Ribbon Cable Sensor Assembly for Multi-Point Catheter Sensing
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Solution Overview
Problem
Existing methods for fabricating multiple sensors on a single cable are inefficient, requiring extra space and increasing labor costs, as they involve terminating each sensor on individual cables and bundling them, which is not feasible for applications like multi-point temperature measurements in medical catheters.
Innovation Solution
The use of printed electronics technology, specifically jet dispensing for applying solder paste or silver ink to form micro-junctions, and subsequent encapsulation with nonconductive material, allows for the fabrication of multiple sensors on a single ribbon cable, enabling automated production and minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple sensors are terminated on individual cables and bundled together, then each sensor can be fabricated separately, but extra space is required inside the catheter and labor costs increase
Solution Approach 1:
The patent combines multiple individual cable terminations into a single integrated ribbon cable assembly. Multiple sensor contacts are fabricated on a single ribbon cable with insulated barriers between them, eliminating the need to bundle multiple separate cables. This merging reduces the volume occupied within the catheter while maintaining the capability to fabricate multiple sensors.
Solution Approach 2:
The ribbon cable serves multiple functions simultaneously: it provides electrical connections for multiple sensors, incorporates insulation barriers to prevent electrical interference, and enables automated fabrication processes. This multi-functional design allows a single component to replace what would otherwise require multiple separate cable assemblies.
2Ease of manufacture
If multiple sensors are terminated on individual cables and bundled together, then each sensor can be fabricated separately, but labor costs increase
Solution Approach 1:
The patent combines multiple individual cable terminations into a single integrated ribbon cable assembly. Multiple sensor contacts are fabricated on a single ribbon cable with insulated barriers between them, eliminating the need to bundle multiple separate cables. This merging reduces the volume occupied within the catheter while maintaining the capability to fabricate multiple sensors.
Solution Approach 2:
The patent replaces manual mechanical processes (hand-stripping wires, manual termination, bundling) with automated printed electronics fabrication. The ribbon cable can be fabricated using automated printing and curing processes, significantly reducing labor requirements and increasing manufacturing productivity.
3Volume of moving object
If printed electronics technology is used to fabricate sensors on a ribbon cable, then automated production is enabled and space is minimized, but complex manufacturing processes are required
Solution Approach 1:
The patent utilizes parameter changes in the fabrication process, specifically using UV-curable conductive and insulating materials that transition from liquid to solid state upon UV exposure. This phase change enables automated printing and immediate curing, simplifying the manufacturing process while achieving miniaturization and integration.
Solution Approach 2:
The patent replaces manual mechanical processes (hand-stripping wires, manual termination, bundling) with automated printed electronics fabrication. The ribbon cable can be fabricated using automated printing and curing processes, significantly reducing labor requirements and increasing manufacturing productivity.
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 approach enables the efficient fabrication of multiple sensors on a single ribbon cable, reducing space requirements and manufacturing costs, while allowing for precise temperature measurements at different locations, enhancing the functionality of medical catheters.
Implementation Method 1
applying conductive ink in the defined area on the exposed individual conductors of the cable to form a sensor; and curing the conductive ink
Data Source
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Figure 7
AI summary
A ribbon cable sensor assembly (2) having a ribbon cable (10) with respective individual wires (14). At least one sensor terminating area (20) is positioned on the ribbon cable. The at least one sensor terminating area has insulation (24) removed from respective individual wires (14) to provide exposed individual conductors. Conductive material (26) is applied to respective exposed individual conductors in the at least one sensor terminating area to form at least one sensor (12). Nonconductive material (30) may be applied to sensor terminating area on top of the conductive material.