Electromagnetic Navigation Sensor Coil With Twist-Pair Assembly
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Solution Overview
Problem
Current sensors used in catheters for luminal navigation are prone to failure due to strain from bending forces, as they require metal bonding connections which are not durable enough for the stresses encountered during use.
Innovation Solution
A method and device for forming a sensor using a twisted pair of wire without mechanical connections, where the wire is wound and twisted to form a cohesive wound region that is tensioned and bonded to itself, eliminating the need for soldering or other mechanical joining, and allowing the sensor to be securely attached to a substrate that can be easily removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal bonding connections (soldering) are used to fabricate the sensor, then the sensor can be assembled with discrete wires, but the sensor and its connections experience strain that can result in failure during use
Solution Approach 1:
The patent merges the discrete wire segments into a continuous twisted pair structure. Instead of assembling separate wire components with mechanical bonds, the sensor is formed from a single continuous wire that is twisted into its functional configuration, eliminating the weak bonding interfaces that cause failure under strain.
Solution Approach 2:
The patent replaces the mechanical bonding system (soldering and mechanical connections) with a continuous twisted pair structure. The electrical and mechanical continuity is achieved through the twisted wire geometry itself rather than through separate bonding processes, eliminating the need for fragile mechanical joints.
2Ease of manufacture
If discrete wires with mechanical connections are used, then the sensor can be fabricated using conventional methods, but the connections are not durable enough to withstand bending forces during catheter navigation
Solution Approach 1:
The patent combines multiple wire functions into a single continuous twisted pair. The electrical conductors, mechanical strength elements, and strain distribution components are all integrated into one continuous structure, eliminating weak points at connection interfaces while maintaining manufacturability through the twisting process.
3Ease of operation
If the sensor uses bonded connections to secure wires, then the assembly can be held together, but the bonded connections fail under the strain of bending forces during luminal navigation
Solution Approach 1:
The patent substitutes the mechanical bonding system with a continuous twisted pair configuration. The twisted geometry provides both electrical connectivity and mechanical strength without requiring separate bonding operations, distributing stresses along the entire length of the continuous wire rather than concentrating them at bond interfaces.
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 enhances the durability and longevity of the sensor by preventing breakage and allowing it to withstand the mechanical stresses of navigation within luminal networks, such as the airways of the lungs, without the need for additional mechanical connections.
Implementation Method 1
the wire is wound and twisted to form a cohesive wound region that is tensioned and bonded to itself, eliminating the need for soldering or other mechanical joining
Data Source
AI summary
A method and device for forming a sensor, the method including winding a desired length of wire from a first spool to a second spool, transferring the second spool to a spindle mounted in axial alignment with a substrate, securing the wire to a substrate, rotating the substrate about its axis such that the wire is drawn from the first spool to form a wound region, transferring the second spool to a twist former on which the first spool is mounted, and rotating the first spool and the second spool relative to each other to form a twist pair from the wire.