Open Magnetic Coil Printing for Catheter Location and Force Sensing
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Solution Overview
Problem
Existing catheter technologies face challenges in fitting accurate location and force sensors within the narrow body of catheters, as conventional methods are time-consuming, costly, and prone to manufacturing defects, especially when attempting to fabricate miniature open magnetic circuit coils with high induced voltage and sensitivity.
Innovation Solution
The use of 3D-printing technology to fabricate electric components with open magnetic circuit electric coils, embedding ceramic and/or glass-ceramic solid bodies with coils made from magnetic, conductive, and non-magnetic dielectric materials, allowing for the creation of high-sensitivity coils with improved aspect ratios and reduced dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wire-winded coils with ferrite cores are used, then location and force sensing is achieved, but manufacturing is time-consuming and costly with high defect rates
Solution Approach 1:
The patent replaces conventional mechanical wire-winding and manual ferrite core insertion with 3D printing technology. The 3D printing process directly fabricates the coil structure with integrated magnetic cores, eliminating manual assembly operations and reducing manufacturing complexity while maintaining sensing accuracy.
Solution Approach 2:
The patent merges the coil winding process and ferrite core integration into a single 3D printing operation. The magnetic cores are printed directly within the coil structure, combining what were previously separate manufacturing steps into one integrated process, thereby reducing time and cost.
2Measurement precision
If miniature open magnetic circuit coils are fabricated with conventional methods, then high induced voltage and sensitivity are achieved, but manufacturing defects increase and production efficiency decreases
Solution Approach 1:
The patent replaces labor-intensive manual fabrication methods with automated 3D printing technology. This substitution enables consistent production of miniature coils with high sensitivity while dramatically improving production efficiency and reducing human error-related defects.
Solution Approach 2:
The patent utilizes 3D printing parameters (layer thickness, infill density, printing speed, material composition) to optimize coil geometry and magnetic properties. By adjusting these parameters, the system achieves high induced voltage and sensitivity in miniature coils while maintaining efficient mass production capability.
3Length of moving object
If catheter dimensions are reduced for better patient comfort, then insertion ease improves, but fitting accurate sensors becomes more difficult
Solution Approach 1:
The patent uses 3D printing to fabricate coils with precise dimensional control at micro-scales. This technology enables the production of accurately dimensioned sensor components that fit within narrow catheter bodies, maintaining sensing accuracy despite reduced overall catheter dimensions.
Solution Approach 2:
The patent segments the catheter into modular sections with integrated sensors positioned at specific locations. The 3D printed coils can be precisely placed at distal tips or intermediate sections, allowing accurate sensing functionality within constrained dimensional boundaries.
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
This method enables the cost-effective and efficient fabrication of miniature open magnetic circuit coils with high induced voltage and sensitivity, suitable for accurate location and force sensing within catheters, while also facilitating mass production with reduced variability.
Implementation Method 1
Catheters having integrated location and pressure sensors for sensing the location of the catheter and the pressure/force applied thereby at the contact region with the tissue, are generally known. Such catheters typically utilize inductive coils for determining the location of the catheter within the body and/or the pressure/force applied thereby to a body tissue it engages with.
Data Source
AI summary
An electric component having electric coils, the component formed by 3D printing of at least three different 3D-printed materials with spatial distributions yielding open magnetic circuit configuration of one of the electric coils. The electric component having a bulk formed by non-magnetic and dielectric 3D printed material; and an electric coil of the open magnetic circuit configuration, 3D-printed in the bulk. A magnetic channel of magnetic material 3D-printed in the bulk forming magnetic core of the electric coil; and an electric channel forming an inductor of the electric coil having conductive material 3D-printed in the bulk with a coil/helical geometry having electrically connected conductive windings arranged to circumference the magnetic channel, which is configured and operable with the open magnetic circuit configuration and has magnetic material occupying a central region of the coil/helical geometry of the inductor while not enclosing the windings with a closed loop of the magnetic material.