Elongated Conductor Insulation Patterns for Automated Connections
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Solution Overview
Problem
Current manufacturing protocols for elongated electrical conductors in medical devices are time-consuming and expensive due to the need for manual or machine-based wire-by-wire connections, requiring color-coding and visual inspection, and involving complex soldering and wire bonding processes.
Innovation Solution
The development of elongated conductors with a pattern of insulation openings at the proximal and distal regions, allowing for easier handling and interconnection with device components, and methods for aligning and fixing insulated conducting members to reduce the need for individual wire identification and connection operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire-by-wire manual or machine connections are used with color-coding and visual inspection, then connection reliability is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The conductor assembly is segmented into distinct insulated conducting members with different insulation characteristics (e.g., insulation openings, insulation thickness, insulation material types) at connection regions. This segmentation allows automated identification and connection without manual wire-by-wire inspection, resolving the contradiction between connection reliability and manufacturing efficiency.
Solution Approach 2:
The manual visual inspection and identification process is replaced with automated optical or electrical detection systems that read the insulation characteristics (openings, thickness variations, material properties) to identify conducting members. This substitution enables high-speed automated assembly while maintaining connection reliability, addressing the productivity-reliability contradiction.
2Manufacturing precision
If individual wire identification and connection operations are performed, then connection accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The insulation structure serves multiple functions: it provides electrical insulation, enables automated identification through characteristic patterns (openings, thickness variations), and guides automated connection processes. This multi-functionality reduces manufacturing process complexity while maintaining connection accuracy, as a single structural feature accomplishes what previously required separate identification and connection steps.
Solution Approach 2:
The insulated conducting members self-identify through their inherent insulation characteristics (openings, thickness, material properties) without requiring external labeling or complex identification systems. The insulation structure itself provides the identification information, simplifying the manufacturing process while ensuring accurate connection, thus resolving the contradiction between precision and complexity.
3Reliability
If complex soldering and wire bonding processes are used, then electrical connection reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The insulation characteristics (openings, thickness, material composition) are changed to create identifiable patterns that enable automated identification and connection processes. These parameter changes in the insulation structure allow for simplified connection methods that maintain electrical reliability while significantly reducing manufacturing cycle time and cost compared to traditional soldering and wire bonding.
Data Source
AI summary
Elongated conductors are provided. Aspects of the elongated conductors include: an elongated structure having a proximal region and a distal region, where the elongated conductor includes two or more insulated conducting members that are in fixed relative position along at least a portion of the elongated structure and extend from the proximal region to the distal region. A pattern of insulation openings among the insulated conducting members is present at one or both of the proximal and distal regions. Aspects of the invention further include methods of making the elongated conductors, as well as devices that include the elongated conductors.