US20110214914A1 - System and method for attaching a substantially three dimensional structure to a substantially two dimensional structure - Google Patents
System and method for attaching a substantially three dimensional structure to a substantially two dimensional structure Download PDFInfo
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- US20110214914A1 US20110214914A1 US13/111,822 US201113111822A US2011214914A1 US 20110214914 A1 US20110214914 A1 US 20110214914A1 US 201113111822 A US201113111822 A US 201113111822A US 2011214914 A1 US2011214914 A1 US 2011214914A1
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- dimensional structure
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0021—Catheters; Hollow probes characterised by the form of the tubing
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/02—Arrangements of circuit components or wiring on supporting structure
- H05K7/06—Arrangements of circuit components or wiring on supporting structure on insulating boards, e.g. wiring harnesses
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0043—Catheters; Hollow probes characterised by structural features
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B81—MICROSTRUCTURAL TECHNOLOGY
- B81C—PROCESSES OR APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OR TREATMENT OF MICROSTRUCTURAL DEVICES OR SYSTEMS
- B81C3/00—Assembling of devices or systems from individually processed components
- B81C3/008—Aspects related to assembling from individually processed components, not covered by groups B81C3/001 - B81C3/002
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/182—Printed circuits structurally associated with non-printed electric components associated with components mounted in the printed circuit board, e.g. insert mounted components [IMC]
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/182—Printed circuits structurally associated with non-printed electric components associated with components mounted in the printed circuit board, e.g. insert mounted components [IMC]
- H05K1/183—Components mounted in and supported by recessed areas of the printed circuit board
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
- H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
- H05K3/341—Surface mounted components
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/40—Forming printed elements for providing electric connections to or between printed circuits
- H05K3/4038—Through-connections; Vertical interconnect access [VIA] connections
- H05K3/4046—Through-connections; Vertical interconnect access [VIA] connections using auxiliary conductive elements, e.g. metallic spheres, eyelets, pieces of wire
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0021—Catheters; Hollow probes characterised by the form of the tubing
- A61M25/0023—Catheters; Hollow probes characterised by the form of the tubing by the form of the lumen, e.g. cross-section, variable diameter
- A61M25/0026—Multi-lumen catheters with stationary elements
- A61M2025/0037—Multi-lumen catheters with stationary elements characterized by lumina being arranged side-by-side
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0021—Catheters; Hollow probes characterised by the form of the tubing
- A61M25/0023—Catheters; Hollow probes characterised by the form of the tubing by the form of the lumen, e.g. cross-section, variable diameter
- A61M25/0026—Multi-lumen catheters with stationary elements
- A61M2025/004—Multi-lumen catheters with stationary elements characterized by lumina being arranged circumferentially
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0021—Catheters; Hollow probes characterised by the form of the tubing
- A61M25/0023—Catheters; Hollow probes characterised by the form of the tubing by the form of the lumen, e.g. cross-section, variable diameter
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0043—Catheters; Hollow probes characterised by structural features
- A61M25/0045—Catheters; Hollow probes characterised by structural features multi-layered, e.g. coated
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0043—Catheters; Hollow probes characterised by structural features
- A61M25/005—Catheters; Hollow probes characterised by structural features with embedded materials for reinforcement, e.g. wires, coils, braids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L3/00—Containers or dishes for laboratory use, e.g. laboratory glassware; Droppers
- B01L3/50—Containers for the purpose of retaining a material to be analysed, e.g. test tubes
- B01L3/502—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures
- B01L3/5027—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B81—MICROSTRUCTURAL TECHNOLOGY
- B81B—MICROSTRUCTURAL DEVICES OR SYSTEMS, e.g. MICROMECHANICAL DEVICES
- B81B2201/00—Specific applications of microelectromechanical systems
- B81B2201/05—Microfluidics
- B81B2201/058—Microfluidics not provided for in B81B2201/051 - B81B2201/054
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0272—Adaptations for fluid transport, e.g. channels, holes
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/10265—Metallic coils or springs, e.g. as part of a connection element
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
- H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
- H05K3/3447—Lead-in-hole components
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/36—Assembling printed circuits with other printed circuits
- H05K3/368—Assembling printed circuits with other printed circuits parallel to each other
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/0318—Processes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/8593—Systems
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
Definitions
- This disclosure generally relates to attachment methods and more particularly to a method of soldering a substantially three dimensional structure to a substantially two dimensional structure.
- the three dimensional structure can be a medical catheter and the two dimensional structure can be a Printed Circuit Board.
- the three dimensional structures can transport different media such as electrical current, liquids, gases, and particulates.
- electrical catheters consist of a hollow tube surrounding fine wires that are individually stripped, either by hand, by a laser, by bead blasting, by chemical etching, or various other methods, and terminated into bulky connectors and solder-cups.
- wires have been getting progressively smaller and smaller. As the wires get smaller they also become physically weaker. These weaker wires tend to break and become difficult to handle during the assembly process required for high conductor count catheters.
- a more desirable situation for modern catheters would be one that incorporates a system for easy termination of an ever increasing number of conductors and that allows for quick, reliable, and or redundant solder joints. Having a mechanical structure designed for flexibility would also aid in reducing field and assembly failures. Ideally, a new catheter termination system would also enable a production operator to easily switch between leaded and lead free solder without sacrificing production speed or capability.
- a method and system for transporting a fluid, gas, semi-solid, cryogen, or particulate matter, or combination thereof, between a three-dimensional structure and a substantially two-dimensional structure are disclosed.
- a system and method for electrically coupling a three-dimensional structure to a substantially two dimensional structure are also disclosed.
- FIG. 1 is a perspective view of an example system
- FIG. 2 is an expanded view of the example system of FIG. 1 ;
- FIG. 3 is a side elevation view of the example system of FIG. 1 ;
- FIG. 4 is a side elevation view of the example system of FIG. 1 with additional electrical connectors;
- FIG. 5 is a perspective view of a second example system
- FIG. 6 is a side elevation view of the example system of FIG. 5 ;
- FIG. 7 is an expanded view of the example system of FIG. 5 with a fully stripped wire
- FIG. 8 is a side elevation view of a fully stripped wire
- FIG. 9 is an expanded view of the example system of FIG. 5 with a partially stripped wire
- FIG. 10 is a side elevation view of a partially stripped wire
- FIG. 11 is a perspective view of a third example system
- FIG. 12 is an expanded view of the example system of FIG. 11 ;
- FIG. 13 is a side elevation view of a fourth example system
- FIG. 14 is a perspective view of a fifth example system
- FIG. 15 is an expanded view of the example system of FIG. 14 ;
- FIG. 16 is a perspective, partially-transparent view of the example system of FIG. 14 with three additional coils of elements;
- FIG. 17 is a side elevation view of the example system of FIG. 14 with three additional coils of elements;
- FIG. 18 is a side elevation view of a sixth example system
- FIG. 19 is a top view of the example system of FIG. 18 ;
- FIG. 20 is a cross-sectional view of an example coil of elements
- FIG. 21 is a cross-sectional view of a second example coil of elements
- FIG. 22 is a cross-sectional view of a third example coil of elements
- FIG. 23 is a cross-sectional view of a fourth example coil of elements.
- FIG. 24 is a cross-sectional view of a fifth example coil of elements
- FIG. 25 is a cross-sectional view of a sixth example coil of elements
- FIG. 26 is a cross-sectional view of a seventh example coil of elements
- FIG. 27 is a cross-sectional view of an eighth example coil of elements.
- FIG. 28 is a cross-sectional view of a ninth example coil of elements
- FIG. 29 is a cross-sectional view of a tenth example coil of elements
- FIG. 30 is a cross-sectional view of an eleventh example coil of elements
- FIG. 31 is a cross-sectional view of a twelfth example coil of elements
- FIG. 32 is a perspective view of a seventh example system
- FIG. 33 is an expanded perspective view of the example system, similar to that of FIG. 32 ;
- FIG. 34 is a more closely expanded perspective view of the system of FIG. 32 ;
- FIG. 35 is a cross-sectional view of the system of FIG. 33 ;
- FIG. 36 is a top view of an eighth example system
- FIG. 37 is an expanded, perspective view of the example system of FIG. 36 ;
- FIG. 38 is a cross-sectional view of the example system of FIG. 36 ;
- FIG. 39 is a cross-sectional view of a ninth example system.
- FIG. 40 is a cross-sectional view of a tenth example system
- FIG. 41 is a cross-sectional view of an eleventh example system
- FIG. 42 is a cross-sectional view of a twelfth example system
- FIG. 43 is a cross-sectional view of a thirteenth example system
- FIG. 44 is a cross-sectional view of a fourteenth example system
- FIG. 45 is a cross-sectional view of an example coil of elements for use in the system.
- FIG. 46 is a cross-sectional view of a second example coil of elements for use in the system.
- FIG. 47 is a transparent side elevation view of a third example coil of elements for use in the system.
- FIG. 48 is a transparent side elevation view of a fourth example coil of elements for use in the system.
- FIG. 49 is a side elevation view of a fifth example coil of elements for use in the system.
- FIG. 50 is a perspective view of a fifteenth example system, representing a fluidic structure
- FIG. 51 is a perspective view of the example system of FIG. 50 with a dissolvable material applied;
- FIG. 52 is a perspective view of the example system of FIG. 51 ;
- FIG. 53 is a perspective view of the example system of FIG. 52 after the dissolvable material is removed;
- FIG. 54 is a cross-sectional view of the example system of FIG. 52 ;
- FIG. 55 is a cross-sectional view of the example system of FIG. 53 ;
- FIG. 56 is a perspective view of a sixteenth example system
- FIG. 57 is a cross-sectional view of the sixteenth example system
- FIG. 58 is a perspective view of a seventeenth example system
- FIG. 59 is a side elevation view of the example system of FIG. 58 ;
- FIG. 60 is a cross-sectional perspective view of the seventeenth example system.
- FIG. 61 is a side view of the example system of FIG. 60 .
- a system for soldering a substantially three dimensional structure to a substantially two dimensional substrate has a coil of elements and a substrate designed to receive the coil.
- the coil lies in a groove formed on one of the surfaces of a dielectric substrate, such as a printed circuit board (“PCB”).
- a connection pad or transfer point is disposed on a surface of the dielectric substrate and is designated to receive the coil.
- the connection pad is adjacent to the groove or the path of the coil such that a connection can be made between an element of the coil and the connector pad.
- the coil element has a coating that is removed at the location of the connection between the coil and the connection pad.
- the system can include a heat transfer pad in thermal communication with the connection pad in order to transfer heat to the coil of elements and the connection material on the pad without physically contacting or contaminating the pad or the connection material.
- the coil of elements has multiple conductors wound therein and the substrate has a plurality of connection pads or transfer points for conductors in the coil. It is possible to vary the number of connection pads in order to provide redundant connections for safety and reliability or to allow for easier access to tightly coiled elements.
- the coil of elements may be wound around a hollow tube, wound over a fiber optic element, or wrapped around any other suitable substrate.
- the shape of the “coil structure” can be formed by any means. A sheath can also cover the wires for further protection or aesthetic reasons.
- the coil of elements can also have varying pitch to increase or decrease the apparent rigidity and flexibility of the resultant system at predetermined points without having to use different materials.
- This change of pitch also allows for the convenient locating of access points to the conductors contained in the coil and the dielectric substrate. This makes it easier to terminate each transfer point within the complex structure of the coil of elements.
- the system can include attachments to multiple dielectric substrates.
- the coil of elements and the substrate can also be formed so that each substrate will only interact with the coil of elements in a predetermined location and orientation.
- the coil of elements may also be used for structural reinforcement of the system, which is especially useful when combined with pull wires or other such steering devices. Any given element within the coil need not be electrically conductive.
- the core of an element may be dissolvable, and once dissolved, leave a hollow core element which would then be capable of carrying a variety of liquid, gaseous, or semi-solid materials, or a combination of materials thereof.
- FIGS. 1-4 depict an example system for electrically coupling a three dimensional structure to a substantially two dimensional structure.
- the two dimensional structure is shown as a dielectric substrate 12 that has a thickness.
- the thickness may be created by a single material or by the combination of a series of substrates that are connected to one another.
- the three-dimensional structure is created by a coil of elements 10 , which in this case, is a coil of wires 14 .
- the coil of wires 10 is positioned between an outer sheath 16 a and an inner sheath 16 b.
- the sheaths are shown as being transparent, flexible material.
- the coil of elements 10 includes a plurality of wires 14 which are spaced one after another within the coil such that a first wire is positioned adjacent a second wire which is positioned adjacent a third wire, etc.
- the coil of elements 10 is coupled to the dielectric substrate 12 at connection points which are defined by a contact pad 20 and connection solder 22 .
- the contact pad 20 is a pad of conductive material that is positioned on a surface of the dielectric substrate 12 .
- the contact pad 20 could be recessed into the surface of the dielectric substrate 12 , or could be positioned on top 28 of the surface 12 . It could be created through plating or any other known means for attaching a conductive material to a dielectric substrate.
- Connection solder 22 is positioned on top of the contact pad 20 .
- mounting hole 38 is a cylindrical hole having a round cross-section and is sized and shaped to receive the coil of elements 10 therethrough.
- the connection points are designed to couple to the wires 14 within the coil of elements 10 to establish an electrical connection between the contact pad 20 and the associated wire 14 .
- the outer sheath 16 a of the coil of elements 10 is cut away in an area of the coil of elements 10 where the contact pad 20 can mate with a preselected wire 14 .
- a protective sheathing 26 such as a plastic coating, on the wire 14 is cut away in the area of the contact pad 20 .
- a heating element can be applied to each contact pad 20 in order to heat the solder 22 positioned thereon.
- the contact pad 20 is heated with the heating element, such as a soldering iron, the connection solder 22 will flow to the wire 14 and wick onto the wire 14 , thereby establishing an electrical and mechanical connection between the solder contact pad 20 and the wire 14 .
- FIG. 1 four wires 14 are shown positioned within the coil of elements 10 .
- the connection points on the dielectric substrate 12 are positioned in order to mate with each one of the wires 14 on an upper surface 28 of the dielectric substrate 12 .
- the present example shows a cylindrical coil of elements 10 having four wires 14
- the coil of elements 10 can have any shape including cylindrical, rectangular, polygonal, oval, or any other type of shape that could be positioned in a mounting hole.
- any number of wires and any number of connection points may be utilized in connection with this example, the example not being limited to the exact configuration shown.
- FIG. 3 shows the coil of elements 10 being connected to the dielectric substrate 12 along a top surface 28 of the dielectric substrate 12 .
- FIG. 4 depicts a similar example, but in this example, the coil of elements 10 is coupled to both the top and bottom surfaces 28 , 32 of the dielectric substrate 12 . In this example, connection points are disposed on both the top and bottom surfaces 28 , 32 of the dielectric substrate 12 .
- the outer sheath 16 a of the coil of elements 10 has openings 36 cut into the sheath such that wires 14 within the coil of elements 10 may be exposed for connection to both the top and bottom surfaces 23 , 32 of the dielectric substrate 12 .
- FIG. 4 provides additional mechanical stability to the system by having the coil of elements 10 coupled to the substrate 12 in more than one plane.
- FIG. 4 provides for additional electrical connections between the wires 14 and the contact pads 20 . This may provide protective redundancy within the system. This may allow electricity to travel from one point in a wire to another across the substrate 12 without requiring an additional via (or hole) to be positioned in the substrate 12 .
- connection points or solder points between the coiled elements 10 and the dielectric substrate 12 assist in improving the mechanical strength of the system for electrically coupling the three-dimensional structure 10 to a substantially two-dimensional structure 12 .
- the two dimensional structure in these examples is the top surface 28 of the dielectric substrate 12 or the bottom surface 32 of the dielectric substrate 12 . While the dielectric substrate 12 has a thickness such that it is actually a three-dimensional structure, the contact pad 20 is considered the two-dimensional structure that the coil of elements 10 is coupled to. The coil of elements 10 is the three-dimensional structure that is being coupled to the two-dimensional structure of the substrate 12 .
- the word “substantially” is used herein to refer to the two-dimensional structure, which, in some examples, is the top surface 28 of the dielectric substrate 12 because it will be recognized that the contact pad 20 and solder 22 themselves do provide more than a strict two-dimensional structure. However, the structure is substantially two-dimensional according to the definition of two-dimensional structure utilized herein.
- FIG. 1 illustrates an exemplary method of attaching a coil of elements 10 in the form of a tubular structure to a dielectric substrate 12 .
- the tubular structure need not be round or even hollow, as can be seen in FIGS. 22-31 described below.
- Connection pads 20 are disposed on the outer planar surfaces of the dielectric substrate 12 .
- Each connection pad 20 can optionally be in electrical communication or thermal communication with other structures on the dielectric substrate 12 , such as electrical traces (not shown).
- Connection material 22 rests on the top of the connection pads 20 and can be either added before the tubular structure or after the tubular structure is inserted into the mounting hole 38 .
- the connection pads 20 are usually arranged in a radial pattern around the mounting hole 38 .
- connection material 22 bonds individual wires 14 contained within the tubular structure to individual connection pads 20 on the dielectric substrate 12 .
- This bonding is usually done through the use of heat from a heating element which can be either a separate device or contained within the dielectric substrate 12 .
- the tubular structure contains patterns of wire 14 disposed between an inside layer 16 a and an outside layer 16 b. While the material of the tube provides for electrical isolation between various wires 14 , each wire 14 can also be coated in an isolative material with a sheathing 26 , or otherwise to either ensure or enhance the dielectric properties of the tube material. The dielectric materials 26 covering any given wire 14 will only be removed to the minimum extent possible so as to maximize the structural integrity of the tubular structure.
- FIGS. 5 and 6 depict an alternative example similar to the examples discussed in FIGS. 1-4 .
- the coil of elements 10 includes an upper portion of wires 34 that are wound around an inner sheath 16 b, but at the point where the coil of elements 10 is positioned in the mounting hole of the dielectric substrate 12 , the wires 14 change direction and, instead of being wound around the inner sheath 16 b, they longitudinally extend along the length of the coil of elements 10 between the inner sheath 16 b and the outer sheath 16 a.
- the connection method previously described in connection with FIG. 4 is utilized for connecting the wires 14 to the contact pads 20 with the connection solder 22 .
- a hole 36 is cut in the outer sheath 16 a in order to allow the solder 22 to couple to the wire 14 that is positioned inside the sheath 16 a.
- the wire 14 is stripped of any protective material 26 around the conductive portion of the wire 14 .
- the wire will have a plastic outer sheathing 26 and either part, or all of this, protective plastic sheathing 26 may be cutaway in the vicinity of the contact pad 20 .
- the tubular structure contains patterns of wires disposed between an inside layer 16 b and an outside layer 16 a. While the material of the tube provides for electrical isolation between various wires 14 , each wire 14 can also be coated in an isolative material to either ensure or enhance the dielectric properties of the tube material. Preferably the dielectric materials covering any given wire will only be removed to the minimum extent possible so as to maximize the structural integrity of the tubular structure.
- FIGS. 5-10 show some patterns and structures that accomplish these goals.
- Wires 14 can be stripped axially either in strips or following the curve of the coil. Wires 14 can be stripped such that the wires 14 are hanging in free space. Wires 14 can also be stripped so that only a portion of their total inner core is exposed. There can exist multiple strip zones along the length of the tubular structure. Each zone can be of a different strip type and can expose only certain selected wires.
- the outer sheath 16 a may be cut at points that mate with both the top and bottom surfaces 28 , 32 of the dielectric substrate 12 .
- connection points on both the top and bottom surfaces 28 , 32 of the dielectric substrate 12 provides additional mechanical stability to the joint between the three-dimensional structure of the coil of elements 10 and the two-dimensional structure of the surface connection for the wire 14 .
- FIGS. 7-10 depict two examples of the way the protective sheathing 26 may be removed from a wire 14 such that the wire can couple to the solder 22 .
- the wire 14 is stripped around the entire circumference of the inner conductive core 40 .
- the outer material 26 because it is not conductive, will not allow the wire to mate with the solder 22 . For this reason, it is necessary to strip the protective sheathing 26 of the wire 14 .
- the solder 22 on the contact pad 20 mates with the inner conductive material 40 of the wire 14 .
- solder 22 and wire 14 In order to establish both an electrical connection between the contact pad 20 and the conductive material 40 of the wire 14 and a mechanical connection between the contact pad 20 , solder 22 and wire 14 such that the wire 14 is coupled to the top surface 28 of the dielectric substrate 12 .
- FIGS. 9 and 10 are similar to FIGS. 7 and 8 except for, in this example, the wire 14 is only stripped of the plastic outer sheathing 26 on one side of the wire 14 in the vicinity of the opening 36 that is cut in the outer sheathing 16 a of the coil of elements 10 .
- a window 42 is created in the wire 14 such that the conductive material of the wire 14 is exposed for connection to the connection solder 22 .
- the method of applying the solder 22 to the conductive member 40 of the wire 14 is the same as that previously discussed in connection with FIGS. 1-4 .
- the heating element not shown may be applied to the contact pad 20 in order to heat the solder 22 .
- Solder 22 then flows towards the conductive material 40 of the wire 14 and wicks onto the conductive material 40 in order to couple the solder 22 to the conductive material 40 of the wire 14 , thereby establishing both an electrical and mechanical connection with the wire 14 .
- FIGS. 11-12 show how the pattern of wires 14 need not be coiled to still be effective. Coiling the wires 14 around a tubular structure allows for some advantages though. Chief among them is that coiled wires 14 are more flexible and less prone to breaking then straight wires. This means that the flexibility and apparent durometer of any given tubular structure can be changed from changing the coiled wires 14 to straight wires, or just by changing the type of coil being used.
- FIGS. 11 and 12 depict another example of a system for electrically coupling a three-dimensional structure to assist a substantially two-dimensional structure.
- the wires 40 of the coil of elements 10 extend axially along the length of the coil of elements 10 .
- the coil in this example is created by the combination of the outer and inner sheaths 16 a, 16 b.
- the wires 14 are not wound around the inner core 16 b. Instead, they extend axially between the inner and outer sheaths 16 a, 16 b.
- the coil of elements 10 is again cylindrical and positioned in a mounting hole 38 that is defined in a dielectric substrate 12 .
- the dielectric substrate 12 includes contact pads 20 and connection solder 22 positioned on each of the contact pads 20 .
- the coil of element 10 is positioned through the hole 38 and the dielectric substrate 12 and the wires 14 of the coil of elements 10 are coupled to the contact pads 20 on the top surface 28 of the dielectric substrate 12 according to any of the methods previously discussed.
- the outer sheath 16 a is cut away to form an opening 36 through which the solder 22 can communicate with the respective wire 14 .
- FIG. 12 shows a close-up of the connection between the solder 22 and the conductive material 40 of the wire 14 .
- the plastic sheathing 26 around the wire 14 has been removed around the circumference of the wire, as previously discussed in connection with FIG. 8 , in the vicinity of the contact pad 20 and the hole positioned in the outer sheath of the coil of elements 10 .
- FIG. 13 is an example similar to the previously disclosed examples where the coil of elements 10 comprises a plurality of wires 14 that are wound around an inner sheath 16 b.
- An outer sheath 16 a holds the wires 14 between the inner and outer sheaths to establish a cylindrical body which makes up the coil of elements 10 .
- three dielectric substrates are disclosed including a top dielectric substrate 12 a, a middle dielectric substrate 12 b, and a lower dielectric substrate 12 c.
- the wires 14 within the coil of elements 10 are coupled to the upper and lower surfaces 28 , 32 of the dielectric substrates in the manner previously discussed in connection with the prior examples.
- the coil of elements outer sheath 16 a has a hole 36 cut into the sheath in the vicinity of each contact pad 20 such that a wire 14 within the coil of elements 10 can be coupled to each of the contact pads 20 via the connection solder 22 .
- the example shown in FIG. 13 can be used for a system where a large number of wires are positioned in the coil of elements 10 such that, for example, each wire could be coupled to one or more of the substrates 12 a, 12 b , 12 c, either one or more times.
- a greater number of wires 14 the number of connection points would be reduced since only a limited number of contact pads 20 and connection solder 22 are provided.
- This example would allow for redundancy between the wire connections such that a single wire could be coupled to a dielectric substrate 12 a number of times.
- this example could be utilized to improve the mechanical strength of the system because a greater number of solder joints provides a greater mechanical strength and retention.
- this example could be utilized in order to couple a wire to a variety of different substrates. By coupling the wires 14 to the substrates 12 , additional vias and connectors can be avoided within the system.
- FIG. 13 shows multiple dielectric substrates disposed along the length of a singular tubular structure.
- Each dielectric substrate 12 a, 12 b, 12 c can be used singly or each can be in electrical communication with another dielectric substrate 12 .
- Having multiple substrates allows for an increase in mechanical alignment for the tubular structure, as well as an increase in the available area for connection pads 20 in high wire count coils.
- FIGS. 14-17 depict an alternative example of the system for electrically coupling a three-dimensional structure to a substantially two-dimensional structure.
- the dielectric substrate 12 includes a plurality of holes or passageways 38 in the form of cut-outs on the corners of the dielectric substrate 12 .
- the dielectric substrate 12 has the corners cut out and the coil of elements 10 is positioned partially into one of the corners.
- the size and shape of the coil of elements 10 and the size and shape of the dielectric substrate 12 and the holes 38 of the dielectric substrate 12 could be modified such that a greater proportion of the coil of elements 10 is positioned within the corner passageway or hole 35 of the dielectric substrate 12 , the example not being limited to the depicted dimensional characteristics.
- the contact pads 20 were disposed around a circular hole in the dielectric substrate 12 .
- the contact pads 20 are disposed around the cutaway opening 38 in the corners of the dielectric substrate 12 .
- the cutaways 38 in the dielectric substrate 12 are arcuate such that the contact pads 20 are spaced along the edge of the arcuate opening for connection with a coil of elements 10 positioned adjacent the arcuate opening.
- the coil of elements 10 includes a plurality of wires 14 that extend axially along the length of the coil of elements 10 between the inner 16 b and outer 16 a sheaths of the coil of elements 10 .
- the wires 14 may be stripped of their plastic outer sheathing 26 to reveal the conductive material 40 of the wires 14 and this conductive material 40 may be coupled to each contact pad 20 in the manner previously described in the prior examples by melting a solder 22 disposed on each contact pad 20 such that the solder 22 wicks onto each wire 14 and establishes electrical communication and mechanical communication between the solder 22 and the conductive portion 40 of the wires 14 .
- FIGS. 16 and 17 show views of how a plurality of coil of elements 10 may be connected to the dielectric substrate 12 that has the corners cut out to form corner passageways.
- four coils of elements 10 are coupled to the dielectric substrate 12 , with one coil being positioned in each arcuate opening on the corners of the dielectric substrate 12 .
- Each coil of elements 10 includes wires 14 that extend axially along the length of the coil of elements 10 and the wires 14 may be joined to the contact pads 20 in a manner previously discussed in connection with FIG. 15 .
- the use of the dielectric substrate 12 to join the four coils of elements 10 together helps to provide mechanical stability between the four coils of elements 10 .
- the coils of elements 10 may be joined to both an upper and a lower surface 28 , 32 of the dielectric substrate 12 , if so desired. While the coil of elements 10 in this example is shown as including axially extending wires 14 , it should be recognized by those skilled in the art that the coil of elements 10 could include wires 14 that are wound around the inner sheath 16 b instead of longitudinally or axially extending wires 14 as shown in the figures.
- FIGS. 14-17 show a similar arrangement of dialectic substrates 12 as that shown in FIG. 13 .
- the tubular structure 10 passes though an edge of the dielectric substrate 12 .
- Such an arrangement would allow for easier integration in compact clamshell type hand pieces as each dielectric substrate 12 would have only a portion of the tubular structure 10 to interact with at any given time. It is also easy to add multiple tubular structures 10 to a single dielectric substrate 12 when the tubular structures 10 are disposed at the edges of the dielectric substrate 12 .
- FIGS. 18 and 19 depict an alternative example of the system for electrically coupling a three-dimensional structure to a substantially two-dimensional structure.
- the dielectric substrate 12 does not have a through-hole 38 , or holes positioned at the corners or anywhere else on the dielectric substrate 12 .
- the coil of elements 10 terminates at the top surface 28 of the dielectric substrate 12 .
- the wires 14 that are positioned at the end of the bundle of wires 14 of the coil of elements 10 terminate at the contact pads 20 established on the upper surface of the dielectric substrate 12 .
- the coil of elements 10 includes a plurality of wires 14 that are wound around an inner sheath 16 b and constrained by an outer sheath 16 a.
- the coil of elements 10 is cylindrical and the dielectric substrate 12 is shown as rectangular, however, any shapes for either of these elements may be utilized, if so desired.
- the outer sheath 16 a includes a cutaway portion 36 where the wire 14 is coupled to the respective contact pad 20 utilizing connection solder 22 .
- connection solder 22 may be coupled to each wire 14 via heating of the solder 22 such that it wicks onto the conductive portion of each wire 14 to establish an electrical and mechanical connection between the contact pad 20 and the wire 14 .
- FIGS. 18-19 illustrate just such a termination wherein the dielectric substrate 12 is disposed at an end of the tubular structure 10 .
- End attached terminations can be combined with any and all of the above described termination methods.
- FIGS. 20-31 depict several different examples of a wire structure within a coil of elements 10 .
- a coil of elements 10 having a circular cross-section includes an inner sheath 16 b and an outer sheath 16 a.
- a plurality of wires 14 are disposed between the inner and outer sheaths 16 b, 16 a.
- FIG. 20 is similar to the examples previously disclosed.
- the wires may be wound around the inner sheath 16 b or the wires may be axially extending along the length of the coil of elements 10 .
- FIGS. 20-31 demonstrate a representative subset of the possible cross sections of a tubular structure.
- Tubular structures 10 can have any number of different types of cross-sections such as round ( FIGS. 20-22 ) , oval ( FIGS. 29-31 ), square ( FIGS. 26-28 ), rectangular, pentagonal, triangular ( FIGS. 23-25 ), or other shapes.
- Tubular structures 10 can also contain not just one central lumen, but a plurality of lumens of different sizes and configurations. What they all have in common is that a pattern of wires 14 exists around the tubular structure.
- FIG. 21 depicts a coil of elements 10 having a round cross-section, similar to that of FIG. 21 , except for, in this example, two different sizes of wires 14 are provided.
- coil of elements 10 has an inner sheath 16 b and an outer sheath 16 a with a first-sized wire 14 a evenly spaced around the circumference of the coil with an equal number of larger conduits 14 b or wires positioned between each of the smaller conduits or wires 14 a.
- the different shaped wires 14 a, 14 b may be used for different functions.
- 14 a is representative of a wire
- 14 b is representative of a conduit or tube having a dissolvable center such that fluid can be transported through the center of the conduits 14 b.
- wires could be positioned in either 14 a and 14 b and fluid could be positioned in 14 a, if so desired.
- the present system may be utilized to establish both electrical connections and fluid connections.
- the wires could alternatively be channels, tubes, or other conduits for transporting a fluidic material including liquids, gases, or other such materials.
- the dielectric substrate 12 would have an associated conduit channel or other feature for receiving the fluid in a fluid type manner. This will be discussed in greater detail below.
- FIG. 21 it is possible to have both fluid transporting conduits and wires within the coil of elements 10 .
- FIG. 22 depicts an alternative example where an outer sheath 16 a is provided with two inner sheaths 16 b.
- the inner sheaths 16 b define openings within the coil of elements 10 that extend axially along the length of the coil of elements 10 .
- the inner sheaths define two cylindrical openings that extend axially within the coil of elements 10 .
- Wires 14 a may be positioned around the periphery of the coil of elements adjacent the outer sheath 16 a.
- FIGS. 23-25 depict alternative examples similar to those previously discussed, except that in this case the coil of elements 10 is triangular in shape.
- the coil of elements 10 is bounded on the outside by sheath 16 a and on the inside by sheaths 16 b and 16 c.
- the plurality of wires 14 a or conduits 14 b are disposed around the periphery of the coil of elements 10 , and the wires 14 may be either wound around the coil of elements 10 or disposed axially along the length of the coil of elements 10 .
- FIG. 24 depicts a triangular coil of elements 10 having an inner sheath 16 b and an outer sheath 16 a with a plurality of wires 14 disposed between the inner and outer sheaths.
- the wires 14 are evenly distributed around the periphery of the coil of elements 10 .
- the wires 14 may be wound around the circumference of the inner sheath 16 b or the wires 14 may extend axially along the length of the coil of elements 10 .
- FIG. 25 depicts a similar triangular coil of elements 10 having an inner sheath 16 b and an outer sheath 16 a.
- a plurality of wires are disposed around the coil of elements 10 .
- a smaller wire 14 a is disposed around an outermost periphery of the coil of elements 10 and an inner larger wire 14 b is equally spaced around the inner sheath 16 b.
- this example is discussed in the context of wires within the coil of elements 10 , it should be recognized that the elements 14 a and 14 b could be either wires or conduits or passageways for receiving a fluid, such as liquids or gases.
- FIGS. 26-28 depict an alternative example of the coil of elements 10 where the outer periphery of the coil of elements 10 is substantially rectangular.
- the coil of elements 10 is a square shape.
- FIG. 26 includes an outer sheath 16 a and an inner sheath 16 b.
- a plurality of wires 14 are equally spaced around the periphery of the coil of elements 10 between the inner and outer sheaths 16 a, 16 b.
- FIG. 26 depicts a square outer sheath 16 a.
- Two inner sheaths 16 b , 16 c are defined as circular tubes or cylinders that extend through the interior of the coil of elements 10 .
- One of the inner sheaths 16 c has a larger diameter than the other inner sheath 16 b.
- a plurality of wires 14 are disposed inside the outer sheath 16 a and evenly spaced around the periphery of the coil of elements 10 .
- FIG. 28 depicts a coil of elements 10 having an outer sheath 16 a that is square in shape and an inner sheath 16 b that is a similar square shape.
- a plurality of wires 14 a, 14 b are positioned between the inner and outer sheaths.
- the wires include smaller diameter wires 14 a that are positioned nearest to the outer sheath 16 a and a plurality of inner larger diameter wires 14 b that are spaced around the inner sheath 16 b.
- the inner wires 14 b are fewer in number than the outer wires 14 a, and each of the wires are evenly spaced around the periphery of the coil of elements 10 .
- wires 14 , 14 a and 14 b in FIGS. 26-28 could alternatively be conduits or passageways for transporting a fluid such as a gas or a liquid.
- the examples are not to be limited to simply wires having electrical connectors disposed therethrough.
- the wires 14 could alternatively be plastic coated tubes having a dissolvable material inside the tubes is dissolved, a conduit for a fluid is provided.
- FIGS. 29-31 depict an alternative example of a coil of elements 10 similar in many respects to the examples previously discussed.
- Each of the examples in FIGS. 29-31 has an oval shaped outer periphery.
- FIG. 29 includes an inner sheath 16 b and an outer sheath 16 a which together bound an interior space having a plurality of wires 14 disposed therein.
- the plurality of wires 14 are evenly spaced around the periphery around the coil of elements 10 .
- the wires 14 may be wound around the inner sheath 16 b or may be axially extending along the length of the coil of elements 10 .
- FIG. 30 depicts an inner sheath 16 b and an outer sheath 16 a with a plurality of wires 14 a, 14 b disposed between the inner and outer peripheries and evenly spaced around the periphery thereof.
- two different sized wires 14 a, 14 b are provided.
- a smaller diameter wire 14 a is evenly spaced around the outer periphery of the coil of elements 10 adjacent the outer sheath 16 a.
- An inner plurality of wires 14 b, having a larger diameter than the outer wires 14 a, are disposed adjacent the inner sheath 16 b.
- the smaller wires 14 a are far more numerous than the larger wires 14 b in this example coil of elements 10 .
- FIG. 31 discloses an outer sheath 16 a and two inner sheaths 16 b, 16 c.
- a plurality of wires 14 are disposed between the inner and outer sheaths 16 b, 16 a, 16 c.
- the inner sheaths 16 b, 16 c form cylinders having a circular cross-section that extend axially along the length of the coil of elements 10 .
- One of the inner sheaths forms a larger diameter circle than the other inner sheath 16 b, which forms a smaller diameter circle than the larger diameter circle.
- the plurality of wires 14 are disposed around the outer edge of the coil of elements 10 adjacent the outer sheath 16 a. In this example, only one diameter wire is disclosed, however, it should be recognized in any of these examples, that any number of wires and any size wires may be utilized to the extent that they fit within the area between the inner and outer sheaths 16 a, 16 b, 16 c. Also, as previously discussed, while the above description was in the context of wires 14 , which typically will have a conductive material positioned within an outer plastic coating, the wires may alternatively be tubes for transporting a fluid such as a gas or a liquid.
- FIG. 32 depicts an alternative example of the system for electrically coupling a three-dimensional structure to a substantially two-dimensional structure.
- a coil of elements 10 is disposed within a recess or passageway 38 that is defined in the surface 28 of substrate 12 . While prior examples positioned the coil of elements 10 perpendicular to the dielectric substrate 12 , in this example, the axis of the coil of elements 10 is substantially perpendicular to the surface 28 of the dielectric substrate 12 .
- a recess 38 is defined within the upper surface 28 of the dielectric substrate 12 in order to receive at least a portion of the coil of elements 10 therein.
- the coil of elements 10 is depicted as seating in the recess 38 such that part of the coil of elements 10 is positioned below the surface 28 of the dielectric substrate 12 and part of the coil of elements 10 as positioned above the surface of the dielectric substrate 12 . It will be recognized that any shape of opening or recess in the dielectric substrate 12 could be utilized such that the coil of elements 10 is positioned at different depth levels within the dielectric substrate 12 . The position of the coil of elements 10 relative to the dielectric substrate 12 is, in part, dependent upon the thickness of the dielectric substrate 12 .
- the coil of elements 10 includes an inner sheath 16 b and an outer sheath 16 a, with the inner sheath 16 b serving as a boundary for a spirally wound plurality of wires 14 that are positioned between the inner and outer sheaths 16 b , 16 a.
- the wires 14 of the coil of elements 10 are coupled to contact pads 20 having solder 22 disposed thereon in a manner similar to that previously discussed in connection with the prior examples. The only difference is that the coil of elements 10 is positioned on its side instead of being straight up and down.
- the outer sheath is cut to expose the wires 14 inside the coil of elements 10 and each respective wire 14 that is to be coupled to a contact pad 20 is also stripped of its protective outer coating 26 in order to reveal the underlying conductive material 40 within the wire 14 .
- solder 22 positioned on the contact pad 20 upon heating, couples to the conductive material 40 within each wire 14 that is aligned for coupling.
- the dielectric substrate 12 in this example shows electrical traces 103 that extend from the contact pads 20 to other components.
- the example shown in FIG. 32 also incorporates a heat transfer pad 24 that is conductively coupled to the contact pads 20 .
- the heat transfer pad 24 is designed to accept heat from a heating element, to transfer the heat to the contact pad 20 which then melts the solder 22 that is positioned on the contact pad 20 , such that the solder 22 wicks or couples to an adjoining wire 14 within the coil of elements 10 .
- the heating pad 24 may be spaced from the contact pad 20 by a conductive conduit 21 which is essentially a pad of conductive material that is coupled to the heat transfer pad 24 and to the contact pad 20 .
- a secondary dielectric may be positioned over the conductive conduit 21 such that communication between the heating pad 24 and the contact pad 20 is avoided.
- the heating pad 24 is also a conductive element that is positioned on a surface of the dielectric substrate 12 .
- the elements referred to as “heating pads” may be connector holes 24 for receiving a connector for coupling to the wire 14 .
- the holes 110 on the left side of the dielectric substrate 12 may be utilized for positioning connectors therein or for coupling to a pin or other similar connector.
- FIG. 33 is a expanded view of the connection between the wires 14 and the contact pad 20 of the example shown in FIG. 32 .
- the outer sheath 16 a of the coil of elements 10 is cut away in the vicinity of the wires 14 to be coupled to the contact pads 20 disposed on the dielectric substrate 12 .
- the protective coating of the wires 14 may be fully stripped in the vicinity of the opening 36 in the outer sheath 16 a, in order to allow the wires 14 to be coupled to the connection solder 22 .
- the wires 14 may be joined to the connection solder 22 .
- the longitudinal axis of the coil elements 10 is substantially perpendicular to the upper surface 28 of the dielectric substrate 12 .
- the longitudinal axis of the coil of elements 10 could align with the upper surface 28 of the substrate 12 or be positioned above or below the upper surface 28 of the substrate 12 .
- the solder connection for FIG. 33 includes a contact pad 20 having a solder 22 disposed thereon.
- a heat transfer pad 24 of conductive material is coupled to the contact pad 20 by a conductive conduit 21 .
- the heat transfer pad 24 has disposed thereon a heat transfer material 23 such that when the heat transfer material 23 of the heat transfer pad 22 comes in contact with a heat source, the heat is transmitted from the heat transfer pad 22 through the conductive conduit 21 to the contact pad 20 which then heats the solder 22 disposed on the contact pad 20 .
- the solder 22 then wicks onto the exposed wire 40 in the vicinity of the solder 22 to establish an electrical and mechanical connection between the contact pad 20 and the wire 14 .
- FIG. 34 depicts an example of how wires 14 are numbered within a coil of wires 10 .
- a first wire 14 a is coupled to the first contact pad 20 a
- a second wire 14 b is coupled to the second contact pad 20 b
- a third wire 14 c is coupled to the third contact pad 20 c
- a fourth wire 14 d is coupled to the fourth contact pad 20 d.
- a similar set of contact pads is disposed on the left side of the coil of elements 10 .
- the wires 1 through 4 will be arranged in a similar scheme on the left side of the coil of elements 10 , or a different arrangement.
- the wire connections on the left side of the coil of elements 10 on the dielectric substrate 12 could be arranged in numerical order starting with 1 through 4. Or, the numbers could be switched around depending upon the pitch of the windings of the wires 14 in the coil of elements 10 .
- FIG. 34 illustrates a method of soldering a substantially three dimensional structure to a substantially two dimensional structure.
- a three dimensional coil 10 of wound wire or wires 14 a - 14 d is attached to a substrate 12 with the use of a connection material 22 displaced on a connection pad 20 which has been permanently affixed to the substrate 12 and can be easily defined in terms of length and width.
- a heat transfer pad 24 a - 24 d having heat transfer material 23 a - 23 d, is coupled to contact pad 20 a - 20 d via a conductive conduit 21 a - 21 d.
- the coil 10 can be used in a medical device such as a probe that is inserted into the human body but the current invention is not so limited.
- the coil 10 need not have a constant cross section for its entire length, indeed the coil can expand and contract at predetermined points along its length independent of the tubular structure.
- the coil 10 can surround a hollow tube, solid tube, guide wire, optical fiber, cavity, etc. All of these structures are hereafter referred to as a tubular structure 16 which will be discussed in detail below.
- a tubular structure contains an outer surface 16 a and an inner surface 16 b and the wires 14 are contained within the tubular structure 16 .
- FIG. 35 shows a cross section of the coil 10 , the wires 14 , the substrate 12 , as well as connection material 22 , conductive conduit 21 , connection pads 20 , heat transfer pads 24 , and heat transfer material 23 , along a common, arbitrary plane.
- connection material 22 wraps around the wire 14 forming a good mechanical joint at the interface of the groove 18 and the connection pad 20 .
- FIGS. 36 , 37 and 38 illustrate another way to attach a substantially three dimensional structure to a substantially two dimensional substrate 12 .
- Each wire 14 is wound around a tubular structure 16 that is placed within a groove 38 of a substrate 12 .
- Connection pads 20 are disposed along a planar surface of the substrate 12 at the spacing of the wires 14 .
- each wire 14 intersects the substrate 12 at multiple locations.
- Contact pads 20 are applied to the substrate 12 at those locations where the wires 14 intersect the substrate 12 and connection material 22 is applied to the top surface of all the connection pads 20 .
- FIGS. 39 through 44 depict alternative examples of the connection between the coil of elements 10 and the opening 38 disposed in the dielectric substrate 12 .
- the channel that is positioned in the top surface 28 of the dielectric substrate 12 for receiving the coil of elements 10 has a rectangular cross-section.
- a side of the coil of elements 10 is positioned at the bottom 44 of the rectangular recess 38 .
- the longitudinal axis of the coil of elements 10 is substantially aligned with the surface 28 of the dielectric substrate 12 .
- Connection solder 22 is utilized to connect wires 14 within the coil of elements 10 to respective contact pads 20 on the surface 28 of the dielectric substrate 12 .
- FIG. 40 depicts an alternative example of a recess 38 in the surface of the dielectric substrate 12 that is V-shaped such that two sides of the coil of elements 10 rests upon the two sides 46 a, 46 b of the V-shaped channel 38 .
- Connection solder 22 is utilized to couple wires 14 disposed within the coil of elements 10 to contact pads 20 that are disposed on the surface 28 of the dielectric substrate 12 .
- the longitudinal axis of the coil of elements 10 is substantially aligned with the surface 28 of the dielectric substrate 12 .
- FIG. 41 depicts a coil of elements 10 positioned between two dielectric substrates 12 .
- a horizontal axis of the dielectric substrates 12 aligns with the longitudinal axis of the coil of elements 10 .
- the dielectric substrates 12 have a height H that is less than the diameter D of the coil of elements 10 .
- Connection solder 22 is utilized on both the top and bottom surfaces 28 , 32 of the dielectric substrates 12 to couple the conductive wires 14 of the coil of elements 10 to the contact pads 20 that are disposed on the surfaces 28 , 32 of the dielectric substrates 12 .
- FIGS. 42 through 44 depict a coil of elements 10 that is positioned on the top surface 28 of the dielectric substrate 12 .
- a recess for retaining the coil of elements 10 is created by the connection solder 22 that is utilized to connect the contact pads 20 to the conductive elements or wires 14 within the coil of elements 10 .
- No recess 38 is defined in the surface 28 of the dielectric substrates 12 .
- FIG. 42 depicts an oval coil of elements 10 wherein the long transverse axis of the oval is positioned parallel to the surface 28 of the dielectric substrate 12 .
- the connection solder 22 is positioned substantially under the edges of the coil of elements 10 .
- FIG. 43 depicts an oval-shaped coil of elements 10 where the long transverse axis of the oval shape is positioned perpendicular to the surface 28 of the dielectric substrate 12 .
- the oval shape is held on the dielectric substrate 12 by the connection solder 22 , which forms supports for the coil of elements 10 .
- the connection solder 22 is positioned on the contact pads 20 and a portion of the connection solder 22 is positioned under the edges of the coil of elements 10 and a portion of the connection solder 22 extends outwardly from the edges of the coil of elements 10 .
- FIG. 44 depicts a coil of elements 10 having a cross-sectional shape like that of a racetrack.
- a long transverse axis of the coil of elements 10 is disposed parallel to the surface 28 of the dielectric substrate 12 .
- Connection solder 22 is positioned on the contact pads 20 and is coupled to the wires 14 of the coil of elements 10 in order to establish an electrical and mechanical connection between the wires 14 and the contact pad 20 .
- the connection solder 22 supports the coil of elements 10 on the surface of the dielectric substrate 12 .
- FIGS. 32-44 show how it is not necessary for the tubular structure and the dielectric to be arranged perpendicularly to one another by using a channel or a groove that has been formed into the surface of a dielectric substrate 12 , the tubular structure can be mechanically retained by attachment to connection pads 20 .
- a channel 38 on a dielectric substrate 12 is not even required. Instead the tubular structure can have a flat side which rests flush with the dielectric substrate (such as shown in FIG. 44 ).
- FIGS. 45-49 depict different examples of tubular structures that contain coils of wire 10 .
- the wires 14 in the examples can be moving in opposite directions, such as clockwise and counterclockwise.
- the alternating coils form braided or woven structures along the length of the tubular structure 10 .
- FIG. 45 shows an example where the wires 14 are braided on the surface of the tubular structure 16 a with one wire going in a first direction and the other wire going in a second direction.
- FIG. 46 is similar to FIG. 45 , but includes a wire 14 a that extends longitudinally along the length of the tubular structure 10 .
- FIG. 47 depicts two wires disposed around the surface 16 a of a tubular structure 10 , with the windings of the wires 14 having different pitches depending upon the location of the wires 14 along the length of the tubular structure 10 .
- FIG. 48 is similar to FIG. 47 except for it only includes a single wire traveling in a single direction. The wire has a different pitch at the one end than at the other end.
- FIG. 49 represents a winding of wires around the tubular structure. The windings have a different pitch at one end and at the other, the pitch gradually changes between the one end and the other end.
- FIGS. 45-49 show how the coil of wire can be combined with other structures inside or alongside the tubular structure.
- the coil can contain wires 14 moving in opposing directions, i.e. clockwise and counterclockwise turns. These alternating coils can interact with each other and form woven or braided structures along the length of the tubular structure 10 . Not all of the individual wires 14 contained within such a braided structure need to be electrically conductive or attached to a dielectric substrate 12 . Selective stripping of the insulation 26 allows for precise control over what is attached to what. Indeed, straight runs of wire (not shown) can be combined with either the braided structure or with regular coils of wire. These straight runs can be for either selective impedance matching, electrical attachment, or as non-conductive safety wires.
- thermocouple pairs can be run down within the coil of wire 10 and mixed gauge wires can be used to both further refine the flexibility characteristics of the tubular structure and to enhance the electrical communication of the system.
- FIGS. 50-55 represent a fluidic structure that is configured to accept fluids, gases or semi-fluid or particulate matter transfer.
- the term conductive element as used herein in connection with the coil of wires 10 is defined to include both electrical transmission and fluidic transmission of an element, such as a fluid, a gas, a cryogen, a particulate, and a semi-solid.
- the wires 14 may alternatively be tubes that are filled with a dissolvable material such that when the material inside the tube is dissolved, a hollow member 14 for transporting the fluid is provided.
- the covering 112 of the dissolvable material within the tube may be stripped at a location where the tube is to be connected with a substrate, such as a dielectric substrate 12 depicted in FIG. 50 .
- the tube can be positioned adjacent a channel opening 106 in a substrate 12 without stripping.
- an epoxy or other plastic type of sealing material 114 may be positioned over the dissolvable material to define a conduit 107 through which a fluid can flow once the dissolvable material has been dissolved.
- a channel 106 is disposed in a substrate 12 and the tube 14 is in communication with that conduit 106 .
- a temporary gusset 105 is disposed adjacent the tube of dissolvable material and is utilized to hold the tube in place and to seal around the tube to create the channel from the tube to the channel that is defined within the substrate 12 .
- the tube filled with dissolvable material is coupled to the channels 106 that is defined in the substrate 12 .
- the example coil of elements 10 can include both a conductive wires and tubes filled with dissolvable material.
- Gusset 105 can be an epoxy-type sealing material, or other material that can be used to seal the tube of dissolvable material to a corresponding conduit in the substrate 12 .
- the electrical connections and fluidic connection can be used side-by-side on a single substrate, and can be used on different layers of a substrate either together alone, can be used on different substrates that are coupled to a single or multiple coils of elements 10 .
- FIG. 50 shows a substrate 12 with a coil 10 disposed in opening 38 therein.
- the substrate 12 has channels 106 formed inside and filled with a removable material.
- contact pads 20 which are also made of a removable material.
- Selected tubes 14 within the coil 10 are filled with a removable material and have stripped areas 112 which expose the removable material inside the tubes 14 .
- FIG. 51 depicts a removable connection material 105 between the wire cores 40 and connection pads 20 .
- the connection material 105 forms part of the mechanical envelope of the transfer passage 107 .
- attachment material 114 is added between the tubular structure 16 and the substrate 12 in order to mechanically restrain the coil 10 and to form the other part of the mechanical envelop of the transfer passage 107 that transfers fluid from the tube 14 to the channel 106 .
- FIG. 53 the removable material is removed from the system. This leaves hollow channels 106 inside the substrate 12 , a hollow transfer passage 107 and hollow wires or tubes 14 in the coil 10 .
- FIG. 54 a section view through one of the connection pads 20 shows a section of the channel 106 in the substrate 12 being filled with a removable material and another removable material forming a transfer passage profile 107 and a third removable material 116 inside the tube 14 . Thus the path from the coil 10 to the substrate 12 is clearly shown.
- FIG. 55 a section view through one of the connection pads 20 shows a section of the system after all the removable material has been removed. This leaves transfer passage 107 empty and allows for the flow of material through the channel 106 .
- any given wire with a coil may also contain a dissolvable core. This allows for a very low cost way of integrating massively multi lumen catheters with electrical connections.
- FIGS. 50-55 Such a system is shown in FIGS. 50-55 .
- the tubular structure shows only a single wire for clarity but it is to be understood that a plurality of wires 14 can also exist within such a system.
- the wire is then stripped of its insulation 112 , but left mostly intact both in the containing insulation and in the tubular wall structure.
- the stripped wire portion is then aligned on the dielectric substrate 12 over the connection pad 20 and a temporary gusset 105 is formed between the wire core and the contact pad 20 .
- the contact pad 20 and gusset material 105 are also formed out of dissolvable material such that when the material is removed, a channel 106 will exist between the dielectric substrate 12 and the tube within the tubular structure. Before the gusset and associated materials are dissolved, a final covering material 114 is used to completely encapsulate the original gusset and retain the tubular structure.
- the channel 107 , 106 inside the dielectric substrate 12 can also be easily attached to a micro-fluidic controller or some other such system. With the material removed; fluids, particulates, gasses, cryogens, and combinations thereof can flow from the tip of the catheter down to the dielectric substrate 12 and vice versa. This allows for activities like drug delivery, blood sampling, and other important activities.
- Transfer Passages 107 are the fluid equivalent of a solder joint. They are a passageway extending from the stripped and opened center of the tube 116 disposed in a helical fashion around the body of the catheter to the opening 20 over the channels 106 inside the 2 D structure 12 .
- a hollow transfer passage 107 is formed between the channel 106 in the substrate 12 and the hollow lumen 116 within the tubular structure 10 .
- a transport system is formed from the micro fluidic channel or channels contained in the substantially 2D structure 12 continuously through to the tubes or lumens in the wall of the 3D structure 10 .
- the channels thus formed inside the substrate 12 can be easily attached to micro fluidic controllers, reagent cavities or can be routed to more macro scale tubing systems, hydraulics, or other such system.
- the remaining tubular structures 10 can be used with micro fluidic devices to allow for reagent mixing, drug delivery, blood sampling, saline delivery, drainage, controlled cryogenic delivery and extraction, as well as a number of other uses. With the material removed; semi-solids, particulates, fluids, cryogens, gasses, and combinations thereof can flow from the tip of the 3D tubular structure down to the 2D dielectric substrate 12 and vice versa.
- Minimally invasive surgical procedures rely on being able to do a lot of work while causing the patient less pain, scarring, and lower recovery times. This is commonly accomplished by making a small artificial incision and feeding a tube up through the incision and having all of the instrumentation needed fed up through the tube. Modern catheters feed wires up through the body of the tube to tips on the catheters which can be used to diagnose and treat a multitude of disorders. Being able to go home directly after a surgical procedure is considered more desirable then long hospital stays. As such, there is an ever growing demand for new procedures and hence for new micro medical devices. Designers are working at a cross purpose though; in order to create a less traumatic experience a smaller catheter body is desired.
- Catheter bodies are not always round and are not always tubes. Ovoid shapes are very popular as they allow for easier bending in certain directions which makes steering the catheter easier in certain situations. Catheters can also contain a number of different “tubes” or lumens that have been all formed at the same time. Typically, certain lumens are used to carry wires and other lumens are used to carry fluids.
- Fluid transportation is useful for a variety of reasons.
- One reason is for drainage, much like what a dentist does with excess saliva except integrated into the same tool being used to clean your teeth.
- Another reason is for sampling of whatever the tip is interacting with, so you could have real time localized blood oxygen content readings as well as measuring what other chemicals are present in the blood stream during surgery.
- Tubes can also be used to push material into the area as well as to take materials away from the area.
- Saline being both neutral to the body and conductive, is often used during ablation procedures. Drugs can also be delivered along the same channels and allow for very specific targeting of problem sites.
- Cryogens can also be sent up the tube to freeze off a very small portion of the body.
- Many people have warts frozen off from external body parts because it is a very effective method of killing off a localized area in a way that the body quickly repairs. Being able to freeze interior portions of bodily anatomy could easily revolutionize current cancer treatments.
- Fiber optics can be split, with only minimal impact on signal integrity by matching up helical tangents on two different tubular structures. Helixes will also eventually cause all the conductors in a system to pass through a single tangent line parallel to the axis of the tubular structure, thus allowing for easy attachment of multiple wires to a single line on a single substrate. This also allows for adding in electrical connections to devices and structures that would otherwise not contain them. For example wires could be wrapped around a fiber optic element. Though separately insulated wires are easy to incorporate, it is also easy to use flex circuits or otherwise added conductive material, by such common processes as sputtering, to the outside of a tubular structure.
- Tubular structures need not apply only to medical catheters. Tubular structures are used in everything from avionics to architecture. Being able to have a high density interconnection system that still allows for structural rigidity and or allows for other devices to share the same space is of great use in a variety of industries. For example, airplanes could move most of their wiring harnesses to the skin of the airframe using the herein described techniques. Also power conduits and network connections could run up a central structural member of a new building and could use the herein described technology to run high density backbones between floors.
- FIGS. 56 and 57 depict an alternative example where the coil of elements 10 is sandwiched between two dielectric substrates 12 .
- the coil of elements 10 can be coupled to surfaces on both dielectric substrates 12 .
- the coil of elements 10 is coupled to the lower dielectric substrate 12 utilizing retention solder 22 positioned on a contact pad 20 .
- a heat transfer pad 24 for thermally communicating with the contact pad 20 and connection solder 22 is disclosed.
- the coil of elements 10 is coupled to the upper dielectric substrate 12 on the bottom surface 32 thereof in a similar manner.
- Both substrates 12 include a recess 38 for receiving at least a portion of the coil of elements 10 therein.
- FIGS. 56-57 show another example of how a single tubular structure can connect to multiple dielectric substrates 12 .
- FIGS. 58 and 59 disclose an example similar to that in FIGS. 11 and 12 , except for the coil of elements 10 in FIGS. 58 and 59 is positioned at an angle relative to the surface 28 of the dielectric substrate 12 .
- the hole or passageway 38 that is defined through the dielectric substrate 12 is similarly angled such that the coil of elements 10 is able to rest within the hole that is defined in the dielectric substrate 12 .
- the coil of elements 10 can be positioned at any angle relative to the surface 28 of the dielectric substrate 12 including a 45° angle, a 60° angle, 80° angle or perpendicular to the dielectric substrate 12 among other angles, the disclosure not being limited to a particular angle of the coil of elements 10 relative to the surface 28 of the dielectric substrate 12 .
- the connections between the wires 14 of the coil of elements 10 and the contact pads 20 and connection solder 22 disposed on the surface of the dielectric substrate 12 are similar to that previously discussed in connection with FIGS. 11 and 12 .
- FIGS. 58-59 illustrate the advantage of the mounting hole 38 not being perpendicular to the dielectric substrate 12 .
- the connection material 22 is placed more and more in shear when axial load is placed on the tubular structure 10 , thus increasing the overall strength of the adhesion between the dielectric substrate 12 and the tubular structure 10 .
- FIGS. 60-61 show how multiple substrates can be laminated together, each with their own connection pads 20 disposed around a common mounting hole 38 , and contact a tubular structure 10 having wires 14 .
- the connection pads are formed from conductive layers 103 similar to those found in common multilayered printed circuit board substrates. Regardless of the substrate used, the connection pads 103 a - 103 d all have connection material 22 disposed along an edge thereof using a variety of reflow methods.
- the wires 14 within the tubular structure are then selectively stripped of their insulation 26 and inserted within the hole 38 .
- the tubular structure 10 is press fit into the hole 38 for added mechanical retention.
- the contact pads 103 a - 103 d are heated, either through resistive heating between another contact point along the wire and the contact pad or through other heating methods, and the connection material 22 melts and attaches to the wire core 40 in a manner similar to the ones described above.
- the substrate 12 can be prepared by forming a groove 38 in a planar surface of the substrate 12 .
- the groove 38 is sized and configured to receive a portion of the coil 10 along its axial length.
- Conductive material 103 is applied to the planar surface of the substrate 12 during the initial manufacture of the substrate 12 at a spacing that matches an even increment of the wires 14 within the coil 10 .
- the conductive material 22 forms a plurality of connection pads 103 a - 103 d which are usually disposed perpendicularly to the axis of the groove 38 and abut the edge of the groove 38 .
- Each connection pad 103 a - 103 d may be surrounded by a secondary dielectric 100 (shown in FIG.
- connection material 22 is added on top of connection pad 103 to enable the electrical and mechanical joining of the substrate 12 to the wire 14 and hence mechanically retain the coil 10 and allow for electrical communication between a distal end of the coil 10 and the substrate 12 .
- the connection material 22 is added before the coil is introduced but after the formation of the groove 38 but the connection material 22 can also be added at the same time as the coil 10 is aligned inside the groove 38 with the connection pads 103 a - 103 d. Also, the connection material 22 would be added in an automated manner, such as with a solder stencil and reflow process standard to the electronics industry.
- the coil 10 is prepared by removing portions of the tubular structure 16 in the area where the wires 14 are to be soldered to the substrate 12 . Furthermore, each wire 14 that is to be attached has some of its insulation 26 removed at that location. Wires 14 can be stripped using a laser cutting or other technique such as but not limited to thermal ablation, chemical etching, and bead blasting. Both the tubular structure 16 and the wire insulation 26 are ideally removed at the same time and only in the locations needed to attach a wire 14 to a connection pad 103 . The wire 14 can be tinned, before or after the insulation is removed, with a coating of connection material 22 to facilitate attaching the wire 14 to a connection pad 103 .
- each wire 14 to be affixed is aligned with a respective connection pad 103 . Because the conductive material 103 was placed at an even increment of the pitch of the wires 14 , only a single wire 14 has to be aligned with a pre-determined connection pad 103 and all other wires 14 will be aligned with their respective connection pads 103 . This saves time during assembly and eases the process of soldering multiple wires 14 to a substrate 12 .
- Each stripped wire 14 is attached to a respective connection pad 103 with an individual connection material 22 .
- a heat source is placed in thermal communication with connection pad 103 .
- the heat then travels through the connection material 22 and is transferred to the wire 14 .
- the connection material 22 then wicks up the heated wire 14 forming a joint between a connection pad 103 and the wire 14 .
- the connection material 22 hardens thus securing the wire 14 to the connection pad 103 and, hence, to the substrate 12 and any other components or structures that may be in electrical communication with the underlying conductive material 103 .
- connection pad 20 it is possible to attach wire 14 to connection pad 20 using a heat transfer technique.
- the heat from a given source typically a soldering iron
- a heat transfer pad 24 which is in thermal communication with a connection pad 20 .
- the heat transfer pad 24 is in communication with the contact pad 20 such that connection material 22 can be melted without physical contact from the original heat source.
- a secondary dielectric 21 may be placed between the heat transfer pad 24 and the connection pad 20 in order to prevent the cross contamination with the connection material 22 disposed on the surface of the connection pad 20 .
- a secondary bump of connection material 23 can be added on top of the heat transfer pad 24 to aid in the thermal communication between a heat source and the heat transfer pad 24 and hence between a heat source and the connection material 22 and from there to the wire 14 .
- Discontinuous Structures By using a process that adds wires or other such conductive elements selectively, it is possible to have wires go only partway down a tubular structure. This means that there can be arbitrary segments of the tubular structure that contain a different number of wires 14 then other portions. It is also possible to run all the wires 14 down the length of the tubular structure but to cut, or otherwise splice, certain wires 14 at a given point, effectively turning a single wire into two electrically separate pieces. Having a different number of wires 14 means that the apparent flexibility of the system can be further refined. However, a more ingenious use of the system is to add in a “backplane” type interconnect system between multiple substrates 12 attached to the coil.
- each wire in the frontplane can be used to carry a different type of information. Electrical signals, light impulses, power connections, fluid samples, gaseous reagents, and many others can be moved from substrate 12 to substrate 12 , either individually or en masse, and from any given substrate 12 to locations further down the tubular structure.
- FIG. 34 An optional method of attaching the wires 14 in a coil 10 to a substrate 12 that allows for redundancy for safety, mechanical stability, and an increased coil density while simultaneously easing the assembly process is seen in FIG. 34 .
- Each instance of conductive material 22 is labeled either “1”, “2”, “3” or “4” for ease of illustration. It can be seen that wire 14 d is aligned and attached to connection pad 20 d, wire 14 c is aligned and attached to connection pad 20 c, wire 14 b is aligned and attached with connection pad 20 b, and wire 14 a is aligned and attached with connection pad 20 a.
- Each of the labels then shows and identifies each wire 14 from the coil 10 as a separate joint and makes it easy to identify. It will be recognized by those of ordinary skill in the art, that any wire 14 can be soldered to the substrate 12 at multiple locations using the techniques described herein and that any number of wires 14 can be attached to a substrate 12 with these techniques.
- a method for transporting a fluid, gas, semi-solid, cryogen, or particulate matter between a three dimensional structure 10 and a substantially two dimensional structure 12 includes a step of providing a hollow member 14 having a removable material disposed therein.
- the hollow member 14 is associated with a three-dimensional structure 10 associated with an electrically conductive element, a fluidically conductive element, or a combination thereof.
- Another step entails associating the hollow member 14 with a hollow transfer passage 107 of a substantially two-dimensional structure 12 .
- Another step entails covering the hollow member 14 , and at least one of the two-dimensional structure 12 and the three-dimensional structure 10 with a substance.
- Yet another step entails removing the removable material 116 to define a passage in communication with the hollow transfer passage 107 of the substantially two-dimensional structure 12 and the hollow member 14 of the three-dimensional structure 10 .
- the method may further include removing part 26 of the hollow member to expose the removable material 116 before applying the substance. It further includes associating the exposed removable material of the hollow member 14 to the hollow transfer passage 107 of a substantially two-dimensional structure 12 , wherein the substance is utilized to cover the exposed removable material to define a passage between the hollow member 14 and the hollow transfer passage 107 .
- the substantially two-dimensional structure 12 is coupled to one or more dielectric substrates 12 , with a fluid passage 106 defined through the dielectric substrates 12 in communication with the hollow transfer passage 107 .
- a fluid, gas, semi-solid, cryogen, or particulate matter is transported from the hollow member 14 , through the substance, through the hollow transfer passage 107 , to the fluid passage 106 .
- a system for transporting a fluid, gas, semi-solid, cryogen, or particulate and for establishing a fluidic or hollow connection between two structures includes the following:
- a three dimensional structure 10 has a plurality of conductive elements 14 associated therewith, the conductive elements 14 each having a channel for transporting materials therealong.
- a removable material 116 is disposed within the channel of the conductive elements 14 and coupled to the substantially two-dimensional structure 12 , the removable material 116 being covered with a substance such that when the material is removed, a hollow transfer passage 107 is defined.
- the substance mechanically connects one of the conductive passageways 106 , 107 in the substantially two-dimensional structure 12 to the passageways in the three-dimensional structure 10 .
- the two-dimensional structure 12 can contain multiple layers for the transfer of multiple media and materials.
- the three dimensional structure 10 further includes conductive elements 14 that have a conductive member 40 disposed therein for establishing an electrical connection with the two-dimensional structure 12 .
- a system for electrically coupling a three dimensional structure 10 to a substantially two-dimensional structure 12 includes a three-dimensional conductive structure and a substantially two-dimensional conductive structure. It further includes a means for electrically coupling the substantially two dimensional conductive structure to the three-dimensional conductive structure along an attached section while maintaining flexibility of the attached section and promoting mechanical retention of the three dimensional structure 10 to the two dimensional structure 12 .
- the three-dimensional conductive structure 10 is tubular and the two-dimensional structure 12 has a passageway 38 defined therein for accepting at least part of the three-dimensional conductive structure 10 .
- a system for electrically coupling a three dimensional structure 10 to a substantially two-dimensional structure 12 includes a tubular coil of conductive elements 14 that are selectively electrically isolated from one another.
- a dielectric substrate 12 is sized and shaped to come into proximity with at least a portion of the tubular coil 10 .
- a connection pad 20 has a connection material 22 disposed thereon positioned on the dielectric substrate 12 .
- the connection material 22 is for coupling the conductive elements 14 to the dielectric substrate 12 .
- connection pad may be a conductive contact pad 20 coupled to a surface of the dielectric substrate 12 and the connection material 22 is a thermally activated conductive connection material 22 for coupling a conductive element from the tubular coil to the connection pad 20 .
- a system for electrically coupling a three-dimensional structure 10 to a substantially two-dimensional structure 12 includes the following:
- a three-dimensional structure 10 has a plurality of conductive members 14 extending along a length thereof, said plurality of conductive members 14 being selectively electrically isolated from one another.
- a dielectric substrate 12 is sized and shaped to come in proximity with at least a portion of said three-dimensional structure 10 to mechanically and electrically couple the conductive members 14 of the three-dimensional structure 10 to the dielectric substrate 12 .
- a connection pad 20 has a connection material 22 disposed thereon positioned on the dielectric substrate 12 .
- the connection material 22 is for coupling the conductive elements 14 to the dielectric substrate 12 .
- the connection pad may be a conductive pad 20 coupled to the dielectric substrate 12 , and the connection material 22 is a conductive material disposed on the conductive pad 20 .
- the three dimensional structure 10 comprises a coil of wires.
- the three dimensional structure 10 comprises a flex circuit.
- the dielectric substrate 12 is a printed circuit board and the connection material 22 is a solder.
- the connection pad 20 on the dielectric substrate 12 is formed as a substantially two dimensional structure 12 .
- the system further comprises a heat transfer pad 24 in thermal communication with the connection pad 20 .
- the coil of wires 14 includes multiple conductors.
- the three-dimensional structure 10 may include at least one inner sheath 16 b and an outer sheath 16 a, with a plurality of wires 14 disposed between the inner and outer sheaths 16 b, 16 a.
- a hole 36 is cut into the outer sheath 16 b at a connection point where one of the conductive elements 14 within the tube 10 is coupled to the connection pad 20 with connection material 22 .
- the wires 14 have a protective coating 26 that is stripped away in the vicinity of the hole 36 that is cut into the outer sheath 16 a.
- the three-dimensional structure 10 is hollow.
- the coil of wires 14 further includes tubes which can transmit semi-solids, particulates, gases, cryogens, and fluids.
- a plurality of three-dimensional structures 10 are coupled to a single two-dimensional structure 12 .
- a plurality of two-dimensional structures 12 are coupled to a single three-dimensional structure 10 .
- the two-dimensional structure 12 is part of a printed circuit board. Connection pads 20 and connection material 22 are disposed on both sides of the printed circuit board, with the printed circuit board having a hole 38 disposed therethrough for receiving the three-dimensional structure 10 such that the three-dimensional structure 10 is coupled to both sides 28 , 32 of the printed circuit board at the connection pads 20 via the connection material 22 .
- the two-dimensional structure 12 is part of a printed circuit board and has four corners, with portions of each corner being cutaway to reveal passageways 38 for receiving the three-dimensional structure 10 therein.
- the two-dimensional structure 23 is part of a printed circuit board. A groove 38 is disposed in the printed circuit board for receiving a three-dimensional structure 10 therein.
- connection material 22 attaches the wire 14 to the contact pad 20 .
- the connection material 22 creates a bump that flows over the stripped wire 14 . As seen in FIG. 38 , only one wire 14 is attached to the substrate 12 at a given section.
- Two wires 14 can be attached to the substrate 12 on opposing sides of the tubular structure 16 .
- wires 14 can then be attached to the substrate 12 using any known method.
- the coil 10 may be comprised of a flat flexible substrate (not shown) upon which is disposed a conductive material such that there are exposed areas and covered areas along the conductive materials path.
- the end of the flexible material is folded under itself, exposing the exposed conductive material all along the outside of radius. With the exposed conductive material displayed in such a manner, it becomes very easy to both mechanically and electrically attach flexible material to connection pad with conductive material.
- the conductive path thus formed can be easily used to connect components 30 to the coil 10 with conductive material disposed on the substrate.
- substrate 12 can be so configured such that mounting pads 20 match corresponding pads on either another substrate 12 or a Flex Circuit, or even Pogo Pins.
- a substrate 12 can become a connector in and of itself.
- pins protrude through or from one of the surfaces of the substrate 12 and are in electrical communication with conductive material, then pins can be easily arranged in such a fashion as to mate with a receptacle that can then carry an electric current to another device or devices. It is to be understood that the previous examples are just that: examples; and that the underlying termination technology can be expanded and incorporated into other electrical and electromechanical devices.
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Abstract
A method and system for transporting a fluid, gas, semi-solid, cryogen, or particulate matter, or combination thereof, between a three-dimensional structure and a substantially two-dimensional structure is disclosed. A system and method for electrically coupling a three-dimensional structure to a substantially two dimensional structure is also disclosed.
Description
- This application is a Continuation of U.S. application Ser. No. 11/377,818, filed on Mar. 15, 2006, which claims priority to U.S. Provisional Application No. 60/662,455, filed on Mar. 15, 2005, the disclosures of which are incorporated herein by reference in their entireties.
- This disclosure generally relates to attachment methods and more particularly to a method of soldering a substantially three dimensional structure to a substantially two dimensional structure. The three dimensional structure can be a medical catheter and the two dimensional structure can be a Printed Circuit Board. The three dimensional structures can transport different media such as electrical current, liquids, gases, and particulates.
- Currently, electrical catheters consist of a hollow tube surrounding fine wires that are individually stripped, either by hand, by a laser, by bead blasting, by chemical etching, or various other methods, and terminated into bulky connectors and solder-cups. In an effort to reduce the size of the catheter, wires have been getting progressively smaller and smaller. As the wires get smaller they also become physically weaker. These weaker wires tend to break and become difficult to handle during the assembly process required for high conductor count catheters. Large numbers of very thin conductors running axially along a catheter are also notorious for being un-flexible and have a tendency to get tangled, twisted, nicked, kinked, skived (exposing the electrical conductor), broken or get in the way of any guiding or steering wires that may be in operation, thus creating electrical shorts and opens. With an increase in the number of conductors, space limitation enhances the electrical issues. Assembly time also increases as more wires are manually fed through the length of the catheter. Reworking and repairing the catheters becomes time consuming, and, in some cases, impossible without destroying the catheter.
- A more desirable situation for modern catheters would be one that incorporates a system for easy termination of an ever increasing number of conductors and that allows for quick, reliable, and or redundant solder joints. Having a mechanical structure designed for flexibility would also aid in reducing field and assembly failures. Ideally, a new catheter termination system would also enable a production operator to easily switch between leaded and lead free solder without sacrificing production speed or capability.
- A method and system for transporting a fluid, gas, semi-solid, cryogen, or particulate matter, or combination thereof, between a three-dimensional structure and a substantially two-dimensional structure are disclosed. A system and method for electrically coupling a three-dimensional structure to a substantially two dimensional structure are also disclosed.
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FIG. 1 is a perspective view of an example system; -
FIG. 2 is an expanded view of the example system ofFIG. 1 ; -
FIG. 3 is a side elevation view of the example system ofFIG. 1 ; -
FIG. 4 is a side elevation view of the example system ofFIG. 1 with additional electrical connectors; -
FIG. 5 is a perspective view of a second example system; -
FIG. 6 is a side elevation view of the example system ofFIG. 5 ; -
FIG. 7 is an expanded view of the example system ofFIG. 5 with a fully stripped wire; -
FIG. 8 is a side elevation view of a fully stripped wire; -
FIG. 9 is an expanded view of the example system ofFIG. 5 with a partially stripped wire; -
FIG. 10 is a side elevation view of a partially stripped wire; -
FIG. 11 is a perspective view of a third example system; -
FIG. 12 is an expanded view of the example system ofFIG. 11 ; -
FIG. 13 is a side elevation view of a fourth example system; -
FIG. 14 is a perspective view of a fifth example system; -
FIG. 15 is an expanded view of the example system ofFIG. 14 ; -
FIG. 16 is a perspective, partially-transparent view of the example system ofFIG. 14 with three additional coils of elements; -
FIG. 17 is a side elevation view of the example system ofFIG. 14 with three additional coils of elements; -
FIG. 18 is a side elevation view of a sixth example system; -
FIG. 19 is a top view of the example system ofFIG. 18 ; -
FIG. 20 is a cross-sectional view of an example coil of elements; -
FIG. 21 is a cross-sectional view of a second example coil of elements; -
FIG. 22 is a cross-sectional view of a third example coil of elements; -
FIG. 23 is a cross-sectional view of a fourth example coil of elements; -
FIG. 24 is a cross-sectional view of a fifth example coil of elements; -
FIG. 25 is a cross-sectional view of a sixth example coil of elements; -
FIG. 26 is a cross-sectional view of a seventh example coil of elements; -
FIG. 27 is a cross-sectional view of an eighth example coil of elements; -
FIG. 28 is a cross-sectional view of a ninth example coil of elements; -
FIG. 29 is a cross-sectional view of a tenth example coil of elements; -
FIG. 30 is a cross-sectional view of an eleventh example coil of elements; -
FIG. 31 is a cross-sectional view of a twelfth example coil of elements; -
FIG. 32 is a perspective view of a seventh example system; -
FIG. 33 is an expanded perspective view of the example system, similar to that ofFIG. 32 ; -
FIG. 34 is a more closely expanded perspective view of the system ofFIG. 32 ; -
FIG. 35 is a cross-sectional view of the system ofFIG. 33 ; -
FIG. 36 is a top view of an eighth example system; -
FIG. 37 is an expanded, perspective view of the example system ofFIG. 36 ; -
FIG. 38 is a cross-sectional view of the example system ofFIG. 36 ; -
FIG. 39 is a cross-sectional view of a ninth example system; -
FIG. 40 is a cross-sectional view of a tenth example system; -
FIG. 41 is a cross-sectional view of an eleventh example system; -
FIG. 42 is a cross-sectional view of a twelfth example system; -
FIG. 43 is a cross-sectional view of a thirteenth example system; -
FIG. 44 is a cross-sectional view of a fourteenth example system; -
FIG. 45 is a cross-sectional view of an example coil of elements for use in the system; -
FIG. 46 is a cross-sectional view of a second example coil of elements for use in the system; -
FIG. 47 is a transparent side elevation view of a third example coil of elements for use in the system; -
FIG. 48 is a transparent side elevation view of a fourth example coil of elements for use in the system; -
FIG. 49 is a side elevation view of a fifth example coil of elements for use in the system; -
FIG. 50 is a perspective view of a fifteenth example system, representing a fluidic structure; -
FIG. 51 is a perspective view of the example system ofFIG. 50 with a dissolvable material applied; -
FIG. 52 is a perspective view of the example system ofFIG. 51 ; -
FIG. 53 is a perspective view of the example system ofFIG. 52 after the dissolvable material is removed; -
FIG. 54 is a cross-sectional view of the example system ofFIG. 52 ; -
FIG. 55 is a cross-sectional view of the example system ofFIG. 53 ; -
FIG. 56 is a perspective view of a sixteenth example system; -
FIG. 57 is a cross-sectional view of the sixteenth example system; -
FIG. 58 is a perspective view of a seventeenth example system; -
FIG. 59 is a side elevation view of the example system ofFIG. 58 ; -
FIG. 60 is a cross-sectional perspective view of the seventeenth example system; and -
FIG. 61 is a side view of the example system ofFIG. 60 . - A system for soldering a substantially three dimensional structure to a substantially two dimensional substrate is described. An example of the system has a coil of elements and a substrate designed to receive the coil. In some examples the coil lies in a groove formed on one of the surfaces of a dielectric substrate, such as a printed circuit board (“PCB”). A connection pad or transfer point is disposed on a surface of the dielectric substrate and is designated to receive the coil. The connection pad is adjacent to the groove or the path of the coil such that a connection can be made between an element of the coil and the connector pad. The coil element has a coating that is removed at the location of the connection between the coil and the connection pad.
- Furthermore, the system can include a heat transfer pad in thermal communication with the connection pad in order to transfer heat to the coil of elements and the connection material on the pad without physically contacting or contaminating the pad or the connection material. Typically, the coil of elements has multiple conductors wound therein and the substrate has a plurality of connection pads or transfer points for conductors in the coil. It is possible to vary the number of connection pads in order to provide redundant connections for safety and reliability or to allow for easier access to tightly coiled elements. The coil of elements may be wound around a hollow tube, wound over a fiber optic element, or wrapped around any other suitable substrate. The shape of the “coil structure” can be formed by any means. A sheath can also cover the wires for further protection or aesthetic reasons.
- The coil of elements can also have varying pitch to increase or decrease the apparent rigidity and flexibility of the resultant system at predetermined points without having to use different materials. This change of pitch also allows for the convenient locating of access points to the conductors contained in the coil and the dielectric substrate. This makes it easier to terminate each transfer point within the complex structure of the coil of elements.
- Additionally, the system can include attachments to multiple dielectric substrates. The coil of elements and the substrate can also be formed so that each substrate will only interact with the coil of elements in a predetermined location and orientation. The coil of elements may also be used for structural reinforcement of the system, which is especially useful when combined with pull wires or other such steering devices. Any given element within the coil need not be electrically conductive. The core of an element may be dissolvable, and once dissolved, leave a hollow core element which would then be capable of carrying a variety of liquid, gaseous, or semi-solid materials, or a combination of materials thereof.
-
FIGS. 1-4 depict an example system for electrically coupling a three dimensional structure to a substantially two dimensional structure. The two dimensional structure is shown as adielectric substrate 12 that has a thickness. The thickness may be created by a single material or by the combination of a series of substrates that are connected to one another. The three-dimensional structure is created by a coil ofelements 10, which in this case, is a coil ofwires 14. The coil ofwires 10 is positioned between anouter sheath 16 a and aninner sheath 16 b. In this example, the sheaths are shown as being transparent, flexible material. - The coil of
elements 10 includes a plurality ofwires 14 which are spaced one after another within the coil such that a first wire is positioned adjacent a second wire which is positioned adjacent a third wire, etc. The coil ofelements 10 is coupled to thedielectric substrate 12 at connection points which are defined by acontact pad 20 andconnection solder 22. Thecontact pad 20 is a pad of conductive material that is positioned on a surface of thedielectric substrate 12. Thecontact pad 20 could be recessed into the surface of thedielectric substrate 12, or could be positioned ontop 28 of thesurface 12. It could be created through plating or any other known means for attaching a conductive material to a dielectric substrate.Connection solder 22 is positioned on top of thecontact pad 20. - In the example shown in
FIGS. 1-4 , fourcontact pads 20 are evenly spaced around a mountinghole 38, which is a through-hole positioned in thedielectric substrate 12. Mountinghole 38 is a cylindrical hole having a round cross-section and is sized and shaped to receive the coil ofelements 10 therethrough. The connection points are designed to couple to thewires 14 within the coil ofelements 10 to establish an electrical connection between thecontact pad 20 and the associatedwire 14. In order to allow coupling of thewires 14 within the coil ofelements 10 tosubstrate 12, theouter sheath 16 a of the coil ofelements 10 is cut away in an area of the coil ofelements 10 where thecontact pad 20 can mate with a preselectedwire 14. In addition, aprotective sheathing 26, such as a plastic coating, on thewire 14 is cut away in the area of thecontact pad 20. - Once the coil of
elements 10 is positioned inside the mountinghole 38, a heating element, not shown, can be applied to eachcontact pad 20 in order to heat thesolder 22 positioned thereon. When thecontact pad 20 is heated with the heating element, such as a soldering iron, theconnection solder 22 will flow to thewire 14 and wick onto thewire 14, thereby establishing an electrical and mechanical connection between thesolder contact pad 20 and thewire 14. - In
FIG. 1 , fourwires 14 are shown positioned within the coil ofelements 10. The connection points on thedielectric substrate 12 are positioned in order to mate with each one of thewires 14 on anupper surface 28 of thedielectric substrate 12. While the present example shows a cylindrical coil ofelements 10 having fourwires 14, it should be noted that the coil ofelements 10 can have any shape including cylindrical, rectangular, polygonal, oval, or any other type of shape that could be positioned in a mounting hole. In addition, any number of wires and any number of connection points may be utilized in connection with this example, the example not being limited to the exact configuration shown. -
FIG. 3 shows the coil ofelements 10 being connected to thedielectric substrate 12 along atop surface 28 of thedielectric substrate 12.FIG. 4 depicts a similar example, but in this example, the coil ofelements 10 is coupled to both the top andbottom surfaces dielectric substrate 12. In this example, connection points are disposed on both the top andbottom surfaces dielectric substrate 12. Theouter sheath 16 a of the coil ofelements 10 hasopenings 36 cut into the sheath such thatwires 14 within the coil ofelements 10 may be exposed for connection to both the top andbottom surfaces dielectric substrate 12. - The example of
FIG. 4 provides additional mechanical stability to the system by having the coil ofelements 10 coupled to thesubstrate 12 in more than one plane. In addition,FIG. 4 provides for additional electrical connections between thewires 14 and thecontact pads 20. This may provide protective redundancy within the system. This may allow electricity to travel from one point in a wire to another across thesubstrate 12 without requiring an additional via (or hole) to be positioned in thesubstrate 12. Lastly, as previously discussed, the connection points or solder points between thecoiled elements 10 and thedielectric substrate 12 assist in improving the mechanical strength of the system for electrically coupling the three-dimensional structure 10 to a substantially two-dimensional structure 12. - The two dimensional structure in these examples is the
top surface 28 of thedielectric substrate 12 or thebottom surface 32 of thedielectric substrate 12. While thedielectric substrate 12 has a thickness such that it is actually a three-dimensional structure, thecontact pad 20 is considered the two-dimensional structure that the coil ofelements 10 is coupled to. The coil ofelements 10 is the three-dimensional structure that is being coupled to the two-dimensional structure of thesubstrate 12. The word “substantially” is used herein to refer to the two-dimensional structure, which, in some examples, is thetop surface 28 of thedielectric substrate 12 because it will be recognized that thecontact pad 20 andsolder 22 themselves do provide more than a strict two-dimensional structure. However, the structure is substantially two-dimensional according to the definition of two-dimensional structure utilized herein. - As discussed above,
FIG. 1 illustrates an exemplary method of attaching a coil ofelements 10 in the form of a tubular structure to adielectric substrate 12. It should be understood that the tubular structure need not be round or even hollow, as can be seen inFIGS. 22-31 described below.Connection pads 20 are disposed on the outer planar surfaces of thedielectric substrate 12. Eachconnection pad 20 can optionally be in electrical communication or thermal communication with other structures on thedielectric substrate 12, such as electrical traces (not shown).Connection material 22 rests on the top of theconnection pads 20 and can be either added before the tubular structure or after the tubular structure is inserted into the mountinghole 38. Theconnection pads 20 are usually arranged in a radial pattern around the mountinghole 38. Once the tubular structure has been inserted into the mountinghole 38,connection material 22 bondsindividual wires 14 contained within the tubular structure toindividual connection pads 20 on thedielectric substrate 12. This bonding is usually done through the use of heat from a heating element which can be either a separate device or contained within thedielectric substrate 12. By attaching the tubular structure to the top 28 and to the bottom 32 of thedielectric substrate 12, a robust mechanical retention is generated at the same time as electrical communication is established. - Generally, the tubular structure contains patterns of
wire 14 disposed between aninside layer 16 a and anoutside layer 16 b. While the material of the tube provides for electrical isolation betweenvarious wires 14, eachwire 14 can also be coated in an isolative material with asheathing 26, or otherwise to either ensure or enhance the dielectric properties of the tube material. Thedielectric materials 26 covering any givenwire 14 will only be removed to the minimum extent possible so as to maximize the structural integrity of the tubular structure. - In the previously described examples of
FIGS. 1-4 , the coil ofelements 10 included a series ofwires 14 that were cylindrically wound around theinner sheath 16 b of coil ofelements 10.FIGS. 5 and 6 depict an alternative example similar to the examples discussed inFIGS. 1-4 . - In
FIGS. 5 and 6 , the coil ofelements 10 includes an upper portion of wires 34 that are wound around aninner sheath 16 b, but at the point where the coil ofelements 10 is positioned in the mounting hole of thedielectric substrate 12, thewires 14 change direction and, instead of being wound around theinner sheath 16 b, they longitudinally extend along the length of the coil ofelements 10 between theinner sheath 16 b and theouter sheath 16 a. The connection method previously described in connection withFIG. 4 is utilized for connecting thewires 14 to thecontact pads 20 with theconnection solder 22. Ahole 36 is cut in theouter sheath 16 a in order to allow thesolder 22 to couple to thewire 14 that is positioned inside thesheath 16 a. Thewire 14 is stripped of anyprotective material 26 around the conductive portion of thewire 14. In general, the wire will have a plasticouter sheathing 26 and either part, or all of this, protectiveplastic sheathing 26 may be cutaway in the vicinity of thecontact pad 20. - Generally, the tubular structure contains patterns of wires disposed between an
inside layer 16 b and anoutside layer 16 a. While the material of the tube provides for electrical isolation betweenvarious wires 14, eachwire 14 can also be coated in an isolative material to either ensure or enhance the dielectric properties of the tube material. Preferably the dielectric materials covering any given wire will only be removed to the minimum extent possible so as to maximize the structural integrity of the tubular structure.FIGS. 5-10 show some patterns and structures that accomplish these goals. - Each method can be accomplished using a variety of techniques ranging from chemical etching to laser stripping to mechanical ablation. Many different methods and patterns can be used, and the ones shown are merely for illustrative purposes.
Wires 14 can be stripped axially either in strips or following the curve of the coil.Wires 14 can be stripped such that thewires 14 are hanging in free space.Wires 14 can also be stripped so that only a portion of their total inner core is exposed. There can exist multiple strip zones along the length of the tubular structure. Each zone can be of a different strip type and can expose only certain selected wires. - As shown in
FIG. 6 , theouter sheath 16 a may be cut at points that mate with both the top andbottom surfaces dielectric substrate 12. As previously discussed in connection withFIG. 4 , the use of connection points on both the top andbottom surfaces dielectric substrate 12 provides additional mechanical stability to the joint between the three-dimensional structure of the coil ofelements 10 and the two-dimensional structure of the surface connection for thewire 14. -
FIGS. 7-10 depict two examples of the way theprotective sheathing 26 may be removed from awire 14 such that the wire can couple to thesolder 22. InFIGS. 7 and 8 , thewire 14 is stripped around the entire circumference of the innerconductive core 40. Theouter material 26, because it is not conductive, will not allow the wire to mate with thesolder 22. For this reason, it is necessary to strip theprotective sheathing 26 of thewire 14. As shown inFIG. 7 , thesolder 22 on thecontact pad 20 mates with the innerconductive material 40 of thewire 14. In order to establish both an electrical connection between thecontact pad 20 and theconductive material 40 of thewire 14 and a mechanical connection between thecontact pad 20,solder 22 andwire 14 such that thewire 14 is coupled to thetop surface 28 of thedielectric substrate 12. -
FIGS. 9 and 10 are similar toFIGS. 7 and 8 except for, in this example, thewire 14 is only stripped of the plasticouter sheathing 26 on one side of thewire 14 in the vicinity of theopening 36 that is cut in theouter sheathing 16 a of the coil ofelements 10. In this example, awindow 42 is created in thewire 14 such that the conductive material of thewire 14 is exposed for connection to theconnection solder 22. The method of applying thesolder 22 to theconductive member 40 of thewire 14 is the same as that previously discussed in connection withFIGS. 1-4 . The heating element not shown may be applied to thecontact pad 20 in order to heat thesolder 22.Solder 22 then flows towards theconductive material 40 of thewire 14 and wicks onto theconductive material 40 in order to couple thesolder 22 to theconductive material 40 of thewire 14, thereby establishing both an electrical and mechanical connection with thewire 14. -
FIGS. 11-12 show how the pattern ofwires 14 need not be coiled to still be effective. Coiling thewires 14 around a tubular structure allows for some advantages though. Chief among them is thatcoiled wires 14 are more flexible and less prone to breaking then straight wires. This means that the flexibility and apparent durometer of any given tubular structure can be changed from changing thecoiled wires 14 to straight wires, or just by changing the type of coil being used. -
FIGS. 11 and 12 depict another example of a system for electrically coupling a three-dimensional structure to assist a substantially two-dimensional structure. In this example, thewires 40 of the coil ofelements 10 extend axially along the length of the coil ofelements 10. The coil in this example, is created by the combination of the outer andinner sheaths wires 14 are not wound around theinner core 16 b. Instead, they extend axially between the inner andouter sheaths elements 10 is again cylindrical and positioned in a mountinghole 38 that is defined in adielectric substrate 12. Thedielectric substrate 12 includescontact pads 20 andconnection solder 22 positioned on each of thecontact pads 20. The coil ofelement 10 is positioned through thehole 38 and thedielectric substrate 12 and thewires 14 of the coil ofelements 10 are coupled to thecontact pads 20 on thetop surface 28 of thedielectric substrate 12 according to any of the methods previously discussed. As with the prior examples, theouter sheath 16 a is cut away to form anopening 36 through which thesolder 22 can communicate with therespective wire 14. -
FIG. 12 shows a close-up of the connection between thesolder 22 and theconductive material 40 of thewire 14. In this example, theplastic sheathing 26 around thewire 14 has been removed around the circumference of the wire, as previously discussed in connection withFIG. 8 , in the vicinity of thecontact pad 20 and the hole positioned in the outer sheath of the coil ofelements 10. -
FIG. 13 is an example similar to the previously disclosed examples where the coil ofelements 10 comprises a plurality ofwires 14 that are wound around aninner sheath 16 b. Anouter sheath 16 a holds thewires 14 between the inner and outer sheaths to establish a cylindrical body which makes up the coil ofelements 10. In this example, three dielectric substrates are disclosed including a topdielectric substrate 12 a, a middledielectric substrate 12 b, and a lowerdielectric substrate 12 c. Thewires 14 within the coil ofelements 10 are coupled to the upper andlower surfaces conductive contact pad 20 disposed on a surface of thedielectric substrate 12 with aconnection solder 22 being coupled to eachcontact pad 20. In addition, the coil of elementsouter sheath 16 a has ahole 36 cut into the sheath in the vicinity of eachcontact pad 20 such that awire 14 within the coil ofelements 10 can be coupled to each of thecontact pads 20 via theconnection solder 22. - The example shown in
FIG. 13 can be used for a system where a large number of wires are positioned in the coil ofelements 10 such that, for example, each wire could be coupled to one or more of thesubstrates wires 14, the number of connection points would be reduced since only a limited number ofcontact pads 20 andconnection solder 22 are provided. This example would allow for redundancy between the wire connections such that a single wire could be coupled to adielectric substrate 12 a number of times. In addition, this example could be utilized to improve the mechanical strength of the system because a greater number of solder joints provides a greater mechanical strength and retention. In addition, this example could be utilized in order to couple a wire to a variety of different substrates. By coupling thewires 14 to thesubstrates 12, additional vias and connectors can be avoided within the system. - As discussed above,
FIG. 13 shows multiple dielectric substrates disposed along the length of a singular tubular structure. Eachdielectric substrate dielectric substrate 12. Having multiple substrates allows for an increase in mechanical alignment for the tubular structure, as well as an increase in the available area forconnection pads 20 in high wire count coils. -
FIGS. 14-17 depict an alternative example of the system for electrically coupling a three-dimensional structure to a substantially two-dimensional structure. In this example, thedielectric substrate 12 includes a plurality of holes orpassageways 38 in the form of cut-outs on the corners of thedielectric substrate 12. Instead of having thehole 38 disposed through the center of thedielectric substrate 12, in this example, thedielectric substrate 12 has the corners cut out and the coil ofelements 10 is positioned partially into one of the corners. While this example shows a part of the coil ofelements 10 being inserted into theopenings 38 in thedielectric substrate 12, the size and shape of the coil ofelements 10 and the size and shape of thedielectric substrate 12 and theholes 38 of thedielectric substrate 12 could be modified such that a greater proportion of the coil ofelements 10 is positioned within the corner passageway or hole 35 of thedielectric substrate 12, the example not being limited to the depicted dimensional characteristics. While in the prior examples, thecontact pads 20 were disposed around a circular hole in thedielectric substrate 12. In this example, thecontact pads 20 are disposed around thecutaway opening 38 in the corners of thedielectric substrate 12. In this example, thecutaways 38 in thedielectric substrate 12 are arcuate such that thecontact pads 20 are spaced along the edge of the arcuate opening for connection with a coil ofelements 10 positioned adjacent the arcuate opening. The coil ofelements 10 includes a plurality ofwires 14 that extend axially along the length of the coil ofelements 10 between the inner 16 b and outer 16 a sheaths of the coil ofelements 10. - As shown in
FIG. 15 , thewires 14 may be stripped of their plasticouter sheathing 26 to reveal theconductive material 40 of thewires 14 and thisconductive material 40 may be coupled to eachcontact pad 20 in the manner previously described in the prior examples by melting asolder 22 disposed on eachcontact pad 20 such that thesolder 22 wicks onto eachwire 14 and establishes electrical communication and mechanical communication between thesolder 22 and theconductive portion 40 of thewires 14. -
FIGS. 16 and 17 show views of how a plurality of coil ofelements 10 may be connected to thedielectric substrate 12 that has the corners cut out to form corner passageways. In the examples shown inFIGS. 16 and 17 , four coils ofelements 10 are coupled to thedielectric substrate 12, with one coil being positioned in each arcuate opening on the corners of thedielectric substrate 12. Each coil ofelements 10 includeswires 14 that extend axially along the length of the coil ofelements 10 and thewires 14 may be joined to thecontact pads 20 in a manner previously discussed in connection withFIG. 15 . The use of thedielectric substrate 12 to join the four coils ofelements 10 together helps to provide mechanical stability between the four coils ofelements 10. While not shown, the coils ofelements 10 may be joined to both an upper and alower surface dielectric substrate 12, if so desired. While the coil ofelements 10 in this example is shown as including axially extendingwires 14, it should be recognized by those skilled in the art that the coil ofelements 10 could includewires 14 that are wound around theinner sheath 16 b instead of longitudinally or axially extendingwires 14 as shown in the figures. -
FIGS. 14-17 show a similar arrangement ofdialectic substrates 12 as that shown inFIG. 13 . However, instead of the tubular structure passing through the core of adielectric substrate 12, thetubular structure 10 passes though an edge of thedielectric substrate 12. Such an arrangement would allow for easier integration in compact clamshell type hand pieces as eachdielectric substrate 12 would have only a portion of thetubular structure 10 to interact with at any given time. It is also easy to add multipletubular structures 10 to a singledielectric substrate 12 when thetubular structures 10 are disposed at the edges of thedielectric substrate 12. -
FIGS. 18 and 19 depict an alternative example of the system for electrically coupling a three-dimensional structure to a substantially two-dimensional structure. In this example, thedielectric substrate 12 does not have a through-hole 38, or holes positioned at the corners or anywhere else on thedielectric substrate 12. In this example, the coil ofelements 10 terminates at thetop surface 28 of thedielectric substrate 12. Thus, thewires 14 that are positioned at the end of the bundle ofwires 14 of the coil ofelements 10 terminate at thecontact pads 20 established on the upper surface of thedielectric substrate 12. Similar to the previously described examples, the coil ofelements 10 includes a plurality ofwires 14 that are wound around aninner sheath 16 b and constrained by anouter sheath 16 a. The coil ofelements 10 is cylindrical and thedielectric substrate 12 is shown as rectangular, however, any shapes for either of these elements may be utilized, if so desired. Theouter sheath 16 a includes acutaway portion 36 where thewire 14 is coupled to therespective contact pad 20 utilizingconnection solder 22. In the depicted examples inFIGS. 18 and 19 , fourcontact pads 20 are utilized to couple to four wires that are disposed within the coil ofelements 10. Eachcontact pad 20 is positioned on thedielectric substrate 12 such that it connects a different wire to eachcontact pad 20. Theconnection solder 22 may be coupled to eachwire 14 via heating of thesolder 22 such that it wicks onto the conductive portion of eachwire 14 to establish an electrical and mechanical connection between thecontact pad 20 and thewire 14. - It is possible to terminate the coils of
wire 10 contained within the tubular structure at locations other than along the length of the tubular structure.FIGS. 18-19 illustrate just such a termination wherein thedielectric substrate 12 is disposed at an end of thetubular structure 10. End attached terminations can be combined with any and all of the above described termination methods. -
FIGS. 20-31 depict several different examples of a wire structure within a coil ofelements 10. As shown inFIG. 20 , a coil ofelements 10 having a circular cross-section includes aninner sheath 16 b and anouter sheath 16 a. A plurality ofwires 14 are disposed between the inner andouter sheaths FIG. 20 is similar to the examples previously disclosed. The wires may be wound around theinner sheath 16 b or the wires may be axially extending along the length of the coil ofelements 10. - The
tubular structure 10 need not have a round cross-section.FIGS. 20-31 demonstrate a representative subset of the possible cross sections of a tubular structure.Tubular structures 10 can have any number of different types of cross-sections such as round (FIGS. 20-22 ) , oval (FIGS. 29-31 ), square (FIGS. 26-28 ), rectangular, pentagonal, triangular (FIGS. 23-25 ), or other shapes.Tubular structures 10 can also contain not just one central lumen, but a plurality of lumens of different sizes and configurations. What they all have in common is that a pattern ofwires 14 exists around the tubular structure. -
FIG. 21 depicts a coil ofelements 10 having a round cross-section, similar to that ofFIG. 21 , except for, in this example, two different sizes ofwires 14 are provided. In this example, coil ofelements 10 has aninner sheath 16 b and anouter sheath 16 a with a first-sized wire 14 a evenly spaced around the circumference of the coil with an equal number oflarger conduits 14 b or wires positioned between each of the smaller conduits orwires 14 a. In this example, the different shapedwires conduits 14 b. Alternatively, wires could be positioned in either 14 a and 14 b and fluid could be positioned in 14 a, if so desired. Although not previously discussed, the present system may be utilized to establish both electrical connections and fluid connections. In each of the previously disclosed examples, the wires could alternatively be channels, tubes, or other conduits for transporting a fluidic material including liquids, gases, or other such materials. In the case where fluid is transported through thewires 14, thedielectric substrate 12 would have an associated conduit channel or other feature for receiving the fluid in a fluid type manner. This will be discussed in greater detail below. However, as shown inFIG. 21 , it is possible to have both fluid transporting conduits and wires within the coil ofelements 10. -
FIG. 22 depicts an alternative example where anouter sheath 16 a is provided with twoinner sheaths 16 b. Theinner sheaths 16 b define openings within the coil ofelements 10 that extend axially along the length of the coil ofelements 10. In the depicted example ofFIG. 22 , the inner sheaths define two cylindrical openings that extend axially within the coil ofelements 10.Wires 14 a may be positioned around the periphery of the coil of elements adjacent theouter sheath 16 a. -
FIGS. 23-25 depict alternative examples similar to those previously discussed, except that in this case the coil ofelements 10 is triangular in shape. The coil ofelements 10 is bounded on the outside bysheath 16 a and on the inside bysheaths wires 14 a orconduits 14 b are disposed around the periphery of the coil ofelements 10, and thewires 14 may be either wound around the coil ofelements 10 or disposed axially along the length of the coil ofelements 10. -
FIG. 24 depicts a triangular coil ofelements 10 having aninner sheath 16 b and anouter sheath 16 a with a plurality ofwires 14 disposed between the inner and outer sheaths. In this example, thewires 14 are evenly distributed around the periphery of the coil ofelements 10. As with prior examples, thewires 14 may be wound around the circumference of theinner sheath 16 b or thewires 14 may extend axially along the length of the coil ofelements 10. -
FIG. 25 depicts a similar triangular coil ofelements 10 having aninner sheath 16 b and anouter sheath 16 a. A plurality of wires are disposed around the coil ofelements 10. Asmaller wire 14 a is disposed around an outermost periphery of the coil ofelements 10 and an innerlarger wire 14 b is equally spaced around theinner sheath 16 b. There aremore wires 14 a thanwires 14 b. Although this example is discussed in the context of wires within the coil ofelements 10, it should be recognized that theelements -
FIGS. 26-28 depict an alternative example of the coil ofelements 10 where the outer periphery of the coil ofelements 10 is substantially rectangular. In the depicted examples inFIGS. 26-28 , the coil ofelements 10 is a square shape.FIG. 26 includes anouter sheath 16 a and aninner sheath 16 b. A plurality ofwires 14 are equally spaced around the periphery of the coil ofelements 10 between the inner andouter sheaths -
FIG. 26 depicts a squareouter sheath 16 a. Twoinner sheaths elements 10. One of theinner sheaths 16 c has a larger diameter than the otherinner sheath 16 b. A plurality ofwires 14 are disposed inside theouter sheath 16 a and evenly spaced around the periphery of the coil ofelements 10. -
FIG. 28 depicts a coil ofelements 10 having anouter sheath 16 a that is square in shape and aninner sheath 16 b that is a similar square shape. A plurality ofwires smaller diameter wires 14 a that are positioned nearest to theouter sheath 16 a and a plurality of innerlarger diameter wires 14 b that are spaced around theinner sheath 16 b. Theinner wires 14 b are fewer in number than theouter wires 14 a, and each of the wires are evenly spaced around the periphery of the coil ofelements 10. - As previously discussed in connection with prior examples, the elements described as
wires FIGS. 26-28 could alternatively be conduits or passageways for transporting a fluid such as a gas or a liquid. The examples are not to be limited to simply wires having electrical connectors disposed therethrough. Thewires 14 could alternatively be plastic coated tubes having a dissolvable material inside the tubes is dissolved, a conduit for a fluid is provided. -
FIGS. 29-31 depict an alternative example of a coil ofelements 10 similar in many respects to the examples previously discussed. Each of the examples inFIGS. 29-31 has an oval shaped outer periphery.FIG. 29 includes aninner sheath 16 b and anouter sheath 16 a which together bound an interior space having a plurality ofwires 14 disposed therein. The plurality ofwires 14 are evenly spaced around the periphery around the coil ofelements 10. Thewires 14 may be wound around theinner sheath 16 b or may be axially extending along the length of the coil ofelements 10. -
FIG. 30 depicts aninner sheath 16 b and anouter sheath 16 a with a plurality ofwires sized wires smaller diameter wire 14 a is evenly spaced around the outer periphery of the coil ofelements 10 adjacent theouter sheath 16 a. An inner plurality ofwires 14 b, having a larger diameter than theouter wires 14 a, are disposed adjacent theinner sheath 16 b. Thesmaller wires 14 a are far more numerous than thelarger wires 14 b in this example coil ofelements 10.FIG. 31 discloses anouter sheath 16 a and twoinner sheaths wires 14 are disposed between the inner andouter sheaths - The
inner sheaths elements 10. One of the inner sheaths forms a larger diameter circle than the otherinner sheath 16 b, which forms a smaller diameter circle than the larger diameter circle. The plurality ofwires 14 are disposed around the outer edge of the coil ofelements 10 adjacent theouter sheath 16 a. In this example, only one diameter wire is disclosed, however, it should be recognized in any of these examples, that any number of wires and any size wires may be utilized to the extent that they fit within the area between the inner andouter sheaths wires 14, which typically will have a conductive material positioned within an outer plastic coating, the wires may alternatively be tubes for transporting a fluid such as a gas or a liquid. -
FIG. 32 depicts an alternative example of the system for electrically coupling a three-dimensional structure to a substantially two-dimensional structure. In this example, a coil ofelements 10 is disposed within a recess orpassageway 38 that is defined in thesurface 28 ofsubstrate 12. While prior examples positioned the coil ofelements 10 perpendicular to thedielectric substrate 12, in this example, the axis of the coil ofelements 10 is substantially perpendicular to thesurface 28 of thedielectric substrate 12. Arecess 38 is defined within theupper surface 28 of thedielectric substrate 12 in order to receive at least a portion of the coil ofelements 10 therein. The coil ofelements 10 is depicted as seating in therecess 38 such that part of the coil ofelements 10 is positioned below thesurface 28 of thedielectric substrate 12 and part of the coil ofelements 10 as positioned above the surface of thedielectric substrate 12. It will be recognized that any shape of opening or recess in thedielectric substrate 12 could be utilized such that the coil ofelements 10 is positioned at different depth levels within thedielectric substrate 12. The position of the coil ofelements 10 relative to thedielectric substrate 12 is, in part, dependent upon the thickness of thedielectric substrate 12. - The coil of
elements 10 includes aninner sheath 16 b and anouter sheath 16 a, with theinner sheath 16 b serving as a boundary for a spirally wound plurality ofwires 14 that are positioned between the inner andouter sheaths wires 14 of the coil ofelements 10 are coupled to contactpads 20 havingsolder 22 disposed thereon in a manner similar to that previously discussed in connection with the prior examples. The only difference is that the coil ofelements 10 is positioned on its side instead of being straight up and down. In this example, the outer sheath is cut to expose thewires 14 inside the coil ofelements 10 and eachrespective wire 14 that is to be coupled to acontact pad 20 is also stripped of its protectiveouter coating 26 in order to reveal the underlyingconductive material 40 within thewire 14. As previously discussed, in connection with the prior examples,solder 22 positioned on thecontact pad 20, upon heating, couples to theconductive material 40 within eachwire 14 that is aligned for coupling. - The
dielectric substrate 12 in this example shows electrical traces 103 that extend from thecontact pads 20 to other components. The example shown inFIG. 32 also incorporates aheat transfer pad 24 that is conductively coupled to thecontact pads 20. Theheat transfer pad 24 is designed to accept heat from a heating element, to transfer the heat to thecontact pad 20 which then melts thesolder 22 that is positioned on thecontact pad 20, such that thesolder 22 wicks or couples to an adjoiningwire 14 within the coil ofelements 10. Theheating pad 24 may be spaced from thecontact pad 20 by aconductive conduit 21 which is essentially a pad of conductive material that is coupled to theheat transfer pad 24 and to thecontact pad 20. A secondary dielectric (not shown) may be positioned over theconductive conduit 21 such that communication between theheating pad 24 and thecontact pad 20 is avoided. Theheating pad 24 is also a conductive element that is positioned on a surface of thedielectric substrate 12. Alternatively, the elements referred to as “heating pads” may be connector holes 24 for receiving a connector for coupling to thewire 14. Theholes 110 on the left side of thedielectric substrate 12 may be utilized for positioning connectors therein or for coupling to a pin or other similar connector. -
FIG. 33 is a expanded view of the connection between thewires 14 and thecontact pad 20 of the example shown inFIG. 32 . In this figure, theouter sheath 16 a of the coil ofelements 10 is cut away in the vicinity of thewires 14 to be coupled to thecontact pads 20 disposed on thedielectric substrate 12. The protective coating of thewires 14 may be fully stripped in the vicinity of theopening 36 in theouter sheath 16 a, in order to allow thewires 14 to be coupled to theconnection solder 22. As with prior examples, thewires 14 may be joined to theconnection solder 22. - In
FIG. 33 , the longitudinal axis of thecoil elements 10 is substantially perpendicular to theupper surface 28 of thedielectric substrate 12. Depending upon the thickness of thedielectric substrate 12 and the diameter of the coil ofelements 10, the longitudinal axis of the coil ofelements 10 could align with theupper surface 28 of thesubstrate 12 or be positioned above or below theupper surface 28 of thesubstrate 12. The solder connection forFIG. 33 includes acontact pad 20 having asolder 22 disposed thereon. Aheat transfer pad 24 of conductive material is coupled to thecontact pad 20 by aconductive conduit 21. Theheat transfer pad 24 has disposed thereon aheat transfer material 23 such that when theheat transfer material 23 of theheat transfer pad 22 comes in contact with a heat source, the heat is transmitted from theheat transfer pad 22 through theconductive conduit 21 to thecontact pad 20 which then heats thesolder 22 disposed on thecontact pad 20. Thesolder 22 then wicks onto the exposedwire 40 in the vicinity of thesolder 22 to establish an electrical and mechanical connection between thecontact pad 20 and thewire 14. -
FIG. 34 depicts an example of howwires 14 are numbered within a coil ofwires 10. In this example, afirst wire 14 a is coupled to the first contact pad 20 a, asecond wire 14 b is coupled to thesecond contact pad 20 b, athird wire 14 c is coupled to the third contact pad 20 c, and afourth wire 14 d is coupled to the fourth contact pad 20 d. A similar set of contact pads is disposed on the left side of the coil ofelements 10. Depending upon the pitch of thewires 14 in the coil ofelements 10, the wires 1 through 4 will be arranged in a similar scheme on the left side of the coil ofelements 10, or a different arrangement. For example, the wire connections on the left side of the coil ofelements 10 on thedielectric substrate 12 could be arranged in numerical order starting with 1 through 4. Or, the numbers could be switched around depending upon the pitch of the windings of thewires 14 in the coil ofelements 10. -
FIG. 34 illustrates a method of soldering a substantially three dimensional structure to a substantially two dimensional structure. Specifically, a threedimensional coil 10 of wound wire orwires 14 a-14 d is attached to asubstrate 12 with the use of aconnection material 22 displaced on aconnection pad 20 which has been permanently affixed to thesubstrate 12 and can be easily defined in terms of length and width. In addition, aheat transfer pad 24 a-24 d, havingheat transfer material 23 a-23 d, is coupled to contactpad 20 a-20 d via aconductive conduit 21 a-21 d. Thecoil 10 can be used in a medical device such as a probe that is inserted into the human body but the current invention is not so limited. Thecoil 10 need not have a constant cross section for its entire length, indeed the coil can expand and contract at predetermined points along its length independent of the tubular structure. Thecoil 10 can surround a hollow tube, solid tube, guide wire, optical fiber, cavity, etc. All of these structures are hereafter referred to as atubular structure 16 which will be discussed in detail below. In general, a tubular structure contains anouter surface 16 a and aninner surface 16 b and thewires 14 are contained within thetubular structure 16. -
FIG. 35 shows a cross section of thecoil 10, thewires 14, thesubstrate 12, as well asconnection material 22,conductive conduit 21,connection pads 20,heat transfer pads 24, andheat transfer material 23, along a common, arbitrary plane. During the wetting of thewire 14 by theconnection material 22, theconnection material 22 wraps around thewire 14 forming a good mechanical joint at the interface of the groove 18 and theconnection pad 20. -
FIGS. 36 , 37 and 38 illustrate another way to attach a substantially three dimensional structure to a substantially twodimensional substrate 12. Eachwire 14 is wound around atubular structure 16 that is placed within agroove 38 of asubstrate 12.Connection pads 20 are disposed along a planar surface of thesubstrate 12 at the spacing of thewires 14. Specifically, whentubular structure 16 is laid in thegroove 38, eachwire 14 intersects thesubstrate 12 at multiple locations. Contactpads 20 are applied to thesubstrate 12 at those locations where thewires 14 intersect thesubstrate 12 andconnection material 22 is applied to the top surface of all theconnection pads 20. -
FIGS. 39 through 44 depict alternative examples of the connection between the coil ofelements 10 and theopening 38 disposed in thedielectric substrate 12. InFIG. 39 , the channel that is positioned in thetop surface 28 of thedielectric substrate 12 for receiving the coil ofelements 10 has a rectangular cross-section. As shown, a side of the coil ofelements 10 is positioned at the bottom 44 of therectangular recess 38. In this example, the longitudinal axis of the coil ofelements 10 is substantially aligned with thesurface 28 of thedielectric substrate 12.Connection solder 22 is utilized to connectwires 14 within the coil ofelements 10 torespective contact pads 20 on thesurface 28 of thedielectric substrate 12. -
FIG. 40 depicts an alternative example of arecess 38 in the surface of thedielectric substrate 12 that is V-shaped such that two sides of the coil ofelements 10 rests upon the twosides channel 38.Connection solder 22 is utilized to couplewires 14 disposed within the coil ofelements 10 to contactpads 20 that are disposed on thesurface 28 of thedielectric substrate 12. As withFIG. 39 , the longitudinal axis of the coil ofelements 10 is substantially aligned with thesurface 28 of thedielectric substrate 12. -
FIG. 41 depicts a coil ofelements 10 positioned between twodielectric substrates 12. A horizontal axis of thedielectric substrates 12 aligns with the longitudinal axis of the coil ofelements 10. Thedielectric substrates 12 have a height H that is less than the diameter D of the coil ofelements 10. As such, when the coil ofelements 10 is positioned between thedielectric substrates 12, a portion of the coil ofelements 10 extends above thetop surfaces 28 of thedielectric substrate 12 and a portion of the coil ofelements 10 extends below the bottom surfaces 32 of thedielectric substrates 12.Connection solder 22 is utilized on both the top andbottom surfaces dielectric substrates 12 to couple theconductive wires 14 of the coil ofelements 10 to thecontact pads 20 that are disposed on thesurfaces dielectric substrates 12. -
FIGS. 42 through 44 depict a coil ofelements 10 that is positioned on thetop surface 28 of thedielectric substrate 12. In these examples, a recess for retaining the coil ofelements 10 is created by theconnection solder 22 that is utilized to connect thecontact pads 20 to the conductive elements orwires 14 within the coil ofelements 10. Norecess 38 is defined in thesurface 28 of thedielectric substrates 12. -
FIG. 42 depicts an oval coil ofelements 10 wherein the long transverse axis of the oval is positioned parallel to thesurface 28 of thedielectric substrate 12. Theconnection solder 22 is positioned substantially under the edges of the coil ofelements 10. -
FIG. 43 depicts an oval-shaped coil ofelements 10 where the long transverse axis of the oval shape is positioned perpendicular to thesurface 28 of thedielectric substrate 12. The oval shape is held on thedielectric substrate 12 by theconnection solder 22, which forms supports for the coil ofelements 10. Theconnection solder 22 is positioned on thecontact pads 20 and a portion of theconnection solder 22 is positioned under the edges of the coil ofelements 10 and a portion of theconnection solder 22 extends outwardly from the edges of the coil ofelements 10. -
FIG. 44 depicts a coil ofelements 10 having a cross-sectional shape like that of a racetrack. A long transverse axis of the coil ofelements 10 is disposed parallel to thesurface 28 of thedielectric substrate 12.Connection solder 22 is positioned on thecontact pads 20 and is coupled to thewires 14 of the coil ofelements 10 in order to establish an electrical and mechanical connection between thewires 14 and thecontact pad 20. Theconnection solder 22 supports the coil ofelements 10 on the surface of thedielectric substrate 12. -
FIGS. 32-44 show how it is not necessary for the tubular structure and the dielectric to be arranged perpendicularly to one another by using a channel or a groove that has been formed into the surface of adielectric substrate 12, the tubular structure can be mechanically retained by attachment toconnection pads 20. With the correct profile of a tubular structure, achannel 38 on adielectric substrate 12 is not even required. Instead the tubular structure can have a flat side which rests flush with the dielectric substrate (such as shown inFIG. 44 ). -
FIGS. 45-49 depict different examples of tubular structures that contain coils ofwire 10. Thewires 14 in the examples can be moving in opposite directions, such as clockwise and counterclockwise. The alternating coils form braided or woven structures along the length of thetubular structure 10. -
FIG. 45 shows an example where thewires 14 are braided on the surface of thetubular structure 16 a with one wire going in a first direction and the other wire going in a second direction.FIG. 46 is similar toFIG. 45 , but includes awire 14 a that extends longitudinally along the length of thetubular structure 10.FIG. 47 depicts two wires disposed around thesurface 16 a of atubular structure 10, with the windings of thewires 14 having different pitches depending upon the location of thewires 14 along the length of thetubular structure 10.FIG. 48 is similar toFIG. 47 except for it only includes a single wire traveling in a single direction. The wire has a different pitch at the one end than at the other end.FIG. 49 represents a winding of wires around the tubular structure. The windings have a different pitch at one end and at the other, the pitch gradually changes between the one end and the other end. -
FIGS. 45-49 show how the coil of wire can be combined with other structures inside or alongside the tubular structure. The coil can containwires 14 moving in opposing directions, i.e. clockwise and counterclockwise turns. These alternating coils can interact with each other and form woven or braided structures along the length of thetubular structure 10. Not all of theindividual wires 14 contained within such a braided structure need to be electrically conductive or attached to adielectric substrate 12. Selective stripping of theinsulation 26 allows for precise control over what is attached to what. Indeed, straight runs of wire (not shown) can be combined with either the braided structure or with regular coils of wire. These straight runs can be for either selective impedance matching, electrical attachment, or as non-conductive safety wires. It is also not necessary for all thewire strands 14 in acoil 10 to be of the same size or of the same material. For example, thermocouple pairs can be run down within the coil ofwire 10 and mixed gauge wires can be used to both further refine the flexibility characteristics of the tubular structure and to enhance the electrical communication of the system. -
FIGS. 50-55 represent a fluidic structure that is configured to accept fluids, gases or semi-fluid or particulate matter transfer. The term conductive element as used herein in connection with the coil ofwires 10 is defined to include both electrical transmission and fluidic transmission of an element, such as a fluid, a gas, a cryogen, a particulate, and a semi-solid. As previously discussed, thewires 14 may alternatively be tubes that are filled with a dissolvable material such that when the material inside the tube is dissolved, ahollow member 14 for transporting the fluid is provided. In order to connect such ahollow member 14 containing a dissolvable material to asubstrate 12, the covering 112 of the dissolvable material within the tube may be stripped at a location where the tube is to be connected with a substrate, such as adielectric substrate 12 depicted in FIG. 50. Alternatively, the tube can be positioned adjacent achannel opening 106 in asubstrate 12 without stripping. - Once the protective material 112 around the dissolvable material is stripped away, leaving the dissolvable material, an epoxy or other plastic type of sealing
material 114 may be positioned over the dissolvable material to define aconduit 107 through which a fluid can flow once the dissolvable material has been dissolved. As shown inFIGS. 50-55 , achannel 106 is disposed in asubstrate 12 and thetube 14 is in communication with thatconduit 106. Atemporary gusset 105 is disposed adjacent the tube of dissolvable material and is utilized to hold the tube in place and to seal around the tube to create the channel from the tube to the channel that is defined within thesubstrate 12. The tube filled with dissolvable material is coupled to thechannels 106 that is defined in thesubstrate 12. In addition, the example coil ofelements 10 can include both a conductive wires and tubes filled with dissolvable material.Gusset 105 can be an epoxy-type sealing material, or other material that can be used to seal the tube of dissolvable material to a corresponding conduit in thesubstrate 12. The electrical connections and fluidic connection can be used side-by-side on a single substrate, and can be used on different layers of a substrate either together alone, can be used on different substrates that are coupled to a single or multiple coils ofelements 10. -
FIG. 50 shows asubstrate 12 with acoil 10 disposed in opening 38 therein. Thesubstrate 12 haschannels 106 formed inside and filled with a removable material. On the surface of thesubstrate 12 arecontact pads 20 which are also made of a removable material.Selected tubes 14 within thecoil 10 are filled with a removable material and have stripped areas 112 which expose the removable material inside thetubes 14. -
FIG. 51 depicts aremovable connection material 105 between thewire cores 40 andconnection pads 20. Theconnection material 105 forms part of the mechanical envelope of thetransfer passage 107. InFIG. 52 ,attachment material 114 is added between thetubular structure 16 and thesubstrate 12 in order to mechanically restrain thecoil 10 and to form the other part of the mechanical envelop of thetransfer passage 107 that transfers fluid from thetube 14 to thechannel 106. - In
FIG. 53 , the removable material is removed from the system. This leaveshollow channels 106 inside thesubstrate 12, ahollow transfer passage 107 and hollow wires ortubes 14 in thecoil 10. InFIG. 54 , a section view through one of theconnection pads 20 shows a section of thechannel 106 in thesubstrate 12 being filled with a removable material and another removable material forming atransfer passage profile 107 and a thirdremovable material 116 inside thetube 14. Thus the path from thecoil 10 to thesubstrate 12 is clearly shown. InFIG. 55 , a section view through one of theconnection pads 20 shows a section of the system after all the removable material has been removed. This leavestransfer passage 107 empty and allows for the flow of material through thechannel 106. - Any given wire with a coil may also contain a dissolvable core. This allows for a very low cost way of integrating massively multi lumen catheters with electrical connections. Such a system is shown in
FIGS. 50-55 . The tubular structure shows only a single wire for clarity but it is to be understood that a plurality ofwires 14 can also exist within such a system. The wire is then stripped of its insulation 112, but left mostly intact both in the containing insulation and in the tubular wall structure. The stripped wire portion is then aligned on thedielectric substrate 12 over theconnection pad 20 and atemporary gusset 105 is formed between the wire core and thecontact pad 20. Thecontact pad 20 andgusset material 105 are also formed out of dissolvable material such that when the material is removed, achannel 106 will exist between thedielectric substrate 12 and the tube within the tubular structure. Before the gusset and associated materials are dissolved, afinal covering material 114 is used to completely encapsulate the original gusset and retain the tubular structure. Thechannel dielectric substrate 12 can also be easily attached to a micro-fluidic controller or some other such system. With the material removed; fluids, particulates, gasses, cryogens, and combinations thereof can flow from the tip of the catheter down to thedielectric substrate 12 and vice versa. This allows for activities like drug delivery, blood sampling, and other important activities. - Dissolvable Cores to Create Transfer Passages:
Transfer Passages 107 are the fluid equivalent of a solder joint. They are a passageway extending from the stripped and opened center of thetube 116 disposed in a helical fashion around the body of the catheter to theopening 20 over thechannels 106 inside the 2D structure 12. - When the material inside the
tube 14 is dissolved, ahollow transfer passage 107 is formed between thechannel 106 in thesubstrate 12 and thehollow lumen 116 within thetubular structure 10. Thus a transport system is formed from the micro fluidic channel or channels contained in the substantially2D structure 12 continuously through to the tubes or lumens in the wall of the3D structure 10. - The channels thus formed inside the
substrate 12 can be easily attached to micro fluidic controllers, reagent cavities or can be routed to more macro scale tubing systems, hydraulics, or other such system. After the core of such awire 14 has been dissolved, the remainingtubular structures 10 can be used with micro fluidic devices to allow for reagent mixing, drug delivery, blood sampling, saline delivery, drainage, controlled cryogenic delivery and extraction, as well as a number of other uses. With the material removed; semi-solids, particulates, fluids, cryogens, gasses, and combinations thereof can flow from the tip of the 3D tubular structure down to the2D dielectric substrate 12 and vice versa. - Minimally invasive surgical procedures rely on being able to do a lot of work while causing the patient less pain, scarring, and lower recovery times. This is commonly accomplished by making a small artificial incision and feeding a tube up through the incision and having all of the instrumentation needed fed up through the tube. Modern catheters feed wires up through the body of the tube to tips on the catheters which can be used to diagnose and treat a multitude of disorders. Being able to go home directly after a surgical procedure is considered more desirable then long hospital stays. As such, there is an ever growing demand for new procedures and hence for new micro medical devices. Designers are working at a cross purpose though; in order to create a less traumatic experience a smaller catheter body is desired. To allow for more complex procedures, more wires are needed inside the catheter, pushing for larger catheter bodies. Catheter bodies are not always round and are not always tubes. Ovoid shapes are very popular as they allow for easier bending in certain directions which makes steering the catheter easier in certain situations. Catheters can also contain a number of different “tubes” or lumens that have been all formed at the same time. Typically, certain lumens are used to carry wires and other lumens are used to carry fluids.
- Fluid transportation is useful for a variety of reasons. One reason is for drainage, much like what a dentist does with excess saliva except integrated into the same tool being used to clean your teeth. Another reason is for sampling of whatever the tip is interacting with, so you could have real time localized blood oxygen content readings as well as measuring what other chemicals are present in the blood stream during surgery. Tubes can also be used to push material into the area as well as to take materials away from the area. Saline, being both neutral to the body and conductive, is often used during ablation procedures. Drugs can also be delivered along the same channels and allow for very specific targeting of problem sites.
- Cryogens can also be sent up the tube to freeze off a very small portion of the body. Many people have warts frozen off from external body parts because it is a very effective method of killing off a localized area in a way that the body quickly repairs. Being able to freeze interior portions of bodily anatomy could easily revolutionize current cancer treatments.
- Instead of running wires inside of a tubular structure as separate elements, we have developed a method of integrating the wires into the very structure of the tube. Moving the wires into the tube wall frees up the lumens for other purposes. Having wires run parallel to the axis of the tubular structure may be easier to manufacture, but it presents difficulties in that it tends to make the resulting tubular structure more rigid. By wrapping the wires around the tubular structure in a coil or a more helical pattern, flexibility can be increased and subsequent work hardening of the wires is greatly reduced. Varying the pattern allows for different levels of stiffness or rigidity at different points along a tubular structure, in effect replacing complex multi durometer tubular structures. Helical coils also allow for some interesting termination options. Fiber optics can be split, with only minimal impact on signal integrity by matching up helical tangents on two different tubular structures. Helixes will also eventually cause all the conductors in a system to pass through a single tangent line parallel to the axis of the tubular structure, thus allowing for easy attachment of multiple wires to a single line on a single substrate. This also allows for adding in electrical connections to devices and structures that would otherwise not contain them. For example wires could be wrapped around a fiber optic element. Though separately insulated wires are easy to incorporate, it is also easy to use flex circuits or otherwise added conductive material, by such common processes as sputtering, to the outside of a tubular structure.
- Tubular structures need not apply only to medical catheters. Tubular structures are used in everything from avionics to architecture. Being able to have a high density interconnection system that still allows for structural rigidity and or allows for other devices to share the same space is of great use in a variety of industries. For example, airplanes could move most of their wiring harnesses to the skin of the airframe using the herein described techniques. Also power conduits and network connections could run up a central structural member of a new building and could use the herein described technology to run high density backbones between floors.
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FIGS. 56 and 57 depict an alternative example where the coil ofelements 10 is sandwiched between twodielectric substrates 12. In this example, as with the prior examples, the coil ofelements 10 can be coupled to surfaces on bothdielectric substrates 12. As shown inFIG. 57 , the coil ofelements 10 is coupled to the lowerdielectric substrate 12 utilizingretention solder 22 positioned on acontact pad 20. In addition, aheat transfer pad 24 for thermally communicating with thecontact pad 20 andconnection solder 22 is disclosed. In addition, the coil ofelements 10 is coupled to the upperdielectric substrate 12 on thebottom surface 32 thereof in a similar manner. Bothsubstrates 12 include arecess 38 for receiving at least a portion of the coil ofelements 10 therein.FIGS. 56-57 show another example of how a single tubular structure can connect to multipledielectric substrates 12. -
FIGS. 58 and 59 disclose an example similar to that inFIGS. 11 and 12 , except for the coil ofelements 10 inFIGS. 58 and 59 is positioned at an angle relative to thesurface 28 of thedielectric substrate 12. The hole orpassageway 38 that is defined through thedielectric substrate 12 is similarly angled such that the coil ofelements 10 is able to rest within the hole that is defined in thedielectric substrate 12. The coil ofelements 10 can be positioned at any angle relative to thesurface 28 of thedielectric substrate 12 including a 45° angle, a 60° angle, 80° angle or perpendicular to thedielectric substrate 12 among other angles, the disclosure not being limited to a particular angle of the coil ofelements 10 relative to thesurface 28 of thedielectric substrate 12. The connections between thewires 14 of the coil ofelements 10 and thecontact pads 20 andconnection solder 22 disposed on the surface of thedielectric substrate 12 are similar to that previously discussed in connection withFIGS. 11 and 12 . -
FIGS. 58-59 illustrate the advantage of the mountinghole 38 not being perpendicular to thedielectric substrate 12. As thetubular structure 10 and thedielectric substrate 12 depart from a right angle, theconnection material 22 is placed more and more in shear when axial load is placed on thetubular structure 10, thus increasing the overall strength of the adhesion between thedielectric substrate 12 and thetubular structure 10. -
FIGS. 60-61 show how multiple substrates can be laminated together, each with theirown connection pads 20 disposed around acommon mounting hole 38, and contact atubular structure 10 havingwires 14. This allows for easy integration of soldered and non-soldered joints in a very compact environment. In one example, the connection pads are formed from conductive layers 103 similar to those found in common multilayered printed circuit board substrates. Regardless of the substrate used, the connection pads 103 a-103 d all haveconnection material 22 disposed along an edge thereof using a variety of reflow methods. Thewires 14 within the tubular structure are then selectively stripped of theirinsulation 26 and inserted within thehole 38. Optionally, thetubular structure 10 is press fit into thehole 38 for added mechanical retention. Once inserted, the contact pads 103 a-103 d are heated, either through resistive heating between another contact point along the wire and the contact pad or through other heating methods, and theconnection material 22 melts and attaches to thewire core 40 in a manner similar to the ones described above. - The
substrate 12 can be prepared by forming agroove 38 in a planar surface of thesubstrate 12. Thegroove 38 is sized and configured to receive a portion of thecoil 10 along its axial length. Conductive material 103 is applied to the planar surface of thesubstrate 12 during the initial manufacture of thesubstrate 12 at a spacing that matches an even increment of thewires 14 within thecoil 10. Theconductive material 22 forms a plurality of connection pads 103 a-103 d which are usually disposed perpendicularly to the axis of thegroove 38 and abut the edge of thegroove 38. Each connection pad 103 a-103 d may be surrounded by a secondary dielectric 100 (shown inFIG. 1 ) in order to preventconnection material 22 from flowing over the surface of thesubstrate 12 in an uncontrolled manner. Theconnection material 22 is added on top of connection pad 103 to enable the electrical and mechanical joining of thesubstrate 12 to thewire 14 and hence mechanically retain thecoil 10 and allow for electrical communication between a distal end of thecoil 10 and thesubstrate 12. Theconnection material 22 is added before the coil is introduced but after the formation of thegroove 38 but theconnection material 22 can also be added at the same time as thecoil 10 is aligned inside thegroove 38 with the connection pads 103 a-103 d. Also, theconnection material 22 would be added in an automated manner, such as with a solder stencil and reflow process standard to the electronics industry. - The
coil 10 is prepared by removing portions of thetubular structure 16 in the area where thewires 14 are to be soldered to thesubstrate 12. Furthermore, eachwire 14 that is to be attached has some of itsinsulation 26 removed at that location.Wires 14 can be stripped using a laser cutting or other technique such as but not limited to thermal ablation, chemical etching, and bead blasting. Both thetubular structure 16 and thewire insulation 26 are ideally removed at the same time and only in the locations needed to attach awire 14 to a connection pad 103. Thewire 14 can be tinned, before or after the insulation is removed, with a coating ofconnection material 22 to facilitate attaching thewire 14 to a connection pad 103. - In order to attach the
coil 10 to asubstrate 12, thecoil 10 is placed within thegroove 38 and eachwire 14 to be affixed is aligned with a respective connection pad 103. Because the conductive material 103 was placed at an even increment of the pitch of thewires 14, only asingle wire 14 has to be aligned with a pre-determined connection pad 103 and allother wires 14 will be aligned with their respective connection pads 103. This saves time during assembly and eases the process of solderingmultiple wires 14 to asubstrate 12. - Each stripped
wire 14 is attached to a respective connection pad 103 with anindividual connection material 22. Specifically, a heat source is placed in thermal communication with connection pad 103. The heat then travels through theconnection material 22 and is transferred to thewire 14. Theconnection material 22 then wicks up theheated wire 14 forming a joint between a connection pad 103 and thewire 14. Once the thermal communication is taken away, theconnection material 22 hardens thus securing thewire 14 to the connection pad 103 and, hence, to thesubstrate 12 and any other components or structures that may be in electrical communication with the underlying conductive material 103. - Additionally, it is possible to attach
wire 14 toconnection pad 20 using a heat transfer technique. In this instance, the heat from a given source, typically a soldering iron, is applied to aheat transfer pad 24 which is in thermal communication with aconnection pad 20. Theheat transfer pad 24 is in communication with thecontact pad 20 such thatconnection material 22 can be melted without physical contact from the original heat source. Asecondary dielectric 21 may be placed between theheat transfer pad 24 and theconnection pad 20 in order to prevent the cross contamination with theconnection material 22 disposed on the surface of theconnection pad 20. A secondary bump ofconnection material 23 can be added on top of theheat transfer pad 24 to aid in the thermal communication between a heat source and theheat transfer pad 24 and hence between a heat source and theconnection material 22 and from there to thewire 14. - Discontinuous Structures: By using a process that adds wires or other such conductive elements selectively, it is possible to have wires go only partway down a tubular structure. This means that there can be arbitrary segments of the tubular structure that contain a different number of
wires 14 then other portions. It is also possible to run all thewires 14 down the length of the tubular structure but to cut, or otherwise splice,certain wires 14 at a given point, effectively turning a single wire into two electrically separate pieces. Having a different number ofwires 14 means that the apparent flexibility of the system can be further refined. However, a more ingenious use of the system is to add in a “backplane” type interconnect system betweenmultiple substrates 12 attached to the coil. Not only does such a backplane, or perhaps more properly a “frontplane”, drastically simplify routing difficulties, but it can also lower the cost of the substrates by allowing for fewer interlayer connections or vias. Each wire in the frontplane can be used to carry a different type of information. Electrical signals, light impulses, power connections, fluid samples, gaseous reagents, and many others can be moved fromsubstrate 12 tosubstrate 12, either individually or en masse, and from any givensubstrate 12 to locations further down the tubular structure. - An optional method of attaching the
wires 14 in acoil 10 to asubstrate 12 that allows for redundancy for safety, mechanical stability, and an increased coil density while simultaneously easing the assembly process is seen inFIG. 34 . Each instance ofconductive material 22 is labeled either “1”, “2”, “3” or “4” for ease of illustration. It can be seen thatwire 14 d is aligned and attached to connection pad 20 d,wire 14 c is aligned and attached to connection pad 20 c,wire 14 b is aligned and attached withconnection pad 20 b, andwire 14 a is aligned and attached with connection pad 20 a. Each of the labels then shows and identifies eachwire 14 from thecoil 10 as a separate joint and makes it easy to identify. It will be recognized by those of ordinary skill in the art, that anywire 14 can be soldered to thesubstrate 12 at multiple locations using the techniques described herein and that any number ofwires 14 can be attached to asubstrate 12 with these techniques. - A method is disclosed for transporting a fluid, gas, semi-solid, cryogen, or particulate matter between a three
dimensional structure 10 and a substantially twodimensional structure 12. The method includes a step of providing ahollow member 14 having a removable material disposed therein. Thehollow member 14 is associated with a three-dimensional structure 10 associated with an electrically conductive element, a fluidically conductive element, or a combination thereof. Another step entails associating thehollow member 14 with ahollow transfer passage 107 of a substantially two-dimensional structure 12. Another step entails covering thehollow member 14, and at least one of the two-dimensional structure 12 and the three-dimensional structure 10 with a substance. Yet another step entails removing theremovable material 116 to define a passage in communication with thehollow transfer passage 107 of the substantially two-dimensional structure 12 and thehollow member 14 of the three-dimensional structure 10. - The method may further include removing
part 26 of the hollow member to expose theremovable material 116 before applying the substance. It further includes associating the exposed removable material of thehollow member 14 to thehollow transfer passage 107 of a substantially two-dimensional structure 12, wherein the substance is utilized to cover the exposed removable material to define a passage between thehollow member 14 and thehollow transfer passage 107. - The substantially two-
dimensional structure 12 is coupled to one or moredielectric substrates 12, with afluid passage 106 defined through thedielectric substrates 12 in communication with thehollow transfer passage 107. A fluid, gas, semi-solid, cryogen, or particulate matter is transported from thehollow member 14, through the substance, through thehollow transfer passage 107, to thefluid passage 106. - A system for transporting a fluid, gas, semi-solid, cryogen, or particulate and for establishing a fluidic or hollow connection between two structures includes the following: A three
dimensional structure 10 has a plurality ofconductive elements 14 associated therewith, theconductive elements 14 each having a channel for transporting materials therealong. Aremovable material 116 is disposed within the channel of theconductive elements 14 and coupled to the substantially two-dimensional structure 12, theremovable material 116 being covered with a substance such that when the material is removed, ahollow transfer passage 107 is defined. The substance mechanically connects one of theconductive passageways dimensional structure 12 to the passageways in the three-dimensional structure 10. - The two-
dimensional structure 12 can contain multiple layers for the transfer of multiple media and materials. The threedimensional structure 10 further includesconductive elements 14 that have aconductive member 40 disposed therein for establishing an electrical connection with the two-dimensional structure 12. - A system for electrically coupling a three
dimensional structure 10 to a substantially two-dimensional structure 12 includes a three-dimensional conductive structure and a substantially two-dimensional conductive structure. It further includes a means for electrically coupling the substantially two dimensional conductive structure to the three-dimensional conductive structure along an attached section while maintaining flexibility of the attached section and promoting mechanical retention of the threedimensional structure 10 to the twodimensional structure 12. - The three-dimensional
conductive structure 10 is tubular and the two-dimensional structure 12 has apassageway 38 defined therein for accepting at least part of the three-dimensionalconductive structure 10. - A system for electrically coupling a three
dimensional structure 10 to a substantially two-dimensional structure 12 includes a tubular coil ofconductive elements 14 that are selectively electrically isolated from one another. Adielectric substrate 12 is sized and shaped to come into proximity with at least a portion of thetubular coil 10. Aconnection pad 20 has aconnection material 22 disposed thereon positioned on thedielectric substrate 12. Theconnection material 22 is for coupling theconductive elements 14 to thedielectric substrate 12. - The connection pad may be a
conductive contact pad 20 coupled to a surface of thedielectric substrate 12 and theconnection material 22 is a thermally activatedconductive connection material 22 for coupling a conductive element from the tubular coil to theconnection pad 20. - A system for electrically coupling a three-
dimensional structure 10 to a substantially two-dimensional structure 12 includes the following: A three-dimensional structure 10 has a plurality ofconductive members 14 extending along a length thereof, said plurality ofconductive members 14 being selectively electrically isolated from one another. Adielectric substrate 12 is sized and shaped to come in proximity with at least a portion of said three-dimensional structure 10 to mechanically and electrically couple theconductive members 14 of the three-dimensional structure 10 to thedielectric substrate 12. Aconnection pad 20 has aconnection material 22 disposed thereon positioned on thedielectric substrate 12. Theconnection material 22 is for coupling theconductive elements 14 to thedielectric substrate 12. - The connection pad may be a
conductive pad 20 coupled to thedielectric substrate 12, and theconnection material 22 is a conductive material disposed on theconductive pad 20. The threedimensional structure 10 comprises a coil of wires. The threedimensional structure 10 comprises a flex circuit. Thedielectric substrate 12 is a printed circuit board and theconnection material 22 is a solder. Theconnection pad 20 on thedielectric substrate 12 is formed as a substantially twodimensional structure 12. The system further comprises aheat transfer pad 24 in thermal communication with theconnection pad 20. The coil ofwires 14 includes multiple conductors. - Also, the three-
dimensional structure 10 may include at least oneinner sheath 16 b and anouter sheath 16 a, with a plurality ofwires 14 disposed between the inner andouter sheaths hole 36 is cut into theouter sheath 16 b at a connection point where one of theconductive elements 14 within thetube 10 is coupled to theconnection pad 20 withconnection material 22. Thewires 14 have aprotective coating 26 that is stripped away in the vicinity of thehole 36 that is cut into theouter sheath 16 a. The three-dimensional structure 10 is hollow. The coil ofwires 14 further includes tubes which can transmit semi-solids, particulates, gases, cryogens, and fluids. - Also, a plurality of three-
dimensional structures 10 are coupled to a single two-dimensional structure 12. A plurality of two-dimensional structures 12 are coupled to a single three-dimensional structure 10. The two-dimensional structure 12 is part of a printed circuit board.Connection pads 20 andconnection material 22 are disposed on both sides of the printed circuit board, with the printed circuit board having ahole 38 disposed therethrough for receiving the three-dimensional structure 10 such that the three-dimensional structure 10 is coupled to bothsides connection pads 20 via theconnection material 22. The two-dimensional structure 12 is part of a printed circuit board and has four corners, with portions of each corner being cutaway to revealpassageways 38 for receiving the three-dimensional structure 10 therein. The two-dimensional structure 23 is part of a printed circuit board. Agroove 38 is disposed in the printed circuit board for receiving a three-dimensional structure 10 therein. - Each
wire 14 is stripped of its insulation at the locations of theconnection pads 20.Connection material 22 attaches thewire 14 to thecontact pad 20. Theconnection material 22 creates a bump that flows over the strippedwire 14. As seen inFIG. 38 , only onewire 14 is attached to thesubstrate 12 at a given section. - Two
wires 14 can be attached to thesubstrate 12 on opposing sides of thetubular structure 16. By varying the spacing ofwire 14 along thetubular structure 16 and hence along thecoil 10 and strippingwires 14 of their insulation at desired locations, it is possible to attach onlycertain wires 14 at certain locations very easily and very accurately. - In addition to the foregoing, it is also possible to attach
wires 14 inside atubular structure 16. Asmall substrate 12 is placed within thetubular structure 16. Thesubstrate 12 hasconnection pads 20 withconnection material 22 formed thereon.Wires 14 can then be attached to thesubstrate 12 using any known method. - The
coil 10 may be comprised of a flat flexible substrate (not shown) upon which is disposed a conductive material such that there are exposed areas and covered areas along the conductive materials path. The end of the flexible material is folded under itself, exposing the exposed conductive material all along the outside of radius. With the exposed conductive material displayed in such a manner, it becomes very easy to both mechanically and electrically attach flexible material to connection pad with conductive material. The conductive path thus formed can be easily used to connect components 30 to thecoil 10 with conductive material disposed on the substrate. - It is not necessary to connect the
coil 10 to something directly on thesubstrate 12. Specifically,substrate 12 can be so configured such that mountingpads 20 match corresponding pads on either anothersubstrate 12 or a Flex Circuit, or even Pogo Pins. - A
substrate 12 can become a connector in and of itself. When a plurality of pins protrude through or from one of the surfaces of thesubstrate 12 and are in electrical communication with conductive material, then pins can be easily arranged in such a fashion as to mate with a receptacle that can then carry an electric current to another device or devices. It is to be understood that the previous examples are just that: examples; and that the underlying termination technology can be expanded and incorporated into other electrical and electromechanical devices. - The term “substantially” is used herein as a term of estimation.
- It will be appreciated by those of ordinary skill in the art that the concepts and techniques described herein can be embodied in various specific forms without departing from the essential characteristics thereof. The presently disclosed examples are considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced.
Claims (16)
1. A method for transporting a fluid, gas, semi-solid, cryogen, particulate matter, or combinations thereof, between a three dimensional structure and a substantially two dimensional structure, comprising:
providing a hollow member having a removable material disposed therein, said hollow member associated with a three-dimensional structure associated with an electrically conductive element, a fluidically conductive element, or a combination thereof;
associating the hollow member with a hollow transfer passage of a substantially two-dimensional structure;
covering the hollow member, and at least one of the two-dimensional structure and the three-dimensional structure with a substance;
removing the removable material to define a passage in communication with the hollow transfer passage of the substantially two-dimensional structure and the hollow member of the three-dimensional structure through the substance.
2. The method of claim 1 , further comprising:
removing part of the hollow member to expose the removable material before applying the substance; and
associating the exposed removable material of the hollow member to the hollow transfer passage of a substantially two-dimensional structure, wherein the substance is utilized to cover the exposed removable material defines a passage between the hollow member and the hollow transfer passage.
3. The method of claim 1 , wherein the substantially three-dimensional structure is coupled to one or more dielectric substrates, with a fluid passage defined through the dielectric substrates in communication with the hollow transfer passage; and further comprising transporting a fluid, gas, semi-solid, cryogen, particulate matter, or combinations thereof, from the hollow member, through the substance, through the hollow transfer passage, to the fluid passage.
4. A system for transporting a fluid, gas, semi-solid, cryogen, particulate, or combinations thereof, and for establishing a fluidic or hollow connection between two structures comprising:
a three dimensional structure having a plurality of conductive elements associated therewith, said conductive elements each having a channel for transporting materials therealong;
a removable material disposed within the channel of the conductive elements and coupled to the substantially two-dimensional structure, the removable material being covered with a substance such that when the material is removed, a hollow transfer passage is defined,
wherein the substance mechanically connects one of the conductive passageways in the substantially two-dimensional structure to the passageways in the three-dimensional structure.
5. The system of claim 4 , wherein the two-dimensional structure can contain multiple layers for the transfer of multiple media and materials.
6. The system of claim 4 , wherein the three dimensional structure further comprises conductive elements that have a conductive member disposed therein for establishing an electrical connection with the two-dimensional structure.
7. A system for electrically coupling a three dimensional structure to a substantially two-dimensional structure comprising:
a three-dimensional conductive structure;
a substantially two-dimensional conductive structure;
means for electrically coupling the substantially two dimensional conductive structure to the three-dimensional conductive structure along an attached section while maintaining flexibility of the three-dimensional structure and promoting mechanical retention of the three dimensional structure to the two dimensional structure.
8. The system of claim 7 , wherein the three-dimensional conductive structure is tubular and the two-dimensional structure has a passageway defined therein for accepting at least part of the three-dimensional conductive structure.
9. A system for electrically coupling a three dimensional structure to a substantially two-dimensional structure comprising:
a tubular coil of conductive elements that are selectively electrically isolated from one another;
a dielectric substrate sized and shaped to come into proximity with at least a portion of the tubular coil; and
a connection pad having a connection material disposed thereon positioned on the dielectric substrate, the connection material for coupling the conductive elements to the dielectric substrate.
10. The system of claim 9 , wherein the connection pad is a conductive contact pad coupled to a surface of the dielectric substrate and the connection material is a thermally activated conductive connection material for coupling a conductive element from the tubular coil to the connection pad.
11.-26. (canceled)
27. The system of claim 4 , wherein the three-dimensional structure contacts a plurality of two-dimensional structures.
28. (canceled)
29. A method for electrically coupling a three-dimensional structure to a substantially two-dimensional structure comprises:
providing the system of claim 7 ,
positioning the three-dimensional structure in the vicinity of the two-dimensional structure;
coupling the two dimensional structure to the three-dimensional structure for communication of the elements therebetween.
30. A method for electrically coupling a three-dimensional structure to a substantially two-dimensional structure comprises:
providing the system of claim 9 ,
positioning the three-dimensional structure in the vicinity of the two-dimensional structure;
coupling the two dimensional structure to the three-dimensional structure for communication of the elements therebetween.
31. A method for electrically coupling a three-dimensional structure to a substantially two-dimensional structure comprises:
providing the system of claim 11,
positioning the three-dimensional structure in the vicinity of the two-dimensional structure;
coupling the two dimensional structure to the three-dimensional structure for communication of the elements therebetween.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US13/111,822 US20110214914A1 (en) | 2005-03-15 | 2011-05-19 | System and method for attaching a substantially three dimensional structure to a substantially two dimensional structure |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US66245505P | 2005-03-15 | 2005-03-15 | |
US11/377,818 US7957155B2 (en) | 2005-03-15 | 2006-03-15 | System for attaching a substantially three-dimensional structure to a substantially two-dimensional structure |
US13/111,822 US20110214914A1 (en) | 2005-03-15 | 2011-05-19 | System and method for attaching a substantially three dimensional structure to a substantially two dimensional structure |
Related Parent Applications (1)
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US11/377,818 Continuation US7957155B2 (en) | 2005-03-15 | 2006-03-15 | System for attaching a substantially three-dimensional structure to a substantially two-dimensional structure |
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US20110214914A1 true US20110214914A1 (en) | 2011-09-08 |
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US11/377,818 Expired - Fee Related US7957155B2 (en) | 2005-03-15 | 2006-03-15 | System for attaching a substantially three-dimensional structure to a substantially two-dimensional structure |
US13/111,822 Abandoned US20110214914A1 (en) | 2005-03-15 | 2011-05-19 | System and method for attaching a substantially three dimensional structure to a substantially two dimensional structure |
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US11/377,818 Expired - Fee Related US7957155B2 (en) | 2005-03-15 | 2006-03-15 | System for attaching a substantially three-dimensional structure to a substantially two-dimensional structure |
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US (2) | US7957155B2 (en) |
EP (1) | EP1869950A4 (en) |
JP (1) | JP2008539367A (en) |
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WO (1) | WO2006099572A2 (en) |
Cited By (1)
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EP3546008A4 (en) * | 2016-11-25 | 2020-09-02 | Sumitomo Bakelite Co., Ltd. | Catheter and method for manufacturing catheter |
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US8735734B2 (en) * | 2009-07-23 | 2014-05-27 | Lexmark International, Inc. | Z-directed delay line components for printed circuit boards |
US8198547B2 (en) | 2009-07-23 | 2012-06-12 | Lexmark International, Inc. | Z-directed pass-through components for printed circuit boards |
US8210422B2 (en) | 2009-09-30 | 2012-07-03 | Apple Inc. | Solder containment brackets |
US20120041411A1 (en) * | 2010-04-19 | 2012-02-16 | Micrus Endovascular Llc | Low profile guiding catheter for neurovascular applications |
WO2013002655A2 (en) * | 2011-06-28 | 2013-01-03 | Fisher & Paykel Healthcare Limited | Improved medical tubing |
US9009954B2 (en) | 2011-08-31 | 2015-04-21 | Lexmark International, Inc. | Process for manufacturing a Z-directed component for a printed circuit board using a sacrificial constraining material |
US9078374B2 (en) | 2011-08-31 | 2015-07-07 | Lexmark International, Inc. | Screening process for manufacturing a Z-directed component for a printed circuit board |
US8658245B2 (en) | 2011-08-31 | 2014-02-25 | Lexmark International, Inc. | Spin coat process for manufacturing a Z-directed component for a printed circuit board |
US8943684B2 (en) * | 2011-08-31 | 2015-02-03 | Lexmark International, Inc. | Continuous extrusion process for manufacturing a Z-directed component for a printed circuit board |
US8790520B2 (en) | 2011-08-31 | 2014-07-29 | Lexmark International, Inc. | Die press process for manufacturing a Z-directed component for a printed circuit board |
US8752280B2 (en) | 2011-09-30 | 2014-06-17 | Lexmark International, Inc. | Extrusion process for manufacturing a Z-directed component for a printed circuit board |
US8822840B2 (en) | 2012-03-29 | 2014-09-02 | Lexmark International, Inc. | Z-directed printed circuit board components having conductive channels for controlling transmission line impedance |
US8912452B2 (en) | 2012-03-29 | 2014-12-16 | Lexmark International, Inc. | Z-directed printed circuit board components having different dielectric regions |
US8830692B2 (en) | 2012-03-29 | 2014-09-09 | Lexmark International, Inc. | Ball grid array systems for surface mounting an integrated circuit using a Z-directed printed circuit board component |
US8822838B2 (en) * | 2012-03-29 | 2014-09-02 | Lexmark International, Inc. | Z-directed printed circuit board components having conductive channels for reducing radiated emissions |
US11883011B2 (en) * | 2015-03-09 | 2024-01-30 | CoreSyte, Inc. | Method for manufacturing a biological fluid sensor |
US10383543B2 (en) * | 2015-11-11 | 2019-08-20 | Biosense Webster (Israel) Ltd. | Symmetric short contact force sensor with four coils |
US10104773B2 (en) * | 2016-01-27 | 2018-10-16 | Northrop Grumman Systems Corporation | Resilient micro lattice electrical interconnection assembly |
CN107817505A (en) * | 2017-11-23 | 2018-03-20 | 苏州迪芬德物联网科技有限公司 | A kind of refrigerator car monitoring and positioning system |
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- 2006-03-15 WO PCT/US2006/009670 patent/WO2006099572A2/en active Application Filing
- 2006-03-15 CN CNA2006800082999A patent/CN101405917A/en active Pending
- 2006-03-15 EP EP06738703A patent/EP1869950A4/en not_active Withdrawn
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Also Published As
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US7957155B2 (en) | 2011-06-07 |
WO2006099572A2 (en) | 2006-09-21 |
EP1869950A2 (en) | 2007-12-26 |
CN101405917A (en) | 2009-04-08 |
WO2006099572A3 (en) | 2008-12-04 |
US20060278072A1 (en) | 2006-12-14 |
JP2008539367A (en) | 2008-11-13 |
EP1869950A4 (en) | 2009-08-12 |
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