PCB cable assembly for a catheter

Abstract

A catheter having a distal end assembly, an elongate flexible printed circuit board (PCB) housed within a shaft of the catheter, the elongate flexible PCB extending substantially along an entire length of the shaft and comprising: a PCB distal portion comprising a plurality of electrical connection pads; a PCB proximal portion including a plurality of conductive traces corresponding to the plurality of electrical connection pads of the PCB distal portion; a PCB intermediate portion, the PCB intermediate portion comprising: a plurality of conductive traces laid longitudinally along more than 75% of the length of the elongated flexible PCB, the conductive traces continuing the conductive traces of the PCB proximal portion and electrically connected to the plurality of electrical pads of the PCB distal portion; and a plurality of slits that cut through the middle portion of the PCB between the conductive traces and extend along the conductive traces. Related apparatus and methods are also described.

Description

[0001] Related Applications

[0002] This application claims the benefit of priority under 35 USC 119(e) to U.S. Provisional Patent Application 63 / 541,306, filed on September 29, 2023, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure describes examples relating to conductive cables and methods for producing conductive cables, and more particularly, but not exclusively, to a conductive cable product comprising an elongated flexible printed circuit board (PCB) cable having a plurality of conductive traces drawn along its length and through slits cut between the traces to provide an elongated flexible PCB conductive cable. Background Art

[0004] The catheter may need to be advanced through tight areas with complex geometries. In order to be able to reach the desired location under such challenging conditions, the catheter should be very flexible. Today, wires extending along the length of the catheter are used to provide electrical connections between sensors and / or electrodes at the distal end of the catheter and connectors and / or plugs at the proximal end of the catheter. The wire provides flexibility.

[0005] Overview

[0006] The problem with using wires relates to the practicality or manufacturability of a harness of conductive wires. Electrically connecting each wire at each end of the conduit is a difficult manual process. The process is difficult due to the number of wires that need to be connected in a small footprint.

[0007] A solution to the above-described problem involves replacing the wires with a cable assembly formed from a flexible PCB strip that includes electrical connection pads and conductive traces at one or both of its ends.

[0008] In some embodiments, the cable assembly can be approximately 1 meter to 2 meters long, such as 1.5 meters long, such that the cable assembly extends along the length of the catheter shaft.

[0009] Another potential improvement involves increasing flexibility by forming through cuts along the length of the flexible PCB between conductive traces when multiple conductors extend along the catheter to improve the flexibility of the PCB along the axis or lumen of the catheter and produce a more flexible PCB cable assembly. Such through cuts potentially improve the flexibility of the PCB, thereby potentially improving the flexibility of the PCB cable assembly and the catheter, and enabling the replacement of multiple conductors with the flexible PCB. The flexible PCB after the cut is potentially easier to roll or twist the PCB into a compact conductive trace bundle as a PCB cable assembly that runs through the catheter and / or the lumen of the catheter.

[0010] Having multiple traces on a flexible PCB creates the equivalent of a cable with multiple wires.

[0011] In some embodiments, traces on a flexible PCB may optionally be shielded from electromagnetic (EM) interference by using an EM shield integrated into the flexible PCB itself and / or by providing the traces themselves with EM shielding.

[0012] In some embodiments, traces on a flexible PCB can optionally be shielded from interference by twisting the traces around each other in a manner similar to twisted pair wires.

[0013] In some embodiments, traces on a flexible PCB may optionally be terminated at one or both ends with connectors and / or connection pads.

[0014] Another non-limiting example method for reducing the cost and / or speed of manufacturing multiple conductors includes creating multiple traces on a flexible PCB to be used rather than running multiple wires through a catheter, or even running multiple wires through multiple lumens in a catheter, thereby potentially reducing the cost and / or speed of manufacturing a device using such multiple conductors.

[0015] Another non-limiting example method for reducing the cost and / or speed of manufacturing PCB cable assemblies includes creating a contact at one or both ends of a conductor so that it is easy to connect to the conductor. In some embodiments, the through cut extends along the length of the flexible PCB between one or both ends of the flexible PCB and does not extend all the way to the end, thereby maintaining the ends with controlled spacing between conductors, which enables the production of connectors to connect to multiple conductors at a time, thereby potentially reducing the cost and / or speed of manufacturing devices that use such multiple conductors.

[0016] Another non-limiting example method for reducing the cost and / or speed of manufacturing a device using a PCB cable assembly includes producing the sensor on the PCB, eliminating the need to attach multiple sensors individually to one or more corresponding conductors, thereby potentially reducing the cost and / or speed of manufacturing a device using such multiple sensors. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Some examples of the present disclosure are described herein only by way of example in conjunction with the accompanying drawings. Now with specific reference to the accompanying drawings, it should be emphasized that the details shown are by way of example and for the purpose of illustrative discussion of the embodiments of the present disclosure. In this regard, the description in conjunction with the accompanying drawings enables those skilled in the art to understand how to practice the embodiments of the present disclosure.

[0018] In the attached picture:

[0019] Figure 1Ais an illustration of an exemplary catheter-based electrophysiological mapping and ablation system.

[0020] Figure 1B is a partially exploded view of an exemplary distal tip assembly of a non-limiting example of a catheter-based EP device;

[0021] Figure 2A is a simplified block diagram illustration of a PCB cable assembly for connecting a distal tip assembly to a proximal tip connector according to an exemplary embodiment;

[0022] Figure 2B is a simplified illustration of a PCB cable assembly according to an exemplary embodiment;

[0023] Figure 3 is a simplified illustration of an elongated flexible PCB according to an exemplary embodiment;

[0024] Figure 4A is a simplified illustration of a PCB cable assembly according to an exemplary embodiment;

[0025] Figure 4B is a simplified illustration of an elongated flexible PCB according to an exemplary embodiment; and

[0026] Figure 5 is a simplified flow chart illustration of a method of connecting a distal tip assembly of a catheter to a connector at a proximal end of the catheter according to an exemplary embodiment. DETAILED DESCRIPTION

[0027] The present disclosure describes examples relating to PCB cable assemblies and methods for producing PCB cable assemblies, and more specifically, but not exclusively, to a conductive cable product comprising an elongated flexible printed circuit board (PCB) cable having a plurality of conductive traces drawn along its length and through slits cut between the traces to provide an elongated flexible PCB conductive cable, and more specifically, but not exclusively, to a PCB cable assembly within a conduit.

[0028] Introduction

[0029] The catheter may need to be advanced through tight areas with complex geometries. In order to be able to reach the desired location under such challenging conditions, the catheter should be very flexible. Today, wires extending through the lumen along the length of the catheter are used to provide electrical connections between sensors and / or electrodes at the distal end of the catheter and connectors and / or plugs at the proximal end of the catheter. The wire provides flexibility.

[0030] Manufacturing multiple conductors along the length of the catheter by using multiple wires requires a lot of manual labor.By using a flexible PCB with the required number of conductive traces arranged thereon, the manufacture and assembly of conductors in the catheter is potentially simplified.

[0031] Typical prior art flexible PCBs do not provide the flexibility required to negotiate the bend angles that a catheter may need to negotiate.

[0032] However, cutting a plurality of slits through the elongated flexible PCB parallel to and between the plurality of traces running along the elongated flexible PCB produces a plurality of narrower flexible PCB strips, thereby producing a PCB cable assembly that is potentially more flexible than an uncut flexible PCB.

[0033] Cutting the slits enables the optional additional act of twisting a narrower flexible PCB strip, thereby potentially enabling the PCB cable assembly to have a diameter smaller than the width of the uncut flexible PCB, thereby potentially being able to fit into a narrower conduit.

[0034] Cutting the slits enables the further optional additional act of rolling up a narrower strip of flexible PCB, thereby potentially enabling a PCB cable assembly to have a smaller diameter than the width of the uncut flexible PCB, thereby potentially being able to fit into a narrower conduit.

[0035] A note about the number of traces per flex PCB and the number of flex PCBs in a conduit 10

[0036] In some embodiments, one or more traces may be placed on the flexible PCB, by way of some non-limiting examples, 1, 2, 3, 4, 5, and up to 10, 15, or even 20 traces.

[0037] In some embodiments, more than one flexible PCB may be inserted into the catheter, by way of some non-limiting examples, 1, 2, 3, 4, 5, and up to 10, 15, or even 15 to 20 flexible PCBs.

[0038] Notes on Slit Length

[0039] In some embodiments, the slit may extend most but not all of the length of the elongated flexible PCB.

[0040] For example, all of the slits may extend 75%, 80%, 85%, 2090%, 95% or even up to 98% or 99% of the length of the elongated flexible PCB, but not reach either end of the elongated flexible PCB. The proximal and distal ends of the elongated flexible PCB are not cut through, and the remaining material connects the strips separated by the slits, making them potentially easier to handle as a set of strips.

[0041] For example, the connector pads may be structured at the proximal and / or distal ends of the elongated flexible PCB. Such connector pads are potentially easy to connect because their spacing is known despite any twisting and turning of the elongated flexible PCB that may occur along its length of 25 degrees.

[0042] In some implementations, one or more of the slits may extend all the way to the end of the elongated flexible PCB.

[0043] In the embodiment where one of the slits extends all the way to the ends of the elongated flexible PCB, the slit separates the elongated flexible PCB into two strips, which are attached at one end and separated at the other 30 end. If desired, the two strips can now optionally be twisted around each other, thereby producing a twisted cable. It should be noted that in the embodiment where one of the slits extends all the way to the two ends of the elongated flexible PCB, two separate strips are produced, and if desired, the two separate strips can be twisted around each other, thereby producing a twisted cable.

[0044] In some embodiments, more than one slit extends all the way to the ends of the elongated flexible PCB, and the slits separate the elongated flexible PCB into several strips attached at one end and separated at the other end. If desired, one or more of the several strips can now optionally be twisted around each other, thereby producing a twisted cable. It should be noted that in embodiments where more than one slit extends all the way to both ends of the elongated flexible PCB, several separate strips are produced, and if desired, two or more of the several separate strips can be twisted around each other, thereby producing a twisted PCB cable assembly.

[0045] In some embodiments, when it is desired to produce at least one twisted pair conductor, a slit can optionally be created on either side of two adjacent conductive traces, extending all the way to at least one end of the elongated flexible PCB, thereby producing two adjacent conductive traces free at at least one end, and the two conductive traces are optionally twisted around each other to produce a twisted pair.

[0046] In some embodiments, when it is desired to create at least one twisted conductor group, a slit may optionally be created on either side of a group of adjacent conductive traces, the slit extending all the way to at least one end of the elongated flexible PCB, thereby creating a group of adjacent conductive traces that are free at at least one end, and the group of conductive traces may optionally be twisted around each other to create a twisted group. By way of some non-limiting examples, the plurality of traces in the group may include 2, 3, 4, 5, up to 10, 15, or 20 traces.]

[0047] A note on the length of the PCB cable assembly

[0048] One purpose of the conductive traces on the elongated flexible PCB is to make a connection between a device used within a patient's body (by way of non-limiting example, a cardiac-related device at the distal end of a catheter, such as a cardiac procedure catheter) and an instrument at the proximal end of the catheter outside the patient's body.

[0049] In some embodiments, the elongated flexible PCB may extend a majority of the length of the catheter, but not all, such as 50%, 60%, 70%, 80%, 90%, 95%, and even 98% or 99% of the length of the catheter. In some embodiments, the elongated flexible PCB may extend the entire length of the catheter. In some embodiments, the elongated flexible PCB may extend beyond the length of the catheter.

[0050] Notes on the Nearside and Distalside Ends of PCB Cable Assemblies

[0051] In some embodiments, the proximal end of the PCB cable assembly includes pads for electrically connecting to an electrical connector that serves as a connection to various electrical devices outside the catheter and outside the patient's body.

[0052] In some embodiments, one end of the PCB cable assembly may optionally include a pad to connect to a connector plug at an end of the catheter (eg, the proximal end or the distal end).

[0053] In some embodiments, one end of a PCB cable assembly may optionally include a pad for connection to an end assembly and / or another PCB including electrodes and / or sensors.

[0054] In some embodiments, the distal end of the elongated flexible PCB includes pads for electrical connection to an electrical connector that serves as a connection to various sensors, electrodes, and / or additional electrical devices outside the catheter and within the patient's body.

[0055] See also Figure 1A , which is a diagram of an exemplary catheter-based electrophysiology mapping and ablation system 10. The system 10 includes a plurality of catheters that are inserted percutaneously through the patient's vascular system into a chamber or vascular structure of a heart 12 by a physician 61. Typically, a delivery sheath catheter is inserted into the left atrium or right atrium near a desired location in the heart 12. One or more catheters may then be inserted into the delivery sheath catheter to reach a desired location in the heart 12. The plurality of catheters may include a catheter dedicated to 15 sensing intracardiac electrogram (IEGM) signals, a catheter dedicated to ablation, and / or a catheter dedicated to both sensing and ablation. An example catheter 14 configured for ablating tissue and / or for sensing cardiac electrical activity and / or mapping is illustrated herein.

[0056] The catheter 14 is an exemplary catheter having an end effector at its distal end 28, the end effector comprising an expandable assembly having one and preferably multiple electrodes 26 optionally distributed on multiple flexible elongated members 20. The electrodes 26 are typically configured to deliver ablation energy to tissue and / or to sense cardiac electrical signals. The catheter 14 further comprises one or more position sensors 70 embedded in or near the distal end 28 for tracking the position and orientation of the distal end 28. Optionally and preferably, the position sensor 70 is a magnetic-based position sensor, such as a position sensor comprising three magnetic coils for sensing three-dimensional (3D) position and orientation; or a position sensor comprising one magnetic coil for sensing a single direction.

[0057] Each of the magnetic-based position sensors 70 can operate with a positioning pad 25 that includes a plurality of magnetic coils 32 configured to generate a magnetic field in a predetermined working space. The real-time position of the distal tip 28 of the catheter 14 can be tracked based on the magnetic field generated by the positioning pad 25 and sensed by the magnetic-based position sensor 70. Details of magnetic-based position sensing technology are described in U.S. Pat. Nos. 5,391,199, 5,443,489, 5,558,091, 6,172,499, 6,239,724, 6,332,089, 6,484,118, 6,618,612, 6,690,963, 6,788,967, 6,892,091.

[0058] Physician 61 may place distal tip 28 of catheter 14 in contact with the heart wall for sensing a target site in heart 12. For ablation, physician 61 may similarly place the distal end of an ablation catheter in contact with a target site for ablating tissue.

[0059] The system 10 includes one or more electrode patches 38 positioned in contact with the skin of the patient 23 to establish a position reference for impedance-based tracking of the positioning pad 25 and the electrodes 26. For impedance-based tracking, current is directed toward the electrodes 26 and sensed at the electrode skin patches 38 so that the position of each electrode can be triangulated via the electrode patches 38. Details of impedance-based position tracking techniques are described in U.S. Patents 7,536,218, 7,756,576, 7,848,787, 7,869,865, and 8,456,182.

[0060] Recorder 11 records and displays electrograms 21 captured using surface ECG electrodes 18 and intracardiac electrograms (IEGMs) captured using electrodes 26 of catheter 14. Recorder 11 may include pacing capabilities for pacing cardiac rhythms and / or may be electrically connected to a separate pacemaker.

[0061] The system 10 may include an ablation energy generator 50 adapted to conduct ablation energy to one or more electrodes at the distal end of a catheter configured for ablation. The energy generated by the ablation energy generator 50 may include, but is not limited to, radio frequency (RF) energy or pulsed field ablation (PFA) energy (including monopolar or bipolar high voltage DC pulses that can be used to achieve irreversible electroporation (IRE)), or a combination thereof.

[0062] The patient interface unit (PIU) 30 is an interface configured to establish electrical communications between catheters, other electrophysiology equipment, a power source, and a workstation 55 for controlling the operation of the system 10. The electrophysiology equipment of the system 10 may include, for example, a plurality of catheters, a positioning pad 25, surface ECG electrodes 18, electrode patches 38, an ablation energy generator 50, and a recorder 11. Optionally and preferably, the PIU 30 additionally includes processing capabilities for enabling real-time calculation of the position of the catheters and for performing ECG calculations.

[0063] The workstation 55 includes a memory, a processor unit having a memory or storage device storing appropriate operating software, and a user interface capability. The workstation 55 can provide multiple functions, optionally including: (1) three-dimensional (3D) modeling of the endocardial anatomy and rendering the model or anatomical map 20 for display on the display device 27; (2) displaying the activation sequence (or other data) compiled from the recorded electrograms 21 on the display device 27 as representative visual markers or images superimposed on the rendered anatomical map 20; (3) displaying the real-time position and orientation of multiple catheters within the heart chamber; and (4) displaying areas of interest on the display device 27, such as where ablation energy has been applied. A commercial product embodying elements of the system 10 can be CARTO TM The 3 system was purchased from Biosense Webster, Inc., 31A Technology Drive, Irvine, CA 92618.

[0064] In some examples, an irrigation module is provided for delivering an irrigation fluid, such as a saline solution, to the treatment site. The irrigation module may include a pump and an associated fluid tank.

[0065] In order to better understand some embodiments of the present disclosure, first refer to Figure 1B A non-limiting example configuration of a catheter-based electrophysiology device is shown.

[0066] Figure 1B is a partially exploded view of an exemplary distal tip assembly of a non-limiting example of a catheter-based electrophysiology device, Figure 1BIn a non-limiting example, a configuration known as a basket catheter is used.

[0067] Figure 1B The non-limiting example shown in is a distal tip assembly of a catheter for operation within a patient.

[0068] In this example, the tip assembly 10 of the catheter 12 has a basket-like shape with a plurality of elongated strips 24 .

[0069] In some embodiments, the strip 24 may optionally include one or more electrodes 26 and / or one or more sensors 26. In some embodiments, the electrodes 26 and / or sensors 26 may be mounted on a flexible PCB included in the strip 24.

[0070] In some embodiments, the ends 42 of the strips 24 (only some of which are labeled for simplicity) are optionally provided with electrical connections to wires (not shown) that pass through the lumen 66 in the catheter 12.

[0071] As described above, manufacturing a catheter having multiple conductors passing through a lumen along the length of the catheter by running wires through the lumen requires a great deal of manual labor. The manufacture and assembly of conductors in a catheter is potentially simplified by using a flexible PCB having the required number of conductive traces arranged thereon.

[0072] It should also be noted that multiple wires running through multiple lumens in a catheter may not provide the flexibility needed to negotiate the bend angles that the catheter may need to negotiate.

[0073] In the various descriptions that follow, embodiments of apparatus suitable for electrically connecting a sensor for operation within the heart to the exterior of a patient's body through a catheter are described, by way of some non-limiting examples.

[0074] One aspect of some embodiments includes replacing the wires (not shown) that pass through the lumen 66 in the catheter 12 with an elongated flexible PCB that includes a plurality of conductive traces for signal conduction along the catheter.

[0075] Before describing in detail at least one embodiment of the present disclosure, it should be understood that the present disclosure is not necessarily limited in its application to the details of construction and arrangement of components and / or methods described in the following description and / or shown in the accompanying drawings. The present disclosure is capable of other embodiments or can be practiced or implemented in various ways.

[0076] See now Figure 2A , which is a simplified block diagram illustration of a PCB cable assembly for connecting a distal end assembly to a proximal end connector according to an exemplary embodiment.

[0077] Figure 2AIt is intended to illustrate the concept of an exemplary elongated flexible PCB 234 within a conduit 240 .

[0078] In some embodiments, the elongated flexible PCB 234 has a distal end connector 236 having electrical connections for connecting to a distal assembly 238 (by way of non-limiting example, to a catheter-based electrophysiology device), optionally, Figure 1B A non-limiting example of a configuration known as a basket catheter sensor.

[0079] In some embodiments, the elongated flexible PCB 234 has a proximal end connector 232 having electrical connections for connecting to (by way of non-limiting example) a medical device to use signals from the distal assembly 238 .

[0080] See now Figure 2B , which is a simplified illustration of a PCB cable assembly according to an exemplary embodiment.

[0081] Figure 2B An elongated flexible PCB 200 is shown having a plurality of conductive traces 202 running along the length of the elongated flexible PCB 200 and a plurality of slits 204 cutting through the elongated flexible PCB 200 parallel to the conductive traces 202 and between the conductive traces.

[0082] Figure 2B Three sections of the elongated flexible PCB 200 are shown - a proximal end section 210, a middle section 212, and a distal end section 214.

[0083] In some embodiments, the end section 210 can be located at a proximal end section of the catheter, the middle section 212 can pass through the shaft of the catheter, and the end section 214 can be located at a distal end section of the catheter.

[0084] In some embodiments, the end section 210 can be located at a distal end section of the catheter, the middle section 212 can pass through the shaft of the catheter, and the end section 214 can be located at a proximal end section of the catheter.

[0085] In some embodiments, the middle section 212 extends 75%, 80%, 85%, 90%, 95%, or even up to 98% or 99% of the length of the elongated flexible PCB 200, but does not reach either end of the elongated flexible PCB. The proximal end 210 and the distal end 214 of the elongated flexible PCB 200 are not cut through, and the remaining material connects the long strips separated by the slits, making them potentially easier to handle as a set of strips.

[0086] In some embodiments, the elongated flexible PCB 200 is sized to be packaged within a catheter.

[0087] In some embodiments, the length of the elongated flexible PCB 200 is designed to extend the full length of a catheter (not shown) into which the elongated flexible PCB 200 is intended to be inserted.

[0088] In some embodiments, the length of the elongated flexible PCB 200 is designed to extend beyond the full length of a catheter (not shown) into which the elongated flexible PCB 200 is intended to be inserted, so some of the proximal end segment 210 and / or the distal end segment 214 may extend out of the catheter.

[0089] In some embodiments, some or all of the proximal end section 210 is located at the end of the catheter that is designed to remain outside the patient's body.

[0090] In some embodiments, conductive trace 202 is optionally electrically connected to an electronic component 206 , such as an electrode 206 or a sensor 206 . Figure 2B The electronic components are shown at the distal end section 214. However, such electronic components may be attached to the conductive trace 202 at the proximal end section 210.

[0091] In some embodiments, conductive traces 202 are optionally electrically connected to electrical connection pads (not shown) for connection to additional circuitry. Figure 2B The electronic component 206 is shown located at the distal end section 214, so the electrical connection pads may be located at the proximal end section 210. However, such electrical connection pads may optionally be located at the distal end section 214 as well.

[0092] In some embodiments, the width of the elongated flexible PCB 200 is designed to be smaller than the diameter of a catheter (not shown) into which the elongated flexible PCB 200 is intended to be inserted.

[0093] In some embodiments, the width of the elongated flexible PCB 200 is designed to be smaller than the circumference of a catheter (not shown) into which the elongated flexible PCB 200 is planned to be inserted, and the elongated flexible PCB 200 is inserted together with the catheter and placed against the inner surface of the catheter along the circumference of the catheter.

[0094] In some embodiments, the elongated flexible PCB 200 is designed to be twisted and / or rolled. When twisted or rolled, the outer diameter of the elongated flexible PCB 200 is smaller than the width of the elongated flexible PCB 200, and can be inserted into a conduit having a diameter smaller than the width of the elongated flexible PCB 200.

[0095] See now Figure 3 , which is a simplified illustration of an elongated flexible PCB according to an exemplary embodiment.

[0096] Figure 3 Intended to illustrate an embodiment in which an elongated flexible PCB forming a PCB cable assembly includes slits and conductive traces similar to Figure 2B The slit 204 and the conductive trace 202 are shown in the middle section 212 of FIG. Figure 3 3 shows a configuration of an elongated flexible PCB 302 having a plurality of conductive traces 304 running along the length of the elongated flexible PCB 302, a plurality of slits 306 cutting through the elongated flexible PCB 302 parallel to and between the conductive traces 304, and an electrical contact 308 at one end of the conductive trace 304, Figure 3 left end.

[0097] Figure 3 The configuration shown is one in which the slits 306 divide the elongated flexible PCB 302 into a plurality of individual strips attached to each other at one end. Figure 3 It should be noted that corresponding configurations are also envisaged in which a plurality of individual strips are attached to each other at the other end, Figure 3 right end.

[0098] It should be noted that corresponding configurations are also contemplated in which the electrical contact 308 is located at the other end. Figure 3 right end.

[0099] In some embodiments, the elongated flexible PCB 302 may optionally include one or more of the slits 306 extending to both ends of the elongated flexible PCB 302 ( Figure 3 In such a configuration ( Figure 3 ), the slits 306 divide the elongated flexible PCB 302 into a plurality of individual strips.

[0100] The proximal and distal ends of the elongated flexible PCBs 302, 312, 322 may or may not include contact pads or sensors.

[0101] See now Figure 4A , which is a simplified illustration of a PCB cable assembly according to an exemplary embodiment.

[0102] Figure 4A An elongated flexible PCB forming a PCB cable assembly is shown, with a twisted set of traces shown.

[0103] Such an elongated flexible PCB provides a set of twisted traces that can potentially remove crosstalk between signals carried via the traces, and / or remove crosstalk between signals carried by adjacent sets of twisted traces.

[0104] In some embodiments, the elongated flexible PCB may optionally include shields for the traces to shield electromagnetic (EM) interference between signals carried via the set of traces.

[0105] Figure 4A 4 shows a configuration of an elongated flexible PCB 420 having a plurality of conductive traces 422 running along the length of the elongated flexible PCB 420, a plurality of slits cut through the elongated flexible PCB 420 parallel to and between the conductive traces 422, and an electrical contact 426 at one end of the conductive trace 422, Figure 4A left end.

[0106] Figure 4A The configuration shown is one in which Figure 4A The configuration of the electrical contact 426 is shown at the left end of . It should be noted that a corresponding configuration in which the electrical contact 426 is located at the other end is also envisioned, Figure 4A In some embodiments, electrical contacts 426 may be present at both ends of conductive trace 422.

[0107] Figure 4A A non-limiting example of a particular number of strips 424 of a twisted-flex PCB having traces is shown.

[0108] In some embodiments, different numbers of twisted strips 424 may be used, such as 2, 3, 5, 6, 7, 8, 9, 10, and even more strips twisted together.

[0109] In some embodiments, multiple flexible PCB strips 420 may be twisted around each other, for example, 2, 3, 4, 5, 6, 7, 8, 9, 10, and even more flexible PCB strips may be twisted around each other.

[0110] See now Figure 4B , which is a simplified illustration of an elongated flexible PCB according to an exemplary embodiment.

[0111] Figure 4B An elongated flexible PCB forming a PCB cable assembly is shown, wherein one or more pairs of traces 5 are shown as being twisted.

[0112] Such elongated flexible PCBs provide twisted traces that can potentially remove crosstalk between signals carried via the traces.

[0113] In some embodiments, the elongated flexible PCB may optionally include shields for the traces to shield electromagnetic (EM) interference between signals carried via the traces. Figure 4B4 shows a configuration of an elongated flexible PCB 400 having a plurality of conductive traces 402 running along the length of the elongated flexible PCB 400, a plurality of slits cut through the elongated flexible PCB 400 parallel to and between the conductive traces 402, and an electrical contact 406 at one end of the conductive trace 402, Figure 4B left end.

[0114] Figure 4B The configuration shown is one in which a slit divides the elongated flexible PCB 400 into a plurality of individual strips attached to each other at one end 15, Figure 4B It should be noted that corresponding configurations are also envisaged in which a plurality of individual strips are attached to each other at the other end, Figure 4B right end.

[0115] Multiple individual strips may optionally be twisted around each other.

[0116] Figure 4B A non-limiting example of a flexible PCB having two twisted pairs 404 of traces is shown.

[0117] In some embodiments, different numbers of twisted pairs 404 may be used, such as 1, 2, 203, 4, 5, 6, 7, 8, 9, 10, and even more twisted pairs.

[0118] In some embodiments, different numbers of flexible PCB strips may be twisted around each other, for example 2, 3, 4, 5, 6, 7, 8, 9, 10 and even more strips with traces may be twisted around each other.

[0119] In some embodiments, different combinations of different numbers of twisted strips can be combined in one flexible PCB. By way of non-limiting example, twisted pairs and twisted triples, or twisted quads, and other similar combinations.

[0120] See now Figure 5 , which is a simplified flow chart illustration of a method of connecting a distal tip assembly of a catheter to a connector at a proximal end of the catheter according to an exemplary embodiment.

[0121] Figure 5 The method illustrated in the example includes: 30 providing a catheter shaft (502);

[0122] providing an elongated flexible PCB (printed circuit board) sized to extend the entire length of the catheter shaft, having a plurality of parallel conductive traces running along the length of the elongated flexible PCB (504;

[0123] cutting elongated slits through the elongated flexible PCB between and parallel to at least some of the conductive traces (506);

[0124] inserting the elongated flexible PCB into the catheter such that the elongated flexible PCB extends at least the full length of the shaft of the catheter (508); and

[0125] The electrical connection pads on the distal end of the slender flexible PCB are connected to the distal end assembly, and the electrical connection pads on the proximal end of the slender flexible PCB are connected to a connector configured to be connected to a controller (510), wherein the controller is configured to transmit electrical signals between the controller and the distal end assembly (510).

[0126] In some embodiments, the elongated flexible PCB includes a plurality of electrical connection pads at the ends of the conductive traces.

[0127] In some embodiments, some of the conductive traces are twisted around each other prior to inserting the conductive cable into the conduit. Summary of the invention

[0128] Example 1

[0129] A catheter having a distal tip assembly, the catheter comprising: a distal tip assembly, the distal tip assembly comprising an electrical connection array; an elongated flexible PCB (printed circuit board) (200), the elongated flexible PCB being housed within the shaft of the catheter, the elongated flexible PCB extending substantially along the entire length of the shaft and comprising: a PCB distal portion (214), the PCB distal portion comprising a plurality of electrical connection pads (206), the plurality of electrical connection pads being configured to establish electrical connections with the electrical connection array of the distal sensing assembly; a PCB proximal portion (210), the PCB proximal portion comprising electrical connection pads corresponding to the PCB distal portion; The invention relates to a PCB comprising a plurality of conductive traces (202) for connecting a plurality of electrical connection pads on a proximal portion of the PCB, wherein the plurality of conductive traces are configured to be electrically connected to an external electrical connector; a PCB middle portion (212), the PCB middle portion comprising: a plurality of conductive traces (202, 304) running longitudinally along more than 75% of the length of the elongated flexible PCB, the conductive traces continuing the conductive traces on the proximal portion of the PCB and electrically connected to a plurality of electrical pads on the distal portion of the PCB; and a plurality of slits (204, 306) cutting through the PCB middle portion between the conductive traces and extending along the conductive traces.

[0130] Example 2

[0131] A catheter as in Example 1, wherein the plurality of slits (204, 306) extend along more than 75% of the elongated flexible PCB.

[0132] Example 3

[0133] A catheter as in any of Examples 1-2, wherein at least two of the traces separated by the slit are twisted around each other (404, 424).

[0134] Example 4

[0135] A catheter according to any of embodiments 1-3, wherein all traces are twisted (424) along the elongated axis of the elongated flexible PCB.

[0136] Example 5

[0137] A catheter according to any of embodiments 1-4, wherein the PCB middle portion (212, 432) includes 10 or more conductive traces.

[0138] Example 6

[0139] A catheter according to any of embodiments 1-5, wherein at least some of the slits (204, 306) extend all the way to the ends of the flexible PCB.

[0140] Example 7

[0141] According to any one of embodiments 1-6, the catheter includes a plurality of elongated flexible PCBs housed within the shaft of the catheter.

[0142] Example 8

[0143] A method for connecting a distal end assembly of a catheter to a connector at the proximal end of the catheter, the method comprising: providing a catheter shaft (502); providing an elongated flexible PCB (printed circuit board) sized to extend the entire length of the catheter shaft and having a plurality of parallel conductive traces laid along the length of the elongated flexible PCB (504); cutting elongated slits through the elongated flexible PCB between and parallel to at least some of the conductive traces (506); inserting the elongated flexible PCB into the catheter shaft so that the elongated flexible PCB extends at least the entire length of the shaft of the catheter (508); and connecting the electrical connection pads on the distal end of the elongated flexible PCB to the distal end assembly and connecting the electrical connection pads on the proximal end of the elongated flexible PCB to a connector configured to be connected to a controller (510), wherein the controller is configured to transmit electrical signals between the controller and the distal end assembly.

[0144] Example 9

[0145] The method of embodiment 8, wherein the elongated flexible PCB includes a plurality of electrical connection pads at the ends of the conductive traces.

[0146] Example 10

[0147] A method according to any one of embodiments 8-9, wherein cutting slits through the elongated flexible PCB between and parallel to at least some of the conductive lines includes cutting slits between all parallel conductive lines.

[0148] Embodiment 11

[0149] A method according to any one of embodiments 8-10, and the method also includes rolling the flexible PCB into an elongated tube shape.

[0150] Example 12

[0151] A method according to any one of embodiments 8-11, and the method also includes twisting the middle portion of the slender flexible PCB.

[0152] Example 13

[0153] The method according to any of embodiments 8-12, and further comprising twisting at least some of the conductive traces around each other to produce a twisted plurality of conductors.

[0154] Embodiment 14

[0155] The method of any one of Embodiments 8-13, wherein cutting slits in the flexible PCB between at least some of the parallel conductive traces includes keeping at least one end of the flexible PCB joined.

[0156] Embodiment 15

[0157] A method according to any one of embodiments 8-14, wherein cutting slits in the flexible substrate between at least some of the parallel conductive lines includes keeping two ends of the flexible PCB bonded.

[0158] Example 16

[0159] A set of conductors, the set of conductors comprising a plurality of elongated flexible strips, each strip comprising a flexible PCB (200, 302, 400, 420), the flexible PCB comprising a PCB distal portion (214, 434), the PCB distal portion comprising a plurality of electrical connection pads (206, 406, 426) configured to establish electrical connections with an electrical connection array of a distal sensing assembly, a PCB proximal portion (210, 430), the PCB proximal portion comprising a plurality of conductive traces (202, 304, 402, 422) corresponding to the plurality of electrical connection pads (206, 406, 426) of the PCB distal portion, wherein the plurality of conductive traces Configured to be electrically connected to an external electrical connector, a PCB middle portion (212, 432), the PCB middle portion including a plurality of conductive traces (202, 304, 402, 422) running longitudinally along more than 75% of the length of the elongated flexible PCB, the conductive traces continuing the conductive traces of the proximal portion of the PCB and electrically connected to a plurality of conductive pads of the distal portion of the PCB, and a plurality of slits (204, 306) cutting through the PCB middle portion between the conductive traces and extending along the conductive traces, and wherein the PCB middle portion includes at least some of the conductive traces twisted (404, 424) around each other.

[0160] Embodiment 17

[0161] Embodiment 16: The set of embodiments wherein the conductive traces are insulated from each other.

[0162] Embodiment 18

[0163] A group according to any of embodiments 16-17, wherein the PCB middle portion includes insulation covering the conductive traces.

[0164] Embodiment 19

[0165] A group according to any one of embodiments 16-18, wherein the flexible PCB includes an electromagnetic (EM) shield.

[0166] Embodiment 20

[0167] The set of any one of embodiments 16-19, wherein the set is covered by a catheter.

[0168] Embodiment 21

[0169] A group according to Example 20, wherein the group extends from a proximal end to a distal end of the catheter.

[0170] Embodiment 22

[0171] Embodiment 21. The set of any of Embodiments 20-21, wherein the set comprises 10 or more conductive traces.

[0172] Embodiment 23

[0173] A group according to any of embodiments 16-22, wherein at least some of the flexible strips are twisted around each other (404, 424).

[0174] Embodiment 24

[0175] A set according to any of embodiments 16-23, wherein the flexible strip is joined at one end.

[0176] Embodiment 25

[0177] A set according to any of embodiments 16-23, wherein the flexible strips are attached to each other at one end.

[0178] Embodiment 26

[0179] A set according to any of embodiments 16-23, wherein the flexible strip is joined at two ends.

[0180] Embodiment 27

[0181] A set according to any one of embodiments 16-23, wherein the flexible strip is attached to each other at two ends.

[0182] Embodiment 28

[0183] A set according to any one of embodiments 16-27, wherein at least one of the conductive lines is connected 5 to a sensor.

[0184] Therefore, those skilled in the art to which the present invention belongs will appreciate that, although the present invention has been described according to preferred embodiments, the concepts upon which the present disclosure is based may be readily utilized as a basis for designing other structures, systems and processes for carrying out the several purposes of the present invention.

[0185] Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

[0186] It should be noted that the words "comprising," "including," and "having" as used throughout the appended claims should be interpreted to mean "including but not limited to." Unless explicitly indicated to the contrary, the indefinite articles "a" and "an" as used herein in the specification and claims should be understood to mean "at least one." The phrase 15 "and / or" as used herein in the specification and claims should be understood to mean "either or both" of the elements so combined, i.e., elements that are present in combination in some cases and separately in other cases.

[0187] It is important, therefore, that the scope of the present invention not be construed as being limited by the illustrative embodiments set forth herein. Other variations are possible within the scope of the invention as defined by the appended claims. Other combinations and subcombinations of features, functions, elements, and / or characteristics may be claimed by amendment of this claim 20 or by new claims in this or a related application. Such amendments or new claims, whether different, broader, narrower, or the same in scope as the original claims, whether directed to a different combination or to the same combination, are deemed to be included in the subject matter of this specification.

[0188] It is expected that during the life of a patent maturing from the present application, many related flexible PCB 25 materials will be developed, and the scope of the term flexible PCB is intended a priori to include all such new technologies.

[0189] The terms "including", "comprising", "having" and variations thereof mean "including but not limited to".

[0190] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0191] The term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations and / or to not include features of other implementations.

[0192] The word “optionally” is used herein to mean “is provided in some embodiments and not provided in other embodiments.” Any particular embodiment of the present disclosure may include a number of “optional” features, unless such features are in conflict.

[0193] Throughout this application, various embodiments of the present disclosure may be presented in a range format. It should be understood that the description of the range format is only for convenience and brevity, and should not be construed as a fixed limitation on the scope of the present disclosure. Therefore, the description of the range should be considered to have clearly disclosed all possible subranges and each numerical value within the range, including the minimum and maximum values ​​of the range and the fractional values ​​within the range.

[0194] Unless otherwise indicated, numerical values ​​used herein and any numerical ranges based thereon are approximations within reasonable measurement precision and rounding error, as understood by one skilled in the art.

[0195] It should be understood that certain features of the present disclosure described in the context of separate embodiments for clarity may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure described in the context of a single embodiment for simplicity may also be provided separately or in any suitable subcombination or as appropriate in any other described embodiment of the present disclosure. Certain features described in the context of various embodiments should not be considered essential features of those embodiments unless the embodiment does not function without those elements.

[0196] Where section headings are used, they should not be construed as necessarily limiting.

Claims

1. A catheter having a distal tip assembly, the catheter comprising: a distal tip assembly comprising an electrical connection array; an elongated flexible PCB (printed circuit board) housed within the shaft of the catheter, the elongated flexible PCB extending substantially along the full length of the shaft and comprising: a PCB distal portion, the PCB distal portion comprising a plurality of electrical connection pads configured to establish electrical connection with the electrical connection array of the distal tip assembly; a proximal portion of the PCB, the proximal portion of the PCB comprising a plurality of conductive traces corresponding to the plurality of electrical connection pads of the distal portion of the PCB, wherein the plurality of conductive traces are configured to be electrically connectable to an external electrical connector; The PCB middle part includes: a plurality of conductive traces running longitudinally along more than 75% of the length of the elongated flexible PCB, the conductive traces continuing the conductive traces of the proximal portion of the PCB and electrically connected to the plurality of electrical connection pads of the distal portion of the PCB; and A plurality of slits are cut through the PCB mid-portion between the conductive traces and extend along the conductive traces.

2. The catheter according to claim 1, wherein The plurality of slits extend along more than 75% of the elongated flexible PCB.

3. The catheter according to any one of claims 1 to 2, wherein: At least two of the traces separated by the slit are twisted around each other.

4. The catheter according to any one of claims 1 to 2, wherein: All traces are twisted along the elongated axis of the elongated flexible PCB.

5. The catheter according to any one of claims 1 to 2, wherein: At least some of the slits extend all the way to the ends of the elongated flexible PCB.

6. A method of connecting a distal end assembly of a catheter to a connector at a proximal end of the catheter, the method comprising: providing a catheter shaft; providing an elongated flexible PCB (printed circuit board) sized to extend the entire length of the catheter shaft, having a plurality of parallel conductive traces running along the length of the elongated flexible PCB; cutting elongated slits through the elongated flexible PCB between and parallel to at least some of the conductive traces; inserting the elongated flexible PCB into the catheter shaft such that the elongated flexible PCB extends at least the full length of the shaft of the catheter; as well as The electrical connection pads on the distal end of the slender flexible PCB are connected to the distal end assembly, and the electrical connection pads on the proximal end of the slender flexible PCB are connected to a connector configured to be connected to a controller, wherein the controller is configured to transmit electrical signals between the controller and the distal end assembly.

7. The method according to claim 6, wherein: Cutting slits through the elongated flexible PCB between and parallel to at least some of the conductive traces includes cutting slits between all of the parallel conductive traces.

8. The method according to any one of claims 6-7, and further comprising rolling the flexible PCB into an elongated tube shape.

9. A method according to any one of claims 6-7, and further comprising twisting a middle portion of the elongated flexible PCB.

10. The method of any one of claims 6-7, and further comprising twisting at least some of the conductive traces around each other to produce a twisted plurality of conductors.

11. A set of conductors, said conductors comprising a plurality of elongated flexible strips, each strip comprising: A flexible PCB, the flexible PCB comprising: a PCB distal portion, the PCB distal portion comprising a plurality of electrical connection pads configured to establish electrical connection with an electrical connection array of a distal sensing assembly; a proximal portion of the PCB, the proximal portion of the PCB comprising a plurality of conductive traces corresponding to the plurality of electrical connection pads of the distal portion of the PCB, wherein the plurality of conductive traces are configured to be electrically connectable to an external electrical connector; The PCB middle part includes: a plurality of conductive traces running longitudinally along more than 75% of the length of the elongated flexible PCB, the conductive traces continuing the conductive traces of the proximal portion of the PCB and electrically connected to the plurality of electrical pads of the distal portion of the PCB, and; a plurality of slits cut through the PCB mid-portion between the conductive traces and extending along the conductive traces; and Wherein, the PCB middle portion includes at least some of the conductive traces twisted around each other.

12. The group according to claim 11, wherein: The PCB middle portion includes insulation covering the conductive traces.

13. A set according to any one of claims 11-12, wherein: The flexible PCB includes an electromagnetic (EM) shield.

14. A set according to any one of claims 11-12, wherein: The set is sheathed by a catheter and the set extends from a proximal end to a distal end of the catheter.

15. The group according to any one of claims 11-12, wherein At least some of the flexible strips are twisted around each other.

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