Intravascular Sensor Insulation Segmentation
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Solution Overview
Problem
Current sensor elements used for intravascular measurements suffer from signal instability and drift issues due to uneven silicone insulation, which affects the accuracy of physiological variable measurements in the clinical environment.
Innovation Solution
A sensor element design where the bond section and intermediate section are coated with an electrically insulating material, while the sensor section remains uncoated, allowing direct access to the fluid medium and reducing the risk of electrical insulation failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire sensor element is coated with silicone insulation material, then electrical insulation is provided and protection from bodily fluids is achieved, but signal stability deteriorates and drift occurs due to uneven coating thickness
Solution Approach 1:
The sensor element is divided into two distinct sections: a sensor section that remains uncoated for direct fluid contact and a bond section that is coated with insulation material. This segmentation allows the uncoated sensor section to provide stable signals while the coated bond section provides electrical insulation and protection, resolving the contradiction between insulation reliability and signal stability.
Solution Approach 2:
Different sections of the sensor element are given different properties: the sensor section is left uncoated to maintain direct contact with the fluid medium for accurate pressure sensing, while the bond section is coated with insulation material to provide electrical protection. This local differentiation of properties eliminates the drift caused by uneven coating while maintaining necessary insulation.
2Reliability
If the sensor section is coated with insulation material, then electrical protection is improved, but direct access to the fluid medium is blocked causing measurement inaccuracies
Solution Approach 1:
The sensor element is segmented into a sensor section and a bond section, with only the bond section being coated. This ensures the sensor section maintains direct unobstructed access to the fluid medium for accurate pressure measurements, while the bond section provides the necessary electrical protection.
Solution Approach 2:
The insulation coating is applied locally only to the bond section where electrical protection is needed, while the sensor section remains uncoated to maintain direct fluid contact. This localized application of insulation resolves the contradiction between electrical protection and measurement accuracy.
3Ease of manufacture
If uneven silicone insulation is applied to the sensor element, then manufacturing simplicity is maintained, but signal drift and measurement instability occur
Solution Approach 1:
By dividing the sensor element into coated and uncoated sections, the patent enables a simplified coating process that only needs to cover the bond section. This segmentation approach maintains manufacturing simplicity while eliminating the signal drift caused by uneven full-surface coating.
Solution Approach 2:
The insulation coating is applied only to the bond section with uniform thickness, rather than attempting to coat the entire sensor element evenly. This local quality approach simplifies the manufacturing process while ensuring signal stability by keeping the sensor section uncoated.
Data Source
AI summary
A sensor element comprises a sensor section comprising a sensor unit configured to measure a physiological variable or any other signal in a living body and to generate a sensor signal in response to the variable or other signal, and a bond section comprising contact members configured to electrically connect at least one signal transmitting microcable. The bond section is coated with an electrically insulating material and the sensor unit is left uncoated. The sensor element may further comprise an intermediate section between the sensor section and the bond section. The intermediate section includes electric connection lines configured to connect the contact members to the sensor unit. The intermediate section is also coated with the electrically insulating material.