Ribbon Cable Sensor Assembly for Multi-Point Temperature 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 micro-thermocouple (MTC) ribbon sensors directly on a ribbon cable, enabling multiple sensors to be spaced along the cable.
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 sensors are fabricated on separate locations of the same ribbon cable, merging what would have been separate cable bundles into one compact unit, thereby reducing the volume required inside the catheter while maintaining the ability to fabricate multiple sensors.
Solution Approach 2:
The ribbon cable serves multiple functions simultaneously: it provides electrical insulation for all conductors, supports multiple sensor fabrication locations, and maintains mechanical integrity for the entire sensor array. This multi-functional design eliminates the need for separate cable management for each sensor.
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 applies electrical insulation to all conductors along the entire ribbon cable length before sensor fabrication. This preliminary action eliminates the need for individual insulation handling at each sensor location, streamlining the manufacturing process and reducing labor requirements for producing multiple sensors.
Solution Approach 2:
By fabricating multiple sensors on a single ribbon cable using automated processes, the patent combines multiple discrete fabrication operations into one integrated manufacturing step, thereby improving productivity and reducing labor costs.
3Volume of moving object
If printed electronics technology is used to fabricate sensors on ribbon cable, then space requirements are minimized and automation is enabled, but additional manufacturing steps are required
Solution Approach 1:
The patent replaces traditional mechanical sensor fabrication methods with printed electronics technology. Conductive materials are deposited through printing processes rather than manual assembly, enabling automation and reducing the complexity of mechanical handling while minimizing space requirements.
Solution Approach 2:
The patent changes the physical state and properties of materials through controlled processing. Electrical insulation is applied and cured, conductive materials are deposited and sintered, transforming the ribbon cable from an uninsulated conductor to a functional sensor array with precise electrical properties.
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 minimizes space requirements, reduces manufacturing and labor costs by enabling automated processes, and allows for precise and efficient fabrication of multiple sensors on a single ribbon cable, suitable for applications like multi-point temperature measurements.
Implementation Method 1
Conductive material is applied to respective exposed individual conductors in the at least one sensor terminating area to form at least one sensor
Implementation Method 2
Nonconductive material may be applied to sensor terminating area on top of the conductive material
Data Source
AI summary
A ribbon cable sensor assembly having a ribbon cable with respective individual wires. At least one sensor terminating area is positioned on the ribbon cable. The at least one sensor terminating area has insulation removed from respective individual wires to provide exposed individual conductors. Conductive material is applied to respective exposed individual conductors in the at least one sensor terminating area to form at least one sensor. Nonconductive material may be applied to sensor terminating area on top of the conductive material.