Heat-Shrink Sensor Mounting for Surgical Navigation
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Solution Overview
Problem
Conventional methods for mounting electromagnetic sensors on surgical instruments, such as soldering, crimping, and adhesives, often damage the fragile sensors and lead wires, leading to connection failures during manufacturing and potentially incorrect navigation during surgery.
Innovation Solution
A medical sensor mounting system using heat-shrinkable polymeric materials to form a secure, insulated axial pathway around the sensor and lead wire, eliminating the need for destructive mechanical or heated engagements, thereby maintaining a reliable electrical connection without damaging the sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting methods (soldering, crimping, adhesives) are used to attach electromagnetic sensors to surgical instruments, then the sensor can be securely mounted, but the fragile sensors and lead wires are damaged leading to connection failures
Solution Approach 1:
The patent introduces a polymeric adhesive composition as an intermediary material between the sensor/lead wire assembly and the surgical instrument. This adhesive layer acts as a protective mediator that distributes mechanical stresses and protects the fragile electrical connections from direct mechanical engagement forces during crimping or soldering operations, thereby preventing connection failures while maintaining secure mounting.
Solution Approach 2:
The patent employs low-temperature adhesive bonding instead of high-temperature soldering or high-force crimping. By changing the mounting parameter from thermal/mechanical stress to chemical adhesion at lower temperatures, the fragile sensor and lead wire connections are protected from damage while achieving reliable attachment to the surgical instrument.
2Stability of the object's composition
If secure mechanical engagement is achieved through conventional methods, then the sensor mounting is stable, but the manufacturing process becomes complex and prone to failures
Solution Approach 1:
The patent replaces complex mechanical mounting systems (soldering equipment, crimping tools, precision alignment fixtures) with a simpler adhesive bonding process. The polymeric adhesive provides stable mechanical engagement through chemical adhesion and cohesive strength, eliminating the need for specialized mechanical mounting equipment and complex manufacturing procedures while achieving equivalent or superior mounting stability.
3Measurement precision
If electromagnetic sensors are used for accurate navigation positioning, then the navigation precision is high, but the sensors are extremely fragile and susceptible to damage
Solution Approach 1:
The patent applies a protective polymeric adhesive layer beforehand to cushion and protect the fragile electromagnetic sensor and lead wire connections from mechanical stresses during manufacturing, handling, and surgical use. This protective cushioning maintains the sensor's structural integrity and electrical connections while preserving its measurement precision for accurate navigation positioning.
Solution Approach 2:
The patent creates a composite mounting structure combining the fragile electromagnetic sensor, conductive lead wires, and polymeric adhesive material. This composite construction provides both the electrical functionality needed for precise navigation and the mechanical durability required to withstand manufacturing and surgical conditions, protecting the sensitive components while maintaining measurement accuracy.
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 system ensures high-quality navigation positioning by maintaining a secure electrical connection between the sensor and lead wire, reducing manufacturing failures and ensuring accurate sensor placement during surgical procedures, thus enhancing the reliability and safety of surgical navigation systems.
Implementation Method 1
heat-shrinkable polymeric materials to form a secure, insulated axial pathway around the sensor and lead wire
Data Source
AI summary
An engagement system for a surgical sensor assembly, formed of a sensing component in a fixed position and a lead wire in an electrical communication therewith. The engagement system employs a jacket of heat shrink polymeric material to hold the sensing component to the lead wire and eliminates the employment of soldering and welding and crimping which can damage such sensing components. The system is employed in combination with catheters having a lumen for control wires for surgical instruments.