Embedded Electrode Sleeve Assembly for Automated Catheter Bonding
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Solution Overview
Problem
The manual process of connecting multiple electrodes on cardiac catheters is labor-intensive, time-consuming, and difficult to regulate for quality control due to their small scale.
Innovation Solution
An automated manufacturing method and apparatus that electrically connects ring-shaped electrodes to a flexible printed circuit board (fPCB) and integrates the electrode-fPCB assembly on a sleeve, using injection molding to form a plastic sleeve over the assembly, while maintaining the proximal end of the fPCB strip exposed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering is used to connect electrodes to wires, then electrical connections can be established, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical soldering operations with an automated wire bonding system that uses ultrasonic welding or thermocompression bonding. This substitution eliminates the need for skilled manual labor while maintaining connection quality, directly resolving the contradiction between reliable electrical connections and manufacturing productivity.
Solution Approach 2:
The automated wire bonding machine performs alignment, bonding, and trimming operations automatically without human intervention. The system self-regulates parameters such as bonding pressure, temperature, and ultrasonic energy to ensure consistent connection quality while maximizing manufacturing speed.
2Manufacturing precision
If manual alignment and soldering are performed, then electrode connections can be made, but quality control becomes difficult to regulate
Solution Approach 1:
The automated wire bonding system incorporates sensors and vision systems that provide real-time feedback on electrode position and bonding quality. This feedback mechanism enables automatic adjustment of alignment and bonding parameters, ensuring consistent manufacturing precision while making quality control easily regulable through programmable parameters.
Solution Approach 2:
The system performs preliminary alignment using vision systems and precision positioning mechanisms before the actual bonding operation. This preliminary action ensures that electrodes are precisely positioned relative to the catheter shaft, eliminating alignment variability and simplifying quality control through standardized pre-positioning procedures.
3Measurement precision
If multiple electrodes are disposed in a small space on catheter, then precision and accuracy are improved, but the complexity of electrical connections increases
Solution Approach 1:
The patent segments the electrode connection process into distinct operational stages: positioning, bonding, and trimming. Each stage is handled by specialized components of the automated system, allowing multiple electrodes in close proximity to be connected systematically without increasing overall process complexity.
Solution Approach 2:
The automated wire bonding machine performs multiple functions including alignment, bonding, insulation application, and wire trimming within a single integrated system. This multi-functionality handles the complexity of connecting multiple electrodes in a small space without requiring separate manual operations for each connection.
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
Facilitates efficient, automated, and high-quality electrical connections between electrodes and fPCB, reducing labor costs and improving precision and accuracy in catheter manufacturing.
Implementation Method 1
The heat source is configured to apply heat for soldering the pad to an inner surface of the electrode
Implementation Method 2
an injection molding device is configured to mold an encapsulating sleeve over the electrode-fPCB assembly
Data Source
AI summary
An apparatus for manufacturing catheter electrode-fPCB assemblies, the apparatus includes a tray, a heat source, and a sleeve molding station. The tray is configured to (i) receive an electrode in a designated first recess in a predefined layout of the recess, wherein the electrode is ring-shaped and (ii) receive a flexible printed circuit board (fPCB) strip in a second recess configured to enable to thread the fPCB strip via the electrode to a predefined position of the strip such that a pad patterned on the fPCB strip is aligned with the electrode. The heat source is configured to apply heat for soldering the pad to an inner surface of the electrode. The sleeve molding station is configured to mold an encapsulating sleeve over the electrode-fPCB assembly, while keeping a proximal end of the strip and at least a portion of the electrode exposed.