmission medium, reducing the complexity burden on the main catheter system while maintaining high imaging accuracy.
Solution Approach 2:
The catheter tip assembly is pre-filled with acoustic transmission medium during manufacturing before sterilization and packaging. This preliminary action eliminates the need for complex fluid filling mechanisms in the clinical setting, reducing device complexity while ensuring proper acoustic coupling for high-quality imaging.
2Reliability
If transducer arrays are cooled during operation to maintain temperature limits, then reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The acoustic transmission medium serves dual functions: it provides acoustic coupling for ultrasound transmission and acts as a cooling medium for the transducer array. This merging of functions eliminates the need for separate cooling systems, reducing device complexity while maintaining reliable temperature control during operation.
Solution Approach 2:
The fluid filling the catheter tip assembly performs multiple roles simultaneously: acoustic transmission medium for ultrasound imaging and thermal management medium for cooling the transducer array. This multi-functionality reduces overall system complexity while ensuring both imaging quality and thermal reliability.
3Productivity
If catheter tips are mass-produced for various catheter types, then cost-effectiveness and productivity are improved, but adaptability to different catheter systems becomes more challenging
Solution Approach 1:
The catheter tip assembly is designed with universal connection features that allow it to interface with multiple types of catheter bodies. Standardized mounting interfaces and connection protocols enable a single disposable tip design to be compatible across different catheter platforms, maintaining adaptability while enabling mass production economies.
Solution Approach 2:
By separating the catheter system into a reusable body and a disposable tip assembly, the design allows standardization of the tip component for mass production while the catheter body can vary to suit different applications. This segmentation enables economies of scale in tip manufacturing without sacrificing system adaptability.
4Reliability
If disposable catheter tip assemblies are used with reusable catheter bodies, then reliability and ease of manufacture are improved, but the quantity of materials and waste management becomes a concern
Solution Approach 1:
The catheter tip assembly is designed as a disposable component that can be sterilized and reused for multiple patients if needed, extending its service life. This approach allows for cost-effective mass production while reducing waste compared to single-use designs, as each tip can serve multiple patients before disposal, thereby managing material consumption more efficiently.
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
These solutions enable cost-effective, reliable, and adaptable catheter tips for real-time three-dimensional imaging, allowing for flexible assembly with different catheter systems and improved thermal management, enhancing the accuracy and durability of ultrasonic imaging.
Implementation Method 1
an acoustic transmission medium in a space between the outer border of the rotatable cylinder and an inner surface of the catheter tip
Implementation Method 2
effectively cooling the transducer array and internal actuator to stay within prescribed temperature limits during use within a living person
Data Source
AI summary
A catheter tip (50, 170, 750) is provided that is adapted for mating attachment to a catheter body (90, 300, 790). In an embodiment, the catheter tip (50, 170, 750) comprises a transducer array (32, 60, 110, 210, 710) in electrical communication with an interconnect (120, 220, 720) and in a mechanical driven relationship with an actuator (80, 730), also in the catheter tip (50, 170, 750), via a drive shaft (38, 82, 732). The transducer array (710) is encapsulated in a potting material body 711 providing a desired ultrasound acoustical transmission, A defined annular space 761 exists between an outer capsule 752 of the catheter tip 750 and the potting material body 711. Oscillating back and forth motion of the transducer array (32, 60, 110, 210, 710) provides ultrasonic imaging functionality that may include real time three-dimensional imaging. Other embodiments of the catheter tip (50, 170, 750) and methods of fabrication also are provided.