Woven sheath for medical devices

Abstract

A medical device includes a shaft and a braided sheath. The braided sheath is coaxial with the shaft and extends at least along the shaft between the distal end of the shaft and the proximal end of the shaft. The braided sheath includes a braided fabric. The braid includes a plurality of mechanical strands and at least one conductor configured to deliver energy or transmit signals to and from an electrical device at or near the distal end of the shaft.

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Provisional Application No. 63 / 512,113, filed July 6, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates in many aspects to medical devices and their operation. Specifically, this disclosure relates to woven sheaths for medical devices. Background Technology

[0003] Medical devices such as endoscopes or other suitable insertion devices are used in a variety of diagnostic and surgical procedures, such as endoscopy, laparoscopy, arthroscopy, gynecological examinations, thoracoscopy, cystoscopy, etc. Endoscopic surgery involves inserting the device into the patient through a surgical incision or via natural orifices such as the mouth, vagina, or rectum.

[0004] The insertion device comprises a shaft containing one or more lumens or working channels extending through it. One or more lumens typically accommodate various devices and structures, such as medical instruments (e.g., infusion cannulas, aspiration cannulas, forceps, power scalpels, brushes, radiofrequency electrodes, and / or other tools), designed to operate at the distal end of the insertion device. Surgical incisions and natural cavities are typically narrow, therefore the distal end of the insertion device must be small enough to fit within and operate within these spaces. Accordingly, the space within the distal shaft is limited, and therefore the space within the lumen is also limited.

[0005] The distal end of the insertion device may also include one or more components (indicator lights, cameras, etc.) that require wires or cables to be actuated (e.g., power supply, control, etc.) and / or to communicate with one or more proximal components (e.g., power supply, controller, display, etc.). These wires or cables are typically contained within the shaft of the insertion device. These wires or cables occupy space within the shaft, which may limit the size and / or number of lumens within the shaft. The wires or cables may also increase the necessary dimensions of the shaft.

[0006] The apparatus and methods disclosed herein can correct some of the above-described defects or otherwise satisfy other aspects of the art. Summary of the Invention

[0007] The various aspects disclosed herein may include one or more features associated with any other disclosed aspect. Aspects of this disclosure may relate to a medical device having a braided sheath extending along the axis of the medical device.

[0008] Some exemplary apparatuses or methods described herein may include any of the following features. A medical device may include a shaft and a braided sheath. The braided sheath may be coaxial with the shaft and may extend at least along the shaft between its distal and proximal ends. The braided sheath may include a braid. The braid may include multiple mechanical strands and at least one conductor, which may be electrically and / or communicatively connected to an electrical device located at or near the distal end of the shaft.

[0009] The medical device may include one or more of the following: At least one conductor may be a first conductor. The braid may include a second conductor that is electrically and / or communicatively connected to a second electrical device. The first conductor may be braided clockwise along the braided sheath, and the second conductor may be braided counterclockwise along the braided sheath. Both the first and second conductors may be braided clockwise or counterclockwise. The first and second conductors may be electrically connected to an end cap. One of the conductors may be connected to the medical device. The medical device may be at least partially housed by a lumen of a shaft. At least one conductor may be a coated core wire. At least one conductor may be a stranded wire. At least one conductor may be a coaxial cable.

[0010] The medical device may include a polyimide overlay covering a braided sheath and extending coaxially with the braided sheath. The polyimide overlay may include a first layer and a second layer. The first layer may be a continuous ground plane. The second layer may include one or more conductors. The second layer may include an outer surface and an inner surface. One or more conductors of the second layer may be disposed on one of the outer and inner surfaces, and a ground plane of the second layer may be disposed on the other of the outer and inner surfaces. The one or more conductors of the second layer may be impedance-controlled conductors.

[0011] On the other hand, a medical device may include a shaft. The shaft may include a distal end, a proximal end, and a working channel. The medical device may include a cladding layer coaxial with the shaft and disposed on the outer surface of the shaft. The cladding layer may include one or more conductors.

[0012] The medical device may include one or more of the following features: One or more conductors may be disposed on one of the inner and outer surfaces of the covering layer, and a grounding layer may be disposed on the other of the inner and outer surfaces. One or more conductors may be configured to transmit power from the handle of the medical device to an end cap located at the distal end of the shaft.

[0013] On the other hand, a medical device may include a handle and a shaft extending from the handle. The shaft may include a proximal end and a distal end. The shaft may include a working channel extending along its length. The medical device may include an end cap containing one or more indicator lights or cameras. The medical device may include a braided sheath coaxial with the shaft and extending along at least the outside of the shaft between the distal and proximal ends of the shaft. The braided sheath may include multiple mechanical strands. The braided sheath may also include a first conductor configured to electrically and / or communicatively connect the handle to one or more indicator lights or cameras in the end cap.

[0014] The medical device may include one or more of the following features: The braided sheath may include a second conductor. The first and second conductors may each include a terminal portion located at the distal end of the braided sheath. The terminal portions may be included within or electrically connected to a flexible circuit. Attached Figure Description

[0015] The accompanying drawings are incorporated in and form part of this specification, illustrating examples of this disclosure and, together with the specification, explaining the principles of this disclosure.

[0016] Figure 1 An exemplary medical device is shown, including an enlarged view of the distal portion of the medical device.

[0017] Figure 2A A side view showing the distal portion of the shaft of the medical device.

[0018] Figure 2B for Figure 2A A lateral cross-sectional view of a portion of the shaft.

[0019] Figure 3A This is a side view of the distal portion of the shaft of the medical device.

[0020] Figure 3B for Figure 3A A lateral cross-sectional view of a portion of the shaft.

[0021] Figure 4A A side view showing the distal portion of the shaft of the medical device.

[0022] Figure 4B for Figure 4A A lateral cross-sectional view of a portion of the shaft.

[0023] Figure 5 A side view showing a portion of another shaft of the medical device.

[0024] Figure 6 A side view showing a portion of another shaft of the medical device.

[0025] Figure 7A side view showing another part of the medical device's shaft.

[0026] Figure 8 A side view showing a portion of another shaft of the medical device. Detailed Implementation

[0027] The examples of this disclosure will now be described in detail with reference to the foregoing description and the accompanying drawings. Throughout the drawings, the same reference numerals are used wherever possible to refer to the same or similar parts.

[0028] As used herein, the terms “proximal” and “distal” refer to the relative positions of components of an exemplary medical device. When used herein, “proximal” means a position relatively close to the exterior of the body or close to a medical professional using the medical device. Conversely, “distal” means a position relatively far from a medical professional using the medical device or close to the interior of the body. As used herein, the terms “comprising,” “having,” “containing,” “including,” “comprise,” or variations thereof are intended to cover non-exclusive inclusion, meaning that an apparatus or method comprising a list of elements may include not only those elements but also other elements not expressly listed or inherent thereto. Unless otherwise stated, the term “exemplary” is used to mean “example” rather than “ideal.” As used herein, the terms “about,” “substantially,” and “approximately” indicate a range of values ​​within ±10% of the stated value.

[0029] Figure 1 Several aspects of an exemplary medical device 100 are illustrated. The medical device 100 includes a handle 110 and a shaft 120. The shaft 120 is generally tubular and extends from a distal end 111 of the handle 110. The shaft 120 includes a proximal end 121 and a distal end 122 located at the distal end 111 of the handle 110. The shaft 120 includes a working channel 123 (at least as shown in the diagram). Figure 2A As can be seen in the image, the working channel 123 extends from the proximal end 121 of the shaft 120 to the distal end 122 of the shaft 120. Figure 2B , 3BIn 4B, the cross-section of shaft 120 is shown as solid, but it should be understood that shaft 120 may be solid or hollow, and / or may define multiple working channels, fluid channels, and lumens. Medical device 100 may include one or more conductors 131 that electrically connect one or more power supplies, controllers, displays, and / or other handle assemblies of handle 110 to corresponding electrical devices located at or near the distal end 122 of shaft 120 or within end cap 126. As detailed later, medical device 100 may include end cap 126 having one or more electrical devices, such as, but not limited to, lighting devices or lamps 127, visualization devices, or cameras 129. As discussed further later, shaft 120 includes a sheath 130 having one or more conductors 131 incorporated into or constituting a braid 132 that at least partially surrounds shaft 120. One or more conductors 131 in the braid 132 electrically or communicatively connect one or more electrical devices (e.g., lamp 127, camera 129, etc.) of the end cap 126 to the handle 110, other components of the medical device 100, or other devices or systems. One or more conductors 131 enable bidirectional communication, for example, for activating / powering the camera 129 and also for transmitting video or image signals from the camera 129 to the proximal side.

[0030] Medical device 100 may accommodate a portion of a medical device (not shown) having an end effector (not shown). A working channel 123 is configured to accommodate at least a portion of the medical device. As previously described, medical device 100 may include an end cap 126, for example, located at the distal end 122 of shaft 120. End cap 126 includes an opening 128 that is in fluid communication with working channel 123 when end cap 126 is coupled to shaft 120. In some aspects, end cap 126 may include one or more fluid channels 124, 125 that are in fluid communication with one or more fluid channels (not shown) of shaft 120. For example, fluid channel 124 may be a fluid delivery channel, while fluid channel 125 may be a suction channel or a negative pressure channel.

[0031] Although Figure 1 Not shown, but a sheath 130 may be disposed above or around the outer surface of the shaft 120 (Figures 2 to 4). The sheath 130 is generally tubular and may extend from the proximal end 121 of the shaft 120 to the distal end 122 of the shaft 120, or from the distal end 111 of the handle 110 to the distal end 122 of the shaft 120. The shaft 120 may include a distal annular portion 115, which may be located between the end cap 126 and the braided sheath 130.

[0032] Handle 110 may include one or more ports 112 and one or more valves 113. Port 112 may be located on a distal portion of handle 110. Port 112 may be fluidly connected to a working channel 123 in shaft 120 and an opening 128 in end cap 126. Port 112 may include a T-joint, Y-joint, or other suitable connector. Port 112 may be threaded, may be a Luer connector, and / or may include one or more internal flexible seals. Port 112 may be configured to receive one or more devices (e.g., grippers, wires, needles, cauterization devices, baskets, etc.). One or more valves 113 may be configured to be actuated to control the delivery and / or aspiration of flushing fluid, for example, through one or more fluid channels of shaft 120 fluidly connected to corresponding fluid channels 124, 125 of end cap 126. Handle 110 may include or otherwise couple to one or more power supplies, controllers, displays, and other handle assemblies known to those skilled in the art. For example, umbilical cord 114 may extend from handle 110 (e.g., from a distal portion of handle 110) and may carry wires, cables, and / or conduits for supplying power, signals, or fluid to and / or from handle 110. For example, umbilical cord 114 may connect handle 110 to one or more user interfaces, monitors, displays, etc.

[0033] In one or more embodiments, the sheath 130 is a braided sheath. The sheath 130 may extend from the distal end 111 of the handle 110 to the distal end 122 of the shaft 120. The sheath 130 may include a braid 132 comprising a plurality of elements woven together. The braid 132 may include a plurality of mechanical strands 133 and one or more conductors 131 (e.g., ...). Figure 1 and Figure 2A (As shown). At least shown in Figure 1 , 2AEach of the braids and one or more conductors of 4A, 5, 6, 7, and 8 may respectively incorporate any features of other braids or one or more conductors. The plurality of mechanical strands 133 should be understood as non-conductive, non-electrical portions of the braided sheath 130. For example, the plurality of mechanical strands 133 provide shape, support, and / or structure for the braided sheath 130. One or more of the plurality of mechanical strands 133 may be braided clockwise and one or more of the plurality of mechanical strands 133 may be braided counterclockwise when viewed from the proximal end 121 of the shaft 120 relative to its longitudinal axis. The plurality of mechanical strands 133 may be configured to provide structure (e.g., stiffness and / or flexibility) for the braided sheath 130. The plurality of mechanical strands 133 may also be configured to help prevent displacement or movement of one or more components of the braid 132. The braided sheath 130 may be coated and / or otherwise covered in one or more substances or materials (not shown), such as, but not limited to, plastics, rubber, polymers, silicone, nitrile rubber, neoprene rubber, or other similar substances or materials known in the art. The coating and / or covering may help prevent movement of the conductor 131 and the plurality of mechanical strands 133 during delivery, positioning, or other use of the medical device 100. In some embodiments, one or more of the plurality of mechanical strands 133 may be welded, brazed, or otherwise attached together. For example, two or more of the plurality of mechanical strands 133 may be welded, brazed, or otherwise attached together, which may help stabilize the plurality of mechanical strands 133 and / or the braided sheath 130.

[0034] It should be understood that including one or more conductors 131 within the braided sheath 130 instead of the shaft 120 can help increase the size and volume of the working channels 123 and openings 128 in the end cap 126, as well as the fluid channels of the shaft 120 and the corresponding fluid channels 124, 125 of the end cap 126. One or more larger channels allow for the accommodation of larger medical devices, larger fluid volumes, and improved suction capacity. Furthermore, including one or more conductors 131 within the braided sheath 130 can help provide one or more additional working channels and fluid channels within the shaft 120, and / or reduce the diameter of the shaft 120.

[0035] Figures 1, 2A to 2B, 4A to 4B, and 5 to 8 illustrate various aspects of an exemplary medical device comprising corresponding braided sheaths 130, 230, 430, 530, 630, 730, and 830. It should be understood that any of the braided sheaths 130, 230, 430, 530, 630, 730, and 830 may have any features of any other braided sheath. Figure 1 , 2AAs shown in Figures 4A and 5 through 8, various braids may include one or more conductors 131, 431A, 531, 631A, 631B, 731A, 731B, 831A, and 831B. One or more conductors may be configured to deliver energy at or near the distal end 122 of the shaft 120. One or more conductors may be configured to transmit signals to, or from, a medical device or other electrical device at or near the end cap 126. One or more conductors may be configured to electrically and / or communicatively connect the assembly of the handle 110 to a medical device or electrical device located at or near the distal end 122 of the shaft 120 or the end cap 126. One or more conductors may be one or more single conductor wires, one or more coated solid core wires, one or more stranded wires, one or more magnetic wires, etc. In some aspects, one or more conductors may be one or more cable assemblies, such as, but not limited to, one or more coaxial cables, one or more shielded biaxial cables, and one or more ribbon cable assemblies. One or more conductors may replace one or more of the multiple mechanical strands 133, or may additionally interweave with the multiple mechanical strands 133. The one or more conductors can be braided clockwise or counterclockwise relative to the shaft 120. In some embodiments, when viewed from the proximal end 121 of the shaft 120, one of the one or more conductors can be braided clockwise relative to the longitudinal axis of the shaft 120, while another conductor can be braided counterclockwise. It should be understood that the scope of this disclosure includes braiding any number of conductors into a braided sheath in a clockwise and / or counterclockwise manner. In embodiments comprising at least one conductor of one or more conductors wound clockwise and at least one conductor of one or more conductors wound counterclockwise (see...) Figure 5 (C) This increases the number of times the two conductors intersect each other across the length of the braided sheath. However, a reverse winding arrangement can help reduce the parallelism of individual conductors. Limiting the parallelism of conductors can help reduce crosstalk between conductors. Crosstalk is defined as any phenomenon in which a signal transmitted on one circuit or channel in a transmission system adversely affects another circuit or channel. Crosstalk is typically caused by unintended capacitive coupling, inductive coupling, or conductive coupling from one circuit or channel to another. In some embodiments, the braided sheath may be configured to prevent unintended electromagnetic waves from being transmitted to and / or from the shaft 120.

[0036] Figure 2A and 2B Several aspects of an exemplary medical device 200 are shown. For example, Figure 2A The distal portion of shaft 120 is shown. Figure 2BA lateral cross-sectional view of a portion of shaft 120 is shown. Although not shown, but as described above, the distal portion of shaft 120 may be coupled to an end cap (e.g., end cap 126). Shaft 120 includes a braided sheath 230 coaxial therewith. Shaft 120 may also include an outer insulating layer 239 covering (e.g., radially surrounding) the braided sheath 230. Braided sheath 230 may have the same or all of the features as described above for braided sheath 130. Outer insulating layer 239 may help limit or prevent current from flowing from braided sheath 230 and / or shaft 120 to the environment (e.g., a patient's body). Outer insulating layer 239 may be further configured to limit or prevent electromagnetic interference from the environment to braided sheath 230 and / or shaft 120. Outer insulating layer 239 may extend from the proximal end 121 of shaft 120 to the distal end 122 of shaft 120. One or more conductors 131 of the braided sheath 230 may include one or more distal terminal portions 235 extending beyond the distal terminals 236 of the plurality of mechanical strands 133. The braided sheath 230 may include flexible circuitry 238 extending beyond the distal terminals 236. The distal terminal portions 235 may be included within or otherwise electrically connected to the flexible circuitry 238. In some embodiments, one or more conductors 131 may be connected to one or more copper traces (not shown) within the flexible circuitry 238. In one or more embodiments, the flexible circuitry 238 may be coupled (e.g., inserted) to a compatible port (not shown) of a circuit or board and electrically connected to an electrical device of the end cap 126, or electrically connected to an electrical device otherwise positioned at the distal end 122 of the shaft 120. In some embodiments, the shaft 120 may include an insulating layer (not shown) between its outer surface and the braided sheath 230.

[0037] like Figure 2A As shown, one or more conductors 131 may include a distal termination portion 235. One or more conductors 131 may converge at a single distal termination portion 235, or each may each include its own distal termination portion 235. The distal termination portion 235 is part of the conductor 131, extending distally beyond the distal termination portions 236 of the plurality of mechanical strands 133. In some embodiments, the distal termination portion 235 of the conductor 131 may be directly connected to an electrical device located at or near the distal end 122 of the shaft 120. In one or more embodiments, the distal termination portion 235 may be electrically connected to the circuitry (not shown) or circuit board (not shown) of the end cap 126, thereby connecting to the electrical device of the end cap 126. The circuitry or circuit board of the end cap 126 may be printed, 3D printed, chemically etched, laser-directly formed, or otherwise formed on the proximal surface of the end cap 126 or any other surface of the end cap 126. In these aspects, the circuitry or circuit board of the end cap 126 may be located inside the end cap 126, for example, electrically connected to one or more lamps 127, cameras 129, etc.

[0038] like Figure 2A As can be seen, the multiple mechanical strands 133 and one or more conductors 131 can be configured such that two or more conductors 131 intersect or otherwise overlap at predetermined points along the length of the braided sheath 230. The braided sheath 230 can be sized such that the distal ends 236 of the multiple mechanical strands 133 are positioned at the intersection or convergence point 234 of the two or more conductors 131. This configuration facilitates the inclusion or connection of the distal end portions 235 of the two or more conductors 131 to the flexible circuit 238 and end cap 126, and further minimizes the circuit length between the distal end 236 and the electrical device located at or near the distal end 122 of the shaft 120. Minimizing the circuit length between the distal end 236 and the electrical device prevents wire congestion at or near the distal end 122 of the shaft 120.

[0039] In one or more embodiments, the distal termination portion 235 may be included within or electrically connected to the flexible circuit 238. In some aspects, the flexible circuit 238 may be a card-edge flat flexible circuit that may be electrically connected to one or more electrical devices, or may be electrically connected to the end cap 126 as described above. The flexible circuit 238 may extend distally from the distal termination portion 236 of the plurality of mechanical strands 133. In some embodiments, the distal termination portion 235 may be electrically connected to one or more flexible plates (not shown) containing or electrically connected to one or more electrical devices located at or near the distal end 122 of the shaft 120, or electrically connected to the end cap 126 as described above. The one or more flexible plates may be wired within the end cap 126 as needed to place one or more electrical devices in desired locations.

[0040] One or more conductors 131 may include proximal terminal portions (not shown). One or more conductors 131 may converge at a single proximal terminal portion, or each may include its own proximal terminal portion. The proximal terminal portion is a part of conductor 131 that extends proximally beyond the proximal terminals 137 of the plurality of mechanical strands 133. Figure 1The proximal terminal portion may be directly connected to the handle assembly of handle 110, such as, but not limited to, a power supply, controller, display, and other handle assemblies known to those skilled in the art. In some embodiments, the proximal terminal portion may be electrically connected to one or more flexible boards (not shown) that contain or are electrically connected to the handle assembly of handle 110. In one or more embodiments, the proximal terminal portion may be contained in or electrically connected to a flexible circuit (not shown), such as a snap-edge flat flexible circuit that may be electrically connected to the handle assembly of handle 110. In some embodiments, one or more conductors 131 may be connected to one or more copper traces within the flexible circuit. The flexible circuit may extend proximally from the proximal terminal 137 of multiple mechanical strands 133. One or more conductors 131 may be electrically and / or communicatively coupled to one or more elements in the umbilical cord 114, for example, for connection to one or more power supplies, controllers, displays, etc.

[0041] It should be understood that Figure 1 One or more conductors of the various braids shown in 4, 5, 6, 7, and 8 may include distal terminal portions and distal connections as well as proximal terminal portions and proximal connections, similar to those described in the preceding paragraphs.

[0042] Figure 3A and 3B Several aspects of another exemplary medical device 300 are shown. A shaft 120 includes a sheath 350 coaxial with it. The sheath 350 can be used to form an electrical conduit, such as, but not limited to, an electrical ground. The sheath 350 can be used in conjunction with a braided sheath 230. The sheath 350 can be used to transmit high-speed differential signals requiring inter- and intra-pair matching. Alternatively or additionally, the sheath 350 can be used for impedance control. The sheath 350 can be located from the proximal end 121 of the shaft 120 (… Figure 1 The shaft 120 may extend to the distal end 122 of the shaft 120. The shaft 120 may also include an insulating layer 339 covering (e.g., radially surrounding) the cladding layer 350. The insulating layer 339 may extend from the proximal end 121 of the shaft 120. Figure 1The sheath 350 extends to the distal end 122 of the shaft 120. The sheath 350 may contain one or more conductors 331. The one or more conductors 331 may be one or more single conductor wires, one or more coated solid core wires, one or more stranded wires, one or more magnetic wires, etc. In some aspects, the one or more conductors 331 may be one or more cable assemblies, such as, but not limited to, one or more coaxial cables, one or more shielded biaxial cables, and one or more ribbon cable assemblies. The one or more conductors 331 may have any of the characteristics of conductors 131, 431A, 431B, 531, 631A, 631B, 731A, 731B, 831A, and 831B. In some embodiments, the shaft 120 may include an insulating layer (not shown) between its outer surface and the sheath 350.

[0043] The cladding layer 350 may include a ground layer. The ground layer is disposed on one of the inner or outer surfaces of the cladding layer 350, and one or more conductors 331 may be disposed on the other of the inner or outer surfaces of the cladding layer 350. In some embodiments, the one or more conductors 331 may be two or more length-matched conductors configured to transmit high-speed signals. It should be understood that length matching is necessary for certain high-speed signals. Figure 3A As shown, one or more conductors 331 may extend linearly along the length of the sheath 350. However, the one or more conductors 331 are not limited to extending linearly along the sheath 350. Alternatively, the one or more conductors 331 may be wound around the surface of the sheath 350, for example, in a clockwise or counterclockwise manner, similar to one or more conductors in the various braided sheaths disclosed in this disclosure.

[0044] One or more conductors 331 of the cover layer 350 can electrically and / or communicatively connect the handle assembly of the handle 110 to an electrical device located at or near the distal end 122 or end cap 126 of the shaft 120. The cover layer 350 can also help limit electromagnetic radiation and electromagnetic interference to and from the shaft 120. In some embodiments, conductors 331 include an electrical ground. One or more conductors 331 of the cover layer 350 can be electrically connected to a medical device at least partially housed within the working channel 123 of the shaft 120. The conductors 331 of the cover layer 350 can facilitate electrical connection and / or communication between the handle assembly within the handle 110 and the medical device at least partially housed within the working channel 123.

[0045] The distal termination portion 335 of one or more conductors 331 may extend beyond the distal termination portion 351 of the cladding layer 350 and may extend into the flexible circuit 338. In some embodiments, one or more conductors 331 may be connected to one or more copper traces (not shown) within the flexible circuit 338. In some embodiments, the distal termination portion 335 of one or more conductors 331 may be directly connected to an electrical device located at or near the distal end 122 of the shaft 120. In one or more embodiments, the distal termination portion 335 may be electrically connected to the end cap 126 ( Figure 1 The circuit (not shown) or circuit board (not shown) may be electrically connected to end cap 126. Figure 1 ) electrical devices.

[0046] The circuitry or circuit board of end cap 126 may be printed, 3D printed, chemically etched, or laser-formed onto the proximal surface of end cap 126 or any other surface of end cap 126. In one or more embodiments, the distal terminal portion 335 may be contained within or electrically connected to the flexible circuit 338. In some aspects, the flexible circuit 338 may be a snap-edge flat flexible circuit that may be electrically connected to one or more electrical devices, or may be electrically connected to end cap 126, as described above. The flexible circuit 338 may extend distally from the distal terminal 351 of the cover layer 350. In some embodiments, the distal terminal portion 335 may be electrically connected to one or more flexible plates (not shown) containing or electrically connected to one or more electrical devices located at or near the distal end 122 of shaft 120, or electrically connected to end cap 126, as described above. One or more flexible boards can be wired within the end cap 126 as needed to place one or more electrical devices in the desired location.

[0047] One or more conductors 331 of the cladding 350 may include proximal termination portions (not shown). One or more conductors 331 may converge at a single proximal termination portion, or each may include its own proximal termination portion. The proximal termination portion is a portion of one or more conductors 331 that extends proximally beyond the proximal termination portion (not shown) of the cladding 350. The proximal termination portion may be directly connected to components of the handle 110, such as, but not limited to, a power supply, controller, display, and other handle components known to those skilled in the art. In one embodiment, the proximal termination portion may be electrically connected to one or more flexible boards (not shown) that include or are electrically connected to components of the handle 110. In one or more embodiments, the proximal termination portion may be contained in or electrically connected to a flexible circuit (not shown), such as a snap-edge flat flexible circuit, which may be electrically connected to a handle assembly of the handle 110. In some embodiments, one or more conductors 331 may be connected to one or more copper traces within the flexible circuit. The flexible circuit may extend proximally from the proximal end of the cladding 350. One or more conductors 331 may be electrically and / or communicatively coupled to one or more elements in the umbilical 114, for example, for connection to one or more power supplies, controllers, displays, etc.

[0048] It should be understood that including one or more conductors 331 within the sheath 350 rather than within the shaft 120 can help increase the dimensions (e.g., cross-sectional area) of the working channels 123 and openings 128 in the end cap 126, as well as the fluid channels of the shaft 120 and the corresponding fluid channels 124, 125 of the end cap 126. One or more larger channels allow for the accommodation of larger medical devices, larger fluid volumes, and improved aspiration capacity. Furthermore, including one or more conductors 331 within the sheath 350 can help provide one or more additional working channels and fluid channels within the shaft 120, and / or reduce the diameter of the shaft 120.

[0049] In some embodiments, any of the braided sheaths 130, 230, 430, 530, 630, 730, and 830 may be disposed on the cover layer 350 and extend from the proximal end 121 of the shaft 120 to the distal end 122 of the shaft 120. At the distal end 122 of the shaft 120, conductors of the braided sheath and cover layer 350 may extend distally to flexible circuitry 338, one or more flexible circuit boards, or be electrically connected to end cap 126 or a medical device. One or more flexible circuit boards may be wired within end cap 126 as needed to place one or more electrical devices in desired locations. At the proximal end 121 of the shaft 120, conductors of the braided sheath and cover layer 350 may extend proximally to flexible circuitry, one or more flexible boards, or be electrically connected to an assembly of handle 110.

[0050] Figure 4A and 4B This illustrates several aspects of another exemplary medical device 400, which combines... Figure 2A and 2B Multiple aspects of the exemplary medical device 200 disclosed herein and Figure 3A and 3B The disclosed medical device 300 includes several aspects. The shaft 120 includes a braided sheath 430. The braid 432 of the braided sheath 430 may include multiple mechanical strands 133 and one or more conductors 431A. The distal terminal portion 435 of one or more conductors 431A may extend into a flexible circuit 438. The braided sheath 430 may have the same or all of the features as the aforementioned braided sheath 230 and / or braided sheath 130. The shaft 120 also includes an inner insulating layer 440 covering (e.g., radially surrounding) the braided sheath 430. The inner insulating layer 440 may extend from the proximal end 121 of the shaft 120 (… Figure 1 The shaft 120 extends to the distal end 122 of the shaft 120. The shaft 120 also includes a first polyimide layer 460 covering (e.g., radially surrounding) the inner insulation layer 440. The shaft 120 also includes a second polyimide layer 461 covering (e.g., radially surrounding) the first polyimide layer 460. The first polyimide layer 460 and the second polyimide layer 461 may extend from the proximal end 121 of the shaft 120. Figure 1 The first polyimide layer 460 and the second polyimide layer 461 are collectively referred to as polyimide overlays, meaning that the polyimide overlays may comprise or include multiple layers. The polyimide overlays can be used to transmit high-speed differential signals requiring matching between and within wire pairs. The shaft 120 also includes an outer insulating layer 439 covering (e.g., radially surrounding) the second polyimide layer 461. The shaft 120 may include an intermediate insulating layer 462 located between the first polyimide layer 460 and the second polyimide layer 461. It should be understood that, in addition to the insulating layers already discussed, the shaft 120 may also include additional insulating layers located outside the second polyimide layer 461 and / or within the first polyimide layer 460. In some embodiments, the shaft 120 may include an insulating layer (not shown) located between its outer surface and the braided sheath 430.

[0051] In one or more embodiments, one of the first polyimide layer 460 or the second polyimide layer 461 may include one or more conductors 431B, and the other of the first polyimide layer 460 and the second polyimide layer 461 may be a ground layer. A polyimide layer having one or more conductors 431B may include a ground layer. The ground layer may be disposed on one of the inner surface or the outer surface of the polyimide layer, while one or more conductors 431B are disposed on the other of the inner surface or the outer surface of the polyimide layer.

[0052] like Figure 4A As shown, one or more conductors 431A, 431B of the braided sheath 430 and one of the polyimide layers 460, 461 may include a distal termination portion 435. One or more conductors 431A, 431B may converge to a single distal termination portion 435, or each may include its own distal termination portion 435. The distal termination portion 435 includes a portion of each conductor 431A, 431B extending distally beyond the distal termination 436 of the plurality of mechanical strands 133. In some embodiments, the distal termination portions 435 of conductors 431A, 431B may be directly connected to an electrical device located at or near the distal end 122 of the shaft 120. In one or more embodiments, the distal termination portion 435 may be connected to the end cap 126 (…). Figure 1 The circuit (not shown) or circuit board (not shown) of the end cap 126 is electrically connected, and the circuit or circuit board can be connected to the end cap 126. Figure 1 Electrical connections to the electrical devices. The circuitry or circuit board of end cap 126 may be printed, 3D printed, chemically etched, or laser-formed onto the proximal surface of end cap 126 or any other surface of end cap 126. In one or more embodiments, the distal terminal portion 435 may be included within or electrically connected to the flexible circuit 438. In some embodiments, one or more conductors 431A, 431B may be connected to one or more copper traces (not shown) within the flexible circuit 438. In some aspects, the flexible circuit 438 may be a snap-edge flat flexible circuit that may be electrically connected to one or more electrical devices or to end cap 126, as described above. The flexible circuit 438 may extend distally from the distal terminal 436 of the plurality of mechanical strands 133. In some embodiments, the distal terminal portion 435 may be electrically connected to one or more flexible plates (not shown) that contain or are electrically connected to one or more electrical devices located at or near the distal end 122 of the shaft 120, or to the end cap 126, as described above. The one or more flexible plates may be wired within the end cap 126 as needed to place one or more electrical devices in desired locations.

[0053] As described above, one or more conductors 431A, 431B in the braided sheath 430 and one of the polyimide layers 460, 461 may include a proximal termination portion (not shown). One or more conductors 431A, 431B may converge at a single proximal termination portion, or each may include its own proximal termination portion. The proximal termination portion is part of conductors 431A, 431B, extending proximally beyond the proximal termination 137 of the plurality of mechanical strands 133. Figure 1The proximal terminal portion may be directly connected to components of the handle 110, such as, but not limited to, a power supply, controller, display, and other handle components known to those skilled in the art. In one embodiment, the proximal terminal portion may be electrically connected to one or more flexible boards (not shown) that contain or are electrically connected to the handle assembly of the handle 110. In one or more embodiments, the proximal terminal portion may be contained in or connected to a flexible circuit (not shown) that can be electrically connected to components of the handle 110, such as a snap-edge flat flexible circuit. In some embodiments, one or more conductors 431A, 431B may be connected to one or more copper traces within the flexible circuit. The flexible circuit may extend proximally from the proximal terminal 137 of the plurality of mechanical strands 133. One or more conductors 431A, 431B may be electrically and / or communicatively coupled to one or more elements in the umbilical cord 114, for example, for connection to one or more power supplies, controllers, displays, etc.

[0054] The stacked arrangement of the braided sheath 430, inner insulation layer 440, first polyimide layer 460, intermediate insulation layer 462, second polyimide layer 461, and outer insulation layer 439 provides numerous advantages. For example, this stacked arrangement helps facilitate the separation of conductors requiring impedance control from those not requiring impedance control. Conductors requiring impedance control (e.g., one or more conductors 431B) can be placed within the first polyimide layer 460 or the second polyimide layer 461, while the remaining polyimide layer, excluding conductors requiring impedance control, can serve as a continuous ground plane. Conductors not requiring impedance control (e.g., one or more conductors 431A) can be interwoven within the braided sheath 430. This separation may be necessary for conductors requiring impedance control. The first polyimide layer 460 and the second polyimide layer 461 are two conductive layers, one for impedance-controlled signal conductors and the other for a ground plane. The distance from the ground plane to one or more conductors 431B and the dielectric constant of the polyimide affect the impedance of one or more conductors 431B. Non-impedance-controlled conductors (e.g., one or more conductors 431A) can be interwoven in the braid 432 because a reliable ground reference is not required. The first polyimide layer 460 and the second polyimide layer 461 can be thin and flexible, for example, to minimize mechanical impact on the shaft 120. It should be understood that one or more conductors 431A, 431B can be any of conductors 131, 331, 531, 631A, 631B, 731A, 731B, 831A, and 831B.

[0055] In some implementations, one or more conductors 431B may be two or more length-matched conductors configured to transmit high-speed signals. It should be understood that length matching may be necessary for certain high-speed signals. For example... Figure 4AAs shown, one or more conductors 431B may extend linearly along the polyimide layer (e.g., within the first polyimide layer 460). However, the one or more conductors 431B are not limited to extending linearly along the polyimide layer, but may be wound around the surface or interior of the polyimide layer in a clockwise or counterclockwise manner, for example, in a manner similar to one or more conductors in the various braided sheaths disclosed in this disclosure.

[0056] Figure 5 One aspect of an exemplary medical device is shown, comprising a braided sheath 530. The braided sheath 530 includes at least one conductor 531. Conductor 531 may comprise two intertwined conductors 531A and 531B. Conductors 531A and 531B may be braided clockwise or counterclockwise around a braid 532. Conductor 531 may be a twisted pair conductor.

[0057] Figure 6 Another aspect of an exemplary medical device is shown. The medical device includes a braided sheath 630. The braided sheath 630 may include two conductors 631A and 631B. The two conductors 631A and 631B may be biaxial cables. The conductors 631A and 631B are intertwined and may be braided clockwise or counterclockwise around a braid 632.

[0058] Figure 7 An aspect of an exemplary medical device is shown. The medical device includes a braided sheath 730. The braided sheath 730 may include a first conductor 731A and a second conductor 731B. The two conductors 731A and 731B may be interwoven with a braid 732. The first conductor 731A may be braided clockwise, and the second conductor 731B may be braided counterclockwise. When viewed from the proximal end 121 of the shaft 120 relative to the longitudinal axis of the shaft 120, arranging one of the conductors 731 and 731B clockwise around the braid 732 and arranging the other of the conductors 731A and 731B counterclockwise around the braid 732 helps to limit the parallelism between the conductors 731A and 731B, while the conductors 731A and 731B extend along the braided sheath 730.

[0059] Figure 8 Another aspect of an exemplary medical device is shown. The medical device includes a braided sheath 830. The braided sheath 830 may include two conductors 831A and 831B. The two conductors 831A and 831B may be interwoven with a braid 832, and both may extend clockwise or counterclockwise. Conductors 831A and 831B may be braided into the fabric using an existing braiding machine by replacing one or more non-conductive strands with one or more conductors.

[0060] One aspect of this disclosure is a method of manufacturing a braided sheath having one or more conductors, as described in the foregoing aspects. Braided sheaths known in the art can be formed by: providing a plurality of mechanical strand spools, each spool including a guide end; arranging the mechanical strand spools such that the guide ends of the mechanical strand spools can be fed into a receiving end of a braiding machine; and actuating the braiding machine to form the braided sheath. The braiding machine may be a bell-gear braiding machine. The braided sheath can be formed by: providing a plurality of mechanical strand spools; providing one or more conductor spools, wherein the mechanical strand spools and conductor spools each include a guide end; arranging the mechanical spools and conductor spools such that the guide ends of the spools can be fed into a receiving end of a braiding machine; and actuating the braiding machine to form the braided sheath. The method of manufacturing the braided sheath may further include: arranging one or more conductor spools to wind counterclockwise relative to a longitudinal axis defined by the braided sheath being formed; and arranging one or more conductor spools to wind clockwise relative to a longitudinal axis defined by the braided sheath being formed. In one or more embodiments, the conductor reel may be formed from one or more single conductor wires, one or more coated solid core wires, one or more stranded wires, etc. Alternatively or additionally, the conductor reel may include one or more cable assemblies, such as, but not limited to, one or more coaxial cables and one or more shielded biaxial cables, and combinations thereof.

[0061] As described above, removing wires or cables from within the shaft and placing them within the various braided sheaths, overlays, and polyimide overlays disclosed herein facilitates the creation of larger lumens for larger devices, more lumens for more devices, more lumens for conveying suction and different types of fluids, larger lumens for conveying more fluids, larger lumens for applying suction, and smaller shaft / insertion diameters, etc. Furthermore, the braided sheaths disclosed above can help reduce conductor parallelism by braiding one or more conductors clockwise and one or more other conductors counterclockwise. Additionally, as... Figure 4A and 4B As disclosed, the present invention helps to facilitate the separation of impedance-controlled conductors from non-impedance-controlled conductors. Those skilled in the art will understand that the above advantages represent a significant advancement in the field.

[0062] Although Figures 1 to 8 The braided sheath, polyimide overlay, insulation layer, and cover shown in this disclosure are discussed as covering an outer shaft (e.g., shaft 120), but the braided sheath, polyimide overlay, insulation layer, and cover can also be applied to an inner shaft (e.g., working channel 123) in the same or similar manner as discussed above for shaft 120.

[0063] While the principles of this disclosure are described with reference to examples of specific applications, it should be understood that this disclosure is not limited thereto. Those skilled in the art, upon reading the teachings provided herein, will understand that other modifications, applications, implementations, and equivalent substitutions fall within the scope of the features described herein. Therefore, the claimed features should not be considered as limited by the foregoing description.

Claims

1. A medical device comprising: Shaft; and A braided sheath that is coaxial with the shaft and extends at least along the shaft between the distal end and the proximal end of the shaft; The woven sheath comprises a woven fabric, and the woven fabric comprises: Multiple mechanical stock lines; and At least one conductor is electrically and / or communicatively connected to a first electrical device located at or near the distal end of the shaft.

2. The medical device according to claim 1, wherein, The at least one conductor is a first conductor, wherein the braid includes a second conductor that is electrically connected and / or communicatively connected to a second electrical device.

3. The medical device of claim 2, wherein the first conductor is woven clockwise along the braided sheath, and the second conductor is woven counterclockwise along the braided sheath.

4. The medical device according to claim 2, wherein, Both the first conductor and the second conductor are woven clockwise or counterclockwise.

5. The medical device according to claim 2, wherein, The first conductor and the second conductor are electrically connected to the end cap.

6. The medical device according to claim 2, wherein, The first conductor is connected to a medical device, wherein the medical device is at least partially contained within the lumen of the shaft.

7. The medical device according to any one of the preceding claims, wherein, The at least one conductor is a coated core wire.

8. The medical device according to any one of claims 1 to 6, wherein, The at least one conductor is a stranded wire.

9. The medical device according to any one of claims 1 to 6, wherein, The at least one conductor is a coaxial cable.

10. The medical device according to any one of the preceding claims, wherein, The woven sheath includes a polyimide overlay layer that covers the woven sheath and extends coaxially with it.

11. The medical device according to claim 10, wherein, The polyimide coating layer comprises a first layer and a second layer.

12. The medical device according to claim 11, wherein, The first layer is a continuous ground plane.

13. The medical device according to claim 12, wherein, The second layer contains one or more conductors.

14. The medical device according to claim 13, wherein, The second layer includes an outer surface and an inner surface, wherein one or more conductors of the second layer are disposed on one of the outer surface and the inner surface, and a ground layer of the second layer is disposed on the other of the outer surface and the inner surface.

15. The medical device according to claim 13, wherein, The one or more conductors are impedance-controlled conductors.

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