MULTI-LAYER SENSOR CORE

• US 20170358388A1
• Filed: 12/11/2015
• Published: 12/14/2017
• Est. Priority Date: 12/11/2014
• Status: Active Grant

• Current Assignee: St. Jude Medical International Holding SARL (Abbott Laboratories Incorporated)
• Original Assignee: ST JUDE MEDICAL INTERNATIONAL HOLDING S. R.L.
• Inventors: Buesseler, Ryan Kenneth
• Granted Patent: US 10,573,448 B2
• Time in Patent Office: Days
• CPC Class Codes: A61B 2562/0223 Magnetic field sensors
• CPC Class Codes: A61B 5/062 using magnetic field
• CPC Class Codes: G01B 7/003 for measuring position, not involving coordinate determination coordinate measuring G01B7/004
• CPC Class Codes: G01D 5/2013 by a movable ferromagnetic element, e.g. a core G01D5/2033 takes precedence
• CPC Class Codes: H01F 10/131 containing iron or nickel
• CPC Class Codes: H01F 10/132 containing cobalt
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/0066 with a magnetic layer
• CPC Class Codes: H01F 3/00 Cores, Yokes, or armatures magnetic materials H01F1/00; permanent magnets H01F7/02
• CPC Class Codes: H01F 3/04 made from strips or ribbons
• CPC Class Codes: H01F 5/003 Printed circuit coils

Abstract

A sensor may include a core and a coil. The core may include a rectangular substrate, a layer of magnetically-permeable material disposed on the substrate, and an adhesive rigidly coupling two ends of the substrate so as to form a tube with the rectangular substrate. The coil may be wound on the tube. The core may further include a layer of radiopaque material. The core may further include a flex pad for electrically coupling the coil with an external system.

Claims

1. A core for a sensor, the core comprising:

a rectangular substrate;

a layer of magnetically-permeable material disposed on said substrate; and

adhesive for rigidly coupling two ends of said substrate with each other so as to form a hollow cylinder.

2. The core of claim 1, wherein the magnetically-permeable material comprises cobalt and nickel.

3. The core of claim 1, further comprising a flex pad on at least one of (a) said rectangular substrate or (b) said magnetically-permeable material, said flex pad providing an electrical connection for the sensor with an external system.

4. The core of claim 3, wherein said flex pad comprises:

a layer of dielectric material disposed on at least one of (a) said rectangular substrate or (b) said magnetically-permeable material; and

a layer of electrically-conductive material disposed on said dielectric layer.

5. The core of claim 1, wherein said rectangular substrate includes a top surface and a bottom surface, such that the top surface is an exterior surface of said hollow cylinder and said bottom surface is an interior surface of said hollow cylinder, further wherein said magnetically-permeable material covers at least one of (a) all of said top surface or (b) all of said bottom surface.

6. The core of claim 1, further comprising a layer of radiopaque material disposed on at least one of (a) said rectangular substrate or (b) said magnetically-permeable material.

7. The core of claim 1, wherein said substrate comprises nitinol.

8. A method of manufacturing a core for a sensor, the method comprising:

providing a rectangular substrate;

depositing a magnetically-permeable material on the substrate; and

rigidly coupling two ends of the substrate with each other so as to form a hollow cylinder.

9. The method of claim 8, wherein the magnetically-permeable material comprises cobalt and nickel.

10. The method of claim 8, further comprising creating a flex pad on at least one of (a) the rectangular substrate or (b) the magnetically-permeable material, the flex pad providing an electrical connection for the sensor with an external system.

11. The method of claim 10, wherein creating the flex pad comprises:

depositing a layer of dielectric material on at least one of (a) the rectangular substrate or (b) the magnetically-permeable material; and

depositing a layer of electrically-conductive material on the layer of dielectric material.

12. The method of claim 8, wherein the rectangular substrate includes a top surface and a bottom surface, such that the top surface is an exterior surface of the hollow cylinder and the bottom surface is an interior surface of the hollow cylinder, further wherein the magnetically-permeable material covers at least one of (a) all of the top surface or (b) all of the bottom surface.

13. The method of claim 8, further comprising depositing a layer of radiopaque material on at least one of (a) the rectangular substrate or (b) the magnetically-permeable material.

14. The method of claim 8, wherein the substrate comprises nitinol.

15. A sensor comprising:

a core comprising;

a rectangular substrate having a top surface, a bottom surface, and four ends;

a layer of magnetically-permeable material disposed on at least one of said substrate top surface or said substrate bottom surface; and

an adhesive rigidly coupling two of said ends of said substrate so as to form a tube with said rectangular substrate, such that said top surface is an outer surface of said tube and said bottom surface is an inner surface of said tube; and

a coil wound on said tube.

16. The sensor of claim 15, wherein said coil is wound on said outer surface of said tube.

17. The sensor of claim 15, wherein said core further comprises an electrically-conductive flex pad comprising at least two connection pads and an electrically-conductive trace electrically coupling the two at least two connection pads, wherein said coil is electrically coupled with one of said connection pads.

18. The sensor of claim 15, wherein said substrate comprises nitinol.

19. The sensor of claim 15, wherein said magnetically-permeable layer comprises cobalt and nickel.

20. The sensor of claim 15, wherein said core further comprises a layer of radiopaque material disposed on at least one of (a) said substrate or (b) said layer of magnetically-permeable material.