Intraluminal Support Member for Catheter-Imaging Junction
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Solution Overview
Problem
Intraluminal imaging devices face variability in connection strength and profile at the junction between the imaging assembly and the catheter shaft, affecting navigational capability and imaging reliability due to inconsistent soldering and epoxy encasement processes.
Innovation Solution
A connecting support member with a proximal section matching the catheter shaft and a distal section matching the imaging assembly, providing a consistent smooth transition, increased mechanical strength, and a complete electrical seal to prevent liquid ingress, which is molded to match the respective diameters and shapes, and includes a lumen for a communication cable and adhesive for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering and epoxy encasement processes are used to connect the imaging assembly and catheter shaft, then electrical connection is achieved, but connection strength and profile consistency deteriorate due to high variation between devices
Solution Approach 1:
A support member is introduced as an intermediary component between the imaging assembly and catheter shaft. This support member provides a consistent structural framework that mediates the connection, replacing the variable soldering and epoxy process with a more reliable mechanical interface while maintaining electrical connectivity through integrated contacts.
Solution Approach 2:
The invention changes the connection methodology from chemical/adhesive-based (soldering and epoxy) to mechanical-based (support member with integrated contacts). This parameter change in the connection mechanism eliminates the variability inherent in manual soldering and epoxy application, providing consistent connection strength and profile across all devices.
2Productivity
If manual soldering and epoxy application are performed to encase connections, then electrical connectivity is established, but labor intensity and manufacturing efficiency worsen due to high variation requiring repeated adjustments
Solution Approach 1:
The support member serves as a pre-fabricated intermediary component that consolidates multiple functions (structural support, electrical connection, signal transmission) into a single unit. This eliminates the need for operators to perform multiple manual steps including soldering, epoxy application, and profile adjustment, thereby reducing labor intensity and improving manufacturing efficiency.
Solution Approach 2:
The invention merges multiple separate components and functions into a single integrated support member. The support member combines structural support, electrical contacts, and signal transmission capabilities in one component, replacing the previously separate soldering, epoxy encasement, and alignment processes with a single assembly operation.
3Device complexity
If a simple electrical cable connection is used in solid-state IVUS, then device complexity is reduced, but mechanical strength and electrical seal at the junction deteriorate
Solution Approach 1:
The support member merges mechanical support and electrical connection functions into a single integrated component. Rather than using a simple cable that provides only electrical connectivity, the support member simultaneously provides structural reinforcement at the junction and maintains electrical contacts, thereby improving mechanical strength without significantly increasing device complexity.
Solution Approach 2:
The support member appears to be constructed from composite materials that provide both mechanical strength and electrical conductivity. This composite structure allows the single component to fulfill dual functions: providing robust mechanical support at the junction while maintaining reliable electrical and signal connections to the imaging assembly.
4Reliability
If epoxy is used to encase soldered connections, then electrical connection is secured, but the outer profile consistency deteriorates due to high variation in epoxy shaping
Solution Approach 1:
The support member acts as an intermediary that provides a pre-formed, consistent structural interface between the imaging assembly and catheter shaft. This eliminates the need for epoxy encasement and subsequent shaping operations, as the support member itself provides the necessary mechanical and electrical interface with a consistent outer profile from manufacturing.
Solution Approach 2:
The invention extracts and eliminates the epoxy encasement step from the assembly process. By removing the epoxy application and shaping operations, the source of profile variation is eliminated. The support member provides all necessary functions without requiring adhesive encasement, thereby ensuring consistent outer profile smoothness.
Data Source
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AI summary
An intraluminal imaging device is provided that includes a flexible elongate member configured for positioning within a vessel of a patient, a support member coupled to the flexible elongate member; and an imaging assembly coupled to the support member. The support member can include a proximal section with a first cross-sectional profile configured to interface with a distal portion of the flexible elongate member and a distal section with a second cross-sectional profile configured to interface with a proximal portion of the imaging assembly, wherein the first cross-sectional profile is different than the second cross-sectional profile. Associated devices, systems, and methods are also provided.