FFR Catheter Sensor Suspension via Flexible PCB
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Solution Overview
Problem
Conventional FFR devices experience inaccurate pressure measurements due to torsional forces affecting the pressure sensor, leading to errors in Fractional Flow Reserve calculations, and manufacturing challenges arise from the complex assembly of sensors within the distal shaft portion of catheters or guidewires.
Innovation Solution
A catheter or guidewire system with a distal shaft housing a pressure sensor suspended on a flexible printed circuit board, isolated from external stresses through a sensor lumen and fixation points, allowing blood flow through an aperture for accurate pressure measurement, and a method for manufacturing this system that simplifies the assembly by using a separate cover and fixation points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pressure sensor is mounted directly on the distal shaft portion, then the manufacturing process becomes simpler, but the sensor becomes vulnerable to torsional forces causing inaccurate measurements
Solution Approach 1:
The patent introduces a flexible printed circuit board (PCB) as an intermediary element between the distal shaft portion and the pressure sensor. The PCB is coupled to the distal shaft portion and suspends the pressure sensor thereon, creating a mechanical decoupling that protects the sensor from torsional forces while maintaining the manufacturing simplicity of direct mounting. This intermediary structure allows the sensor to be isolated from harmful stresses without complicating the overall assembly process.
2Measurement precision
If the pressure sensor is suspended on a flexible printed circuit board, then the sensor is protected from torsional forces, but the manufacturing complexity increases
Solution Approach 1:
The patent employs a flexible printed circuit board (PCB) as a thin, flexible structure that serves multiple functions: it provides mechanical support for the pressure sensor, electrical connections, and acts as a protective element isolating the sensor from torsional forces. The flexible nature of the PCB allows it to conform to the distal shaft portion while maintaining the sensor's protection, achieving a balance between structural complexity and functional requirements.
3Reliability
If the distal shaft portion is designed with a housing and cover structure, then the sensor is better protected from external stresses, but the manufacturing process becomes more difficult
Solution Approach 1:
The patent divides the protective structure into separate components: a distal shaft portion housing and a removable cover. The pressure sensor is mounted on the flexible PCB within the housing, and the cover can be separately attached to complete the protective enclosure. This segmentation allows each component to be manufactured and assembled independently, reducing the overall manufacturing difficulty while maintaining the reliability benefits of a complete housing structure.
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
The solution provides stable and accurate distal pressure measurements, reducing errors from torsional forces and simplifying the manufacturing process, enabling precise Fractional Flow Reserve calculations.
Implementation Method 1
A flexible printed circuit board is coupled to the housing. The pressure sensor is coupled to the flexible printed circuit board and suspended within the housing
Implementation Method 2
An aperture is configured to allow blood flow into the housing and into contact with the pressure sensor
Data Source
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AI summary
A catheter for measuring a pressure distal of a stenosis includes a shaft including a housing in a distal portion of the shaft. A flexible printed circuit board is coupled to the housing. A pressure sensor is coupled to the flexible printed circuit board and is suspended within the housing. An aperture enables blood flow into the housing and into contact with the pressure sensor.