Laser Structured Catheter Connector for Reliable Signal Transmission

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Solution Overview

Problem

Existing intravascular imaging catheters have fragile connection mechanisms that are difficult and expensive to manufacture, prone to misassembly, and limit the number of electrical contacts, leading to unreliable signal transmission and increased costs and complications in imaging procedures.

Innovation Solution

A connector system with micron-scale thin electrical contacts formed on a unitary body made of thermoplastic doped with an organo-metal complex, allowing for reliable and consistent connections and increased signal transmission capacity, enabling more efficient and safer intravascular imaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional assemblage connectors with metal rings and plastic slugs are used, then electrical contacts can be made, but the connectors are fragile, difficult to manufacture, and prone to misassembly

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (metal rings, plastic slugs, mounting structures) into a single integrated connector body made of laser-structured plastic. This unitary construction eliminates the fragility and misassembly issues of assemblage connectors while maintaining all necessary electrical contact functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical assembly methods with laser structuring technology. The connector features are directly formed into the plastic body using laser beams, eliminating the need for separate metal rings, plastic slugs, and manual assembly operations. This substitution creates a more reliable and manufacturable connector.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If traditional connectors with spaced metal rings are used, then electrical contacts are provided, but the number of contacts is limited and scaling is difficult

Engineering Contradiction:

Improvenumber of electrical contactsVSAvoidmanufacturing scalability

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental parameters of connector construction by using laser-structured plastic features instead of traditional metal rings. This enables continuous scaling of the number of contacts by simply adding more laser-structured features to the plastic body, without increasing manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The laser-structured plastic connector body serves multiple functions simultaneously: it provides the structural housing, creates the electrical contact features, and enables scalable contact arrangements. This universal approach allows the same manufacturing process to produce connectors with any number of contacts needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If traditional connectors are used, then connections can be made, but assembly errors and misuse increase costs and require do-overs

Engineering Contradiction:

Improveimaging operation efficiencyVSAvoidconnection reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The connector features are pre-formed into the plastic body during manufacturing using laser structuring, before the connector is ever assembled or used. This preliminary formation of all contact features eliminates the possibility of assembly errors and ensures consistent, reliable connections from the first use.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent embraces the disposable nature of intravascular catheters by creating a connector that is inherently reliable and consistent for single-use applications. The laser-structured plastic connector ensures that every disposable catheter provides reliable electrical contact without requiring complex reusable components, eliminating the need for do-overs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 connector system ensures reliable connections, reduces imaging failures, and allows for the incorporation of new technologies, enabling more precise and widespread detection of plaque buildup, thus improving patient care and reducing costs.

Implementation Method 1

A laser beam is used to deposit metal onto a plastic body to provide a structured catheter connection

Methodology Applied

Scientific EffectLaser deposition: Pulsed Laser Deposition

Data Source

PatentUS10027075B2Laser direct structured connection for intravascular device

Publication Date: 2018.07.17 PHILIPS IMAGE GUIDED THERAPY CORP

AI summary

The invention generally relates to intravascular imaging catheters and methods of making catheters for imaging systems. The invention provides a connector for an imaging catheter that includes a unitary body with very thin electrical contacts that are formed on the surface of the body. Due to the scale of the contacts, the connector operates essentially as a single unitary piece of material. Each of the leads may be less than about 100 μm wide and less than about 8 μm thick, and further the leads may be spaced apart by less than about 160 μm.