Sensor Core with Adhesive Tube and Permeable Layers
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Solution Overview
Problem
Existing electromagnetic induction-based position sensors face limitations in sensitivity due to the number of wire turns, core size, and magnetic permeability, which restricts their performance without significant size increases.
Innovation Solution
A sensor core design incorporating a rectangular substrate with layers of magnetically-permeable and radiopaque materials, coupled with adhesive to form a hollow cylinder, and featuring flex pads for electrical connections, enhances magnetic permeability and radiopacity while reducing component count and improving electrical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of wire turns is increased to improve sensitivity, then sensor sensitivity improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies composite materials by combining a magnetically permeable core material with a conductive polymer material to form an integrated core structure. This composite approach provides both the magnetic properties needed for sensitivity and the conductive pathways for electrical connections, eliminating the need for separate wire windings and reducing device complexity while maintaining or improving sensitivity.
Solution Approach 2:
The patent merges the magnetic core function and the electrical connection function into a single integrated component. The conductive polymer material serves dual purposes: providing structural support for the core and establishing electrical connections, thereby combining multiple functions into one element and reducing the number of separate components needed.
2Measurement precision
If the core size is increased to improve sensitivity, then sensor sensitivity improves, but device volume increases
Solution Approach 1:
The patent changes the material parameters by using high-permeability magnetic materials that provide enhanced magnetic properties without requiring increased core dimensions. This allows the core to maintain small volume while achieving the sensitivity improvements that would traditionally require larger core sizes.
Solution Approach 2:
The composite structure of magnetically permeable material combined with conductive polymer creates a high-performance core that achieves superior magnetic properties in a compact form factor, avoiding the need to increase core size for improved sensitivity.
3Measurement precision
If the magnetic permeability is increased to improve sensitivity, then sensor sensitivity improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical wire-winding processes with a deposition-based manufacturing approach using conductive polymer material. This substitution eliminates the need for precise manual or automated wire winding, reducing manufacturing precision requirements while achieving the desired electrical connections and magnetic core properties.
Solution Approach 2:
The use of composite materials with integrated magnetic and conductive properties allows for simplified manufacturing processes that do not require high-precision assembly, as the functional properties are inherent to the material structure rather than requiring precise mechanical construction.
4Reliability
If multiple separate components are used for core and electrical connections, then component functionality is achieved, but device complexity increases
Solution Approach 1:
The patent merges the magnetic core and electrical connection components into a single integrated structure where the conductive polymer material provides both magnetic pathway and electrical conductivity. This eliminates the need for separate components and their associated interfaces, reducing device complexity while maintaining reliable functionality.
Solution Approach 2:
The conductive polymer material performs multiple functions simultaneously: providing structural support, establishing electrical connections, and contributing to the magnetic properties of the core. This multi-functionality reduces the number of separate components needed and simplifies the overall device architecture.
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 design increases sensor sensitivity and radiopacity, improves shape retention, and simplifies electrical coupling, enabling more effective position tracking in magnetic field-based navigation systems without substantial size increases.
Implementation Method 1
A sensor core design incorporating a rectangular substrate with layers of magnetically-permeable and radiopaque materials... enhances magnetic permeability and radiopacity
Implementation Method 2
Sensors in the system, which may each include a small inductive coil, are consequently able to detect this magnetic field. These sensors may include coils of wound wire, which in the presence of a magnetic field produce a voltage across the two leads according to the principles of electromagnetic induction.
Implementation Method 3
In an embodiment, the core may further include a layer of radiopaque material... increases sensor sensitivity and radiopacity
Data Source
AI summary
A sensor may include a core and a coil. The core may include a rectangular substrate, a layer of magnetically-permeable material disposed on the substrate, and an adhesive rigidly coupling two ends of the substrate so as to form a tube with the rectangular substrate. The coil may be wound on the tube. The core may further include a layer of radiopaque material. The core may further include a flex pad for electrically coupling the coil with an external system.