Sensor Guide Wire Crimped Jacket Coil Attachment
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Solution Overview
Problem
Existing sensor and guide wire assemblies face challenges in achieving strong and reliable attachment of coils to the jacket due to small contact areas, alignment issues, and variability in manual gluing or soldering processes, leading to inconsistent joint strength and manufacturing inefficiencies.
Innovation Solution
The jacket is designed with crimpable end portions that securely attach to the core wire, allowing for a larger contact area with coils, which are then optionally glued or soldered, ensuring a robust and centered assembly without the need for extensive manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the jacket has uniform inner and outer diameters over its entire length, then the manufacturing process is simple, but the contact area between the jacket end surface and the coil is very small, resulting in weak attachment
Solution Approach 1:
The jacket is designed with different diameters at different locations: the middle portion has a first diameter while the end portions have a second diameter that is smaller than the first diameter. This local variation in geometry increases the contact area between the jacket end surface and the coil, thereby strengthening the attachment while maintaining simple manufacturing of the uniform middle portion.
2Adaptability or versatility
If manual gluing or soldering is used to attach the coil to the jacket, then the attachment process is flexible, but the joint strength varies over time and differs between operators
Solution Approach 1:
The jacket end portions are pre-formed with a smaller diameter than the middle portion, creating a geometric feature that facilitates consistent and reliable attachment of the coil. This preliminary geometric preparation ensures that when the coil is attached (whether by gluing, soldering, or other methods), the contact area is maximized, leading to consistent joint strength across different operators and over time.
3Device complexity
If the jacket and coil are aligned manually, then the assembly process is simple, but it is difficult to align and centre the jacket and coils with respect to each other, resulting in uneven transition
Solution Approach 1:
The jacket is designed with asymmetric diameter variation: the end portions have a smaller diameter than the middle portion. This asymmetric geometry creates a natural guide that facilitates automatic alignment and centering of the coil on the jacket during assembly, eliminating the need for complex alignment procedures while ensuring uniform transition and high manufacturing precision.
4Strength
If the outer diameter of the jacket after crimping is adapted to the inner diameter of the coil, then a large contact area is provided for strong attachment, but the manufacturing process becomes more complex
Solution Approach 1:
The jacket is designed with local quality variation where the end portions have a smaller diameter than the middle portion. This local geometry allows the jacket to be crimped onto the core wire to create a customized outer diameter at the end portions that matches the inner diameter of the coil, providing large contact area for strong attachment. The uniform middle portion maintains simple manufacturing while the end portions achieve optimized geometry for coil attachment.
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
This approach results in a more reliable and efficient manufacturing process with stronger joints and a smoother transition between the jacket and coils, reducing variability and facilitating the production of sensor and guide wire assemblies with improved mechanical properties.
Implementation Method 1
at least one end portion of the jacket has been crimped onto a core wire
Implementation Method 2
The first and second coils can be attached to the respective end of the jacket by gluing, or alternatively soldering
Implementation Method 3
The first and second coils can be attached to the respective end of the jacket by gluing, or alternatively soldering
Implementation Method 4
The sensor element comprises a pressure sensitive device, e.g. a membrane, with piezoresistive elements connected in a Wheatstone bridge-type of arrangement mounted thereon
Data Source
AI summary
The invention relates to a sensor and guide wire assembly (21) for intravascular measurements of physiological variables in a living body, comprising a core wire (22), a first coil (23), a jacket (24), and a second coil (25). The jacket (24) comprises a first end portion (24a), which is crimped onto the core wire (22) and over which a portion of the first coil (23) is threaded, and a second end portion (24b), which is crimped onto the core wire (22) and over which a portion of the second coil (25) is threaded.