Spiral-Wrapped Sensor Strip for Intermittent Electrical Contact
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Solution Overview
Problem
Existing interventional devices face challenges in providing reliable and efficient electrical connections to sensors, particularly in medical applications where precise alignment and electromagnetic interference (EMI) protection are crucial.
Innovation Solution
The interventional device features a sensor interconnection region with a spiral-wrapped sensor strip, including electrical conductors and a shield layer, which simplifies alignment and provides a rotationally-invariant contact point, along with an anisotropically conductive elastic layer and a guard ring for EMI reduction, allowing for a single electrical shield in the connecting cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor strip with multiple layers and conductors is wrapped around the elongate shaft, then electrical contact and EMI protection are achieved, but the device complexity increases
Solution Approach 1:
The sensor strip employs a nested multi-layer structure where the first polymer layer, second polymer layer, electrical shield layer, and conductors are stacked sequentially around the elongate shaft. Each layer is positioned within or adjacent to the previous layer, creating a compact nested arrangement that provides electrical contact, insulation, and EMI protection simultaneously without requiring excessive space or complexity.
Solution Approach 2:
The sensor strip is designed as a multi-functional component that simultaneously provides electrical contact through the conductors, electromagnetic interference protection through the electrical shield layer, mechanical support and insulation through the polymer layers, and structural integration with the elongate shaft. This universal design consolidates multiple functions into a single integrated component, reducing overall device complexity.
2Object-affected harmful factors
If the electrical shield layer faces outwards in the spiral wrap, then EMI protection is improved, but the alignment precision requirements increase
Solution Approach 1:
The electrical shield layer is positioned asymmetrically within the sensor strip structure, with the shield facing outwards toward the external environment rather than inwards toward the sensor elements. This asymmetric arrangement optimizes the shield's ability to intercept and redirect electromagnetic interference from external sources, while the layered construction provides reference surfaces that facilitate alignment during manufacturing.
Solution Approach 2:
The sensor strip is pre-formed with the electrical shield layer already positioned in its optimal outward-facing orientation before wrapping around the elongate shaft. The spiral wrap configuration and layer stacking are predetermined in the manufacturing process, establishing the correct alignment and orientation of the shield layer prior to final assembly, thereby reducing alignment precision requirements during installation.
3Ease of manufacture
If the sensor strip is wrapped in a spiral form, then ease of manufacture is improved, but the contact point stability decreases
Solution Approach 1:
The sensor strip is configured in a spiral wrap around the elongate shaft, transforming the straight conductors into a curved helical path. This curvature allows the strip to conform to the cylindrical geometry of the shaft while maintaining continuous electrical contact. The spiral form distributes contact points along the length of the shaft, providing stability through multiple contact zones rather than relying on a single point, thereby maintaining contact stability despite the flexible wrapped configuration.
4Ease of operation
If the electrical conductors extend along the longitudinal axis within the window, then alignment ease is improved, but the device complexity increases
Solution Approach 1:
The electrical conductors are segmented into distinct functional zones: a sensor region where conductors contact the sensor elements, an intermediate region where conductors extend along the longitudinal axis within the window to facilitate alignment, and a terminal region where conductors connect to external circuitry. This segmentation allows each portion of the conductor to be optimized for its specific function, with the intermediate axial extension providing alignment ease while the overall segmented structure manages complexity.
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 configuration enhances the ease of manufacturing, reduces EMI susceptibility, and provides a lightweight, flexible connection that maintains effective electrical contact and shields against electromagnetic interference.
Implementation Method 1
an electrical shield layer (109) disposed on a second side of the first polymer layer... such that the electrical shield layer faces outwards
Implementation Method 2
anisotropically conductive elastic layer for providing electrical conduction in a radial direction with respect to the elongate axis
Data Source
Figure 1~3
Figure 4
AI summary
An interventional device includes a sensor interconnection region (101) for making electrical contact to a sensor (102) disposed on the interventional device. The interventional device includes an electrically conductive elongate shaft, a sensor strip (104), electrical conductors (105, 106), and an electrical shield layer (109). The electrical conductors (105, 106) extend along the sensor strip between a sensor region (111) and a window (112) within which the electrical conductors (105, 106) are exposed. The sensor strip (104) is wrapped around the elongate shaft (103) in a spiral such that the electrical conductors (105, 106) extend along the longitudinal axis (A – A') within the window (112), and such that an electrical shield contact portion (109') adjacent the window (112), the window (112), and an exposed portion of the electrically conductive elongate shaft (103') beyond the wrapped sensor strip provide the sensor interconnection region (101).