Micro-Electrode Bead Formation by Electrical Discharge
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Solution Overview
Problem
Existing methods for creating extremely small electrodes for invasive medical probes are tedious, time-consuming, and require specialized equipment for soldering small platinum beads to conducting wires, limiting efficiency and scalability.
Innovation Solution
A method involving creating a bead of predefined size on the end of a metal wire through an electrical discharge between the wire and a conductor, which is then assembled into an invasive probe, eliminating the need for soldering and allowing for precise positioning and insulation of the bead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering methods are used to attach platinum beads to conducting wires, then reliable electrical contact is achieved, but the process becomes tedious, time-consuming, and requires specialized equipment
Solution Approach 1:
The patent replaces the mechanical soldering process with an electrical discharge (spark) process. A spark is generated between a conductor and the wire end, melting and forming a bead directly on the wire without requiring soldering equipment or materials. This substitution eliminates the need for specialized soldering equipment while maintaining reliable electrical contact through direct metallurgical bonding formed by the discharge.
Solution Approach 2:
The patent utilizes controlled changes in electrical parameters (voltage, current, pulse duration) to generate sparks of specific energy levels. By adjusting these parameters, the process forms beads of predefined sizes on the wire end. This parameter control enables precise bead formation and eliminates the time-consuming nature of traditional soldering, thereby improving productivity while ensuring reliable electrical contact.
2Manufacturing precision
If specialized equipment for soldering small platinum beads is used, then precise electrode assembly is achieved, but device complexity and time requirements increase
Solution Approach 1:
The patent replaces complex mechanical soldering equipment with a simpler electrical discharge system. The spark generation apparatus consists of basic electrical components (power supply, conductor positioning mechanism) rather than specialized soldering equipment. This substitution reduces device complexity while achieving precise bead formation through controlled electrical parameters and geometric relationships between the conductor and wire.
Solution Approach 2:
The electrical discharge system serves multiple functions: it heats the wire end, melts the metal, forms the bead, and creates the electrical connection all in one process. This multi-functionality eliminates the need for separate soldering equipment, flux application tools, and heating devices, thereby reducing overall device complexity while maintaining manufacturing precision.
3Adaptability or versatility
If multiple electrodes are placed on a single probe, then simultaneous sensing and ablation capabilities are improved, but the size of each electrode must be extremely small
Solution Approach 1:
The patent creates multiple discrete electrodes on a single probe by sequentially forming beads at different positions along the wire or by using multiple wires. Each bead is formed as a separate, isolated electrode through controlled spark discharge. This segmentation allows multiple electrodes to be placed on one probe for simultaneous sensing and ablation while maintaining precise control over each electrode's size and position through the standardized bead formation process.
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
Enables the efficient and precise production of micro-electrodes with defined sizes, reducing the complexity and time required for assembly while maintaining accurate electrical contact, suitable for minimally invasive medical procedures.
Implementation Method 1
creating an electrical discharge between the conductor and the end, while setting the distance and an electrical potential of the discharge, so as to create a bead of a predefined size on the end
Data Source
AI summary
A method, consisting of providing a metal wire having a wire diameter and an end, and positioning a conductor at a distance from the end of the wire. The method further includes creating an electrical discharge between the conductor and the end, while setting the distance and an electrical potential of the discharge, so as to create a bead of a predefined size on the end. The method also includes assembling the wire with the created bead into an invasive probe, so that the bead is positioned at an outer surface of the probe.