Two-Piece Sensor Housing for Robust Intraluminal Device Assembly
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Solution Overview
Problem
Current intraluminal devices, such as intravascular catheters and guidewires, face challenges in assembly due to delicate sensor components that require manual soldering and high dexterity, leading to high scrap rates and complex assembly processes.
Innovation Solution
A sensor housing design comprising a two-piece construction with embedded conductors and insulators, utilizing additive manufacturing to simplify assembly by snapping components together, reducing manual steps and enhancing robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering and bonding of microcables to sensors is used, then electrical connection is achieved, but assembly complexity increases and scrap rates increase due to delicate components requiring high dexterity
Solution Approach 1:
The patent combines the sensor housing, electrical contacts, and microcable routing into a single integrated subassembly that is pre-assembled and tested before insertion into the catheter. This merging of components eliminates the need for manual soldering and bonding steps during final assembly, reducing both complexity and scrap rates while maintaining reliable electrical connections.
Solution Approach 2:
The sensor subassembly is pre-assembled, pre-tested, and pre-qualified in a controlled manufacturing environment before being inserted into the catheter housing. This preliminary action ensures that all delicate electrical connections are established and verified before final assembly, reducing the risk of damage during subsequent handling and eliminating the need for complex on-site assembly steps.
2Reliability
If multi-component housing construction is used, then sensor protection and electrical isolation are improved, but manufacturing complexity increases
Solution Approach 1:
The catheter is divided into modular sections: a pre-assembled sensor subassembly containing the sensor and its electrical connections, a middle section containing the flexible elongate member, and a proximal handling section. This segmentation allows each module to be manufactured and tested independently, simplifying the overall manufacturing process while maintaining comprehensive protection and isolation of the sensor components.
Solution Approach 2:
The housing utilizes composite construction with dielectric materials providing electrical isolation between conductive elements, while maintaining mechanical strength and flexibility. The combination of conductive and dielectric materials in a multi-layer housing structure achieves both sensor protection and electrical isolation without requiring excessive manufacturing steps.
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
The improved assembly process reduces manufacturing errors, decreases time and skill requirements, and increases the robustness of the devices, making them more amenable to automation.
Implementation Method 1
The distal portion includes a first conductive material and a first dielectric material, whereas the proximal portion includes a second conductive material and a second dielectric material
Data Source
AI summary
An intraluminal device is provided, which includes a flexible elongate member configured to extend in a longitudinal direction within a body lumen of a patient, with a sensor disposed at a distal region of the flexible elongate member and facing in the longitudinal direction. The sensor is configured obtain intraluminal data associated with the body lumen. The intraluminal device includes a housing at least partially surrounding the sensor. The housing includes a distal portion including a first conductive material and a first dielectric material. The distal portion is fixedly attached to a different proximal portion which includes a second conductive material and a second dielectric material. The first conductive material and the second conductive material are in electrical communication with the sensor.