Medical Probe Uniform Helix Interconnect for MRI Stability
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Solution Overview
Problem
Existing medical probes for deep brain stimulation face mechanical instability and damage due to bends and connections in the coiled thin film foils, leading to unreliable electrical connections and increased risk of breakage.
Innovation Solution
A medical probe design featuring a uniform helix element made from a single thin film foil, wound onto a cylindrical base element, providing a stable and efficient connection between the proximal and distal ends without mechanical connections or bends, and protected by a transparent overmould for enhanced durability and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the thin film foil is coiled as a helix to suppress MRI-induced currents, then MRI compatibility is improved, but the mechanical stability and integrity of the foil deteriorates due to bends and connection points
Solution Approach 1:
The thin film foil is divided into multiple sections that are connected through overlapping regions. Each section can be coiled independently as a helix, allowing MRI compatibility while the overlapping connections distribute mechanical stress, preventing breakage at single points
Solution Approach 2:
The thin film foil is pre-coated with a protective layer before coiling into a helix. This protective coating is applied in advance to prevent mechanical damage during the coiling process and to maintain integrity throughout the device's lifetime, addressing reliability concerns before assembly occurs
2Length of moving object
If multiple sections of thin film foil are connected to form long lengths, then the required length for interconnect is achieved, but mechanical and electrical properties become non-uniform at connection points
Solution Approach 1:
Multiple thin film foil sections are merged through overlapping connections where adjacent sections are positioned to overlap by a predetermined distance. This merging approach ensures continuous electrical conductivity and uniform mechanical properties across the entire length, eliminating weak points at connection regions
Solution Approach 2:
The overlapping connection method ensures that all sections of the thin film foil have identical mechanical and electrical properties throughout. The overlap regions are designed to maintain consistent thickness, material composition, and conductive characteristics, achieving homogeneity across the entire interconnect length
3Length of moving object
If the thin film foil is folded into bends to achieve long straight structures, then the required length is achieved, but the bend areas become thicker and prone to cracking
Solution Approach 1:
Instead of sharp bends and folds, the thin film foil is coiled into a smooth helical structure. This curved configuration distributes mechanical stress evenly throughout the foil, eliminating concentrated stress points that would lead to cracking, while achieving the required length through the helical geometry
Data Source
AI summary
A medical probe is provided that has a single longitudinally uniform interconnect that provides a connection between a distal end and a proximal end of the probe. The interconnect is obtained by forming a thin uniform film as a spiral on a wafer and subsequently applying this spiral as a helix on a base element of a medical probe. The thin film spiral is manufactured with multiple connecting wires to enable connection between an electronics module and a multiplicity of electrodes (an electrode array) at the distal end of the medical probe.