Intraoral X-Ray Sensor Cable with Braided Shield and Thermal Conduction

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Solution Overview

Problem

Intraoral x-ray sensor cables face mechanical stress and heat management issues due to repeated use and operation within the oral cavity, leading to potential malfunction and temperature-related safety concerns.

Innovation Solution

A twisted-quad USB cable with a braided shield and heat-conducting wire, along with a thermally conductive isolation layer, is integrated into the sensor housing to enhance mechanical strength and heat transfer, featuring a metallic layer for efficient heat dissipation and a stress relief mechanism to prevent cable damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a standard cable is used to couple the intraoral sensor to the output device, then the device complexity is low and ease of manufacture is high, but the cable suffers from mechanical stress and wear leading to reduced reliability

Engineering Contradiction:

Improvecable reliabilityVSAvoidcable structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable incorporates a composite structure combining multiple materials: a braided shield layer for mechanical strength and EMI shielding, a thermally conductive isolation layer for heat management, and a twisted-quad USB cable core for data transmission. This composite construction enhances cable reliability while maintaining practical manufacturability through modular assembly of standardized components.

Inventive Principle:

Principle #40Composite materials

2Productivity

If the intraoral sensor operates continuously to capture images, then productivity is improved, but mechanical stress on the cable increases leading to reduced durability

Engineering Contradiction:

Improveimage capture efficiencyVSAvoidcable service life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The cable design incorporates a braided shield layer and thermally conductive isolation layer that provide mechanical reinforcement and stress distribution before damage can occur. These protective layers are integrated into the cable structure in advance, allowing the cable to withstand repeated positioning operations and twisting forces that occur during continuous image capture procedures.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Power

If the electronics within the intraoral sensor generate heat during operation, then the sensor can function properly, but the temperature can rise above safety limits causing patient injury

Engineering Contradiction:

Improvesensor operating powerVSAvoidheat damage to patient

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The thermally conductive isolation layer serves as an intermediary between the heat-generating electronics and the patient's oral tissues. This layer provides a controlled thermal pathway that dissipates heat away from the sensor housing while maintaining electrical insulation, preventing direct heat transfer to the patient and keeping operating temperatures within safety limits established by IEC 60601-1.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If a thicker cable with better mechanical protection is used, then the cable strength is improved, but the ease of operation and patient comfort are reduced

Engineering Contradiction:

Improvecable mechanical strengthVSAvoidcable flexibility and patient comfort

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The cable employs local quality enhancement by concentrating protective features where needed: the braided shield provides mechanical strength and EMI shielding at the cable exterior, while the thermally conductive isolation layer is positioned internally near heat-generating components. The core twisted-quad USB cable maintains flexibility for easy positioning. This distributed protection strategy achieves high overall strength without uniformly increasing cable diameter, preserving ease of operation and patient comfort.

Inventive Principle:

Principle #3Local quality

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 significantly increases the cable's resistance to mechanical stress and improves heat transfer, extending the lifespan of the intraoral sensor system while ensuring safe operating temperatures within regulatory limits.

Implementation Method 1

The outer sheath includes a braided shield and is coupled via a heat-conducting wire to a metallic layer substantially covering an inner surface of the top portion

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

a metallic layer substantially covering an inner surface of the top portion... efficient heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

an isolation layer within the sensor housing... electrically insulating and heat conducting

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

At least two lines of the first data line, the second data line, the ground line, and the power line are twisted together to form a single bundle

Methodology Applied

Scientific EffectMechanical strength through twisted bundle structure:

Data Source

PatentUS9510796B2Intraoral x-ray sensor with embedded standard computer interface

Publication Date: 2016.12.06 DENTAL IMAGING TECHNOLOGIES CORP

AI summary

An intraoral x-ray sensor including a sensor housing and a universal serial bus (USB) data cable. The sensor housing has an opening. The USB data cable includes an outer sheath and a first data line, a second data line, a ground line, a power line, and at least two independent fillers positioned within the outer sheath. In one embodiment, at least two lines selected from the group including the first data line, the second data line, the ground line, and the power line are twisted together to form a single bundle. The opening receives the data cable.