Wire Lock Spool for Steerable Medical Devices
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Solution Overview
Problem
Existing steerable medical devices face challenges in securing pull wires due to complex solder connections, which complicate manufacturing and reprocessing, as solder connections are difficult to re-solder and can damage components during the process.
Innovation Solution
A wire lock structure featuring a spool body with rims and a tapering through-hole, where the pull wire is routed through and wrapped around the spool body under tension to secure it, allowing for a simpler and more reliable attachment method that does not require soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solder connections are used to secure pull wires to the deflection mechanism, then the connection strength is improved, but the manufacturing complexity increases and reprocessing becomes difficult
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining) with a mechanical wire lock system. The wire lock features a spool body with a through-hole that allows the pull wire to pass through and be secured mechanically, eliminating the need for solder connections while maintaining secure attachment of the pull wire to the deflection mechanism
Solution Approach 2:
The wire lock acts as an intermediary component between the pull wire and the deflection mechanism. Instead of directly soldering the pull wire to the deflection mechanism, the wire lock provides a intermediate mechanical connection point, simplifying both manufacturing and reprocessing operations
2Reliability
If solder connections are used to secure pull wires, then the connection reliability is improved, but the ease of reprocessing deteriorates
Solution Approach 1:
The connection system is segmented into distinct components: the pull wire, the wire lock, and the deflection mechanism. This segmentation allows the wire lock to be independently manipulated during reprocessing, enabling easy removal and reattachment of the pull wire without affecting other components, thus maintaining connection reliability while greatly improving reprocessing ease
Solution Approach 2:
By replacing the irreversible soldering process with a reversible mechanical wire lock system, the patent enables easy reprocessing. The wire lock's through-hole design allows the pull wire to be passed through and secured mechanically, which can be undone and redone without specialized equipment or risk of damaging other components
3Strength
If soldering process is used to attach pull wires, then the connection strength is improved, but the risk of component damage increases
Solution Approach 1:
The patent eliminates the soldering process entirely by using a mechanical wire lock system. This substitution removes the harmful thermal effects of soldering that could damage internal wiring and protective sleeves, while still providing secure mechanical attachment of the pull wire through the wire lock's spool body and through-hole structure
Data Source
AI summary
A pull wire assembly for a steerable medical device can include wire lock and a wire. The wire lock includes a spool body having first and ends and first and second rims respectively around the first and second ends. A through-hole extends diametrically through the spool body. The wire enters through a distal end of the through-hole, emerges through a proximal end of the through-hole, wraps around an exterior of the spool body, re-enters into the distal end of the through-hole, and re-emerges through the proximal end of the through-hole. The wire may make multiple such passes. The wire may also be tensioned to at least partially embed into the surface of the spool body.