Medical Imaging PCB Assembly for Sealed Fluid Protection
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Solution Overview
Problem
Medical imaging devices often malfunction due to overcrowding and interference between components, leading to field failures, compromised image feeds, and wear between cables and components, resulting in significant rework or replacement costs.
Innovation Solution
A medical device design featuring a printed circuit board (PCB) with an optically clear covering, fixed cables, and an overmold that seals and protects the PCB and electronic components from external environments, while allowing channels for fluid and instrument passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If components are potted into a distal cap to consolidate structure, then structural integration is improved, but component overcrowding and interference worsen
Solution Approach 1:
The device is divided into functionally independent sections: a distal cap housing fluid channels and a separate PCB section housing electronic components (imager, lights, cables). This segmentation eliminates component overcrowding by distributing components across different spatial zones while maintaining structural integration through modular assembly.
2Illumination intensity
If plastic optical fibers are placed near imaging cables to provide illumination, then illumination function is improved, but interference with image feed worsens
Solution Approach 1:
The illumination function is extracted from the imaging pathway by placing plastic optical fibers in the distal cap separate from the imaging cables on the PCB. The distal cap acts as an independent illumination zone, preventing fiber-cable interference while maintaining adequate illumination of the imaging field.
3Volume of moving object
If cables are routed close to components to reduce device size, then device compactness is improved, but wear and corrosion between cables and components worsen
Solution Approach 1:
Different spatial zones are assigned different functions to minimize harmful interactions: the distal cap contains fluid channels and illumination fibers, while the PCB section contains electronic components and cables. This local quality differentiation creates adequate separation between cables and components, reducing wear and corrosion while maintaining overall device compactness.
4Ease of operation
If the PCB is exposed to the external environment to maintain channel access, then fluid passage is improved, but fluid ingress to electronic components worsens
Solution Approach 1:
The distal cap is designed with asymmetric functionality: it remains open to the external environment for fluid and instrument passage while the PCB is housed in a separate protected zone. The cap acts as an asymmetric barrier that allows necessary fluid access while preventing fluid ingress to the electronic components on the PCB.
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 design enhances image clarity and illumination, reduces wear and corrosion, and prevents fluid ingress, thereby improving device reliability and reducing maintenance costs.
Implementation Method 1
an optically clear covering, wherein the covering covers the imager and the at least one light
Data Source
AI summary
A medical device comprising a shaft defining a first channel having a distal opening, a printed circuit board (PCB) coupled to a distal end of the shaft to expose the distal opening to an external environment, wherein the PCB includes an imager and at least one light, the imager and the at least one light mounted on a distal facing surface of the PCB, and an optically clear covering, wherein the covering covers the imager and the at least one light.