Thermoplastic Sheath Fusion for Medical Cable Connections
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Solution Overview
Problem
Current methods for producing flexible medical electrodes and catheters face challenges in creating durable, reliable, and cost-effective electrical connections, particularly for longer lengths, which often require assembly of multiple sections and use of non-biocompatible materials.
Innovation Solution
A method involving thermally fusing semi-finished products with specially shaped connection points, where the conductor is partially exposed and embedded in a thermoplastic sheath, allowing for a permanent and inseparable electrical connection without additional materials, using a key-lock principle and ultrasonic treatment to ensure a hermetically sealed joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple cable sections are assembled to achieve longer lengths, then the required cable length is increased, but the electrical connection reliability deteriorates due to additional connection points and potential use of non-biocompatible materials
Solution Approach 1:
The cable is divided into modular semi-finished products with standardized connection points that can be assembled to achieve desired lengths. Each segment contains conductors embedded in biocompatible insulating material with exposed contact surfaces designed for reliable connection.
Solution Approach 2:
Multiple cable sections are permanently joined through thermal fusion of thermoplastic materials at connection points, creating a unified structure that maintains electrical reliability and biocompatibility across the entire assembled cable length.
2Ease of manufacture
If conventional connection methods are used to join cable sections, then the manufacturing cost is reduced, but the electrical resistance increases due to transition resistance at connection points
Solution Approach 1:
The mechanical connection process is replaced with thermal fusion that directly bonds the thermoplastic insulating materials together, creating a seamless connection that eliminates traditional mechanical connectors and reduces transition resistance.
Solution Approach 2:
The connection process utilizes controlled thermal parameters to melt and fuse the thermoplastic materials at connection points, transforming the physical state of the material to create a low-resistance electrical pathway while maintaining structural integrity.
3Object-affected harmful factors
If biocompatible materials are used for all components, then the safety for intracorporeal use is improved, but the available connection methods are limited
Solution Approach 1:
The insulating material surrounding the conductors is made from homogeneous biocompatible thermoplastic material throughout the entire cable structure, including at connection points, ensuring uniform biocompatibility while enabling thermal fusion connection methods.
Solution Approach 2:
The cable structure combines conductive metal elements with biocompatible thermoplastic insulating material to create a composite structure that maintains electrical functionality while ensuring biocompatibility and enabling thermal fusion for connections.
4Duration of action of stationary object
If additional materials are used to create connections, then the connection durability is improved, but the manufacturing complexity increases
Solution Approach 1:
The thermoplastic insulating material serves dual functions: it provides electrical insulation and acts as the bonding agent for connections through thermal fusion, eliminating the need for separate connection materials or additional manufacturing steps.
Solution Approach 2:
The thermoplastic material performs multiple functions including insulation, structural support, and connection medium, simplifying the overall manufacturing process by eliminating the need for separate materials dedicated to each function.
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 method enables reliable, cost-effective, and biocompatible electrical connections for medical devices, allowing for longer cable sections without increasing electrical resistance, and maintains mechanical integrity through a tightly enclosing plastic body.
Implementation Method 1
c) Thermal fusing of the thermoplastic material in the area of the joints
Implementation Method 2
using a key-lock principle and ultrasonic treatment to ensure a hermetically sealed joint
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a medical electrode lead or catheter and an associated semi-finished product (10). The semi-finished product (10) comprises a cable (12) with at least one electrical conductor (16) embedded in a sheath (18) made of an electrically insulating thermoplastic material. It is characterized in that the cable (12) forms a connection point (20) at at least one cable end (14) via which the conductor (16) can be permanently and inseparably connected to other components, wherein: - a portion of the surface of the conductor (16) is exposed in the region of the connection point (20) and forms a contact surface, and - the sheath (18) has a recess (22) extending longitudinally along the cable (12) in the region of the connection point (2).