Braided sheath for medical devices

Abstract

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

Description

Technical Field

[0001] Aspects of the present disclosure generally relate to medical devices and procedures. In particular, aspects of the present disclosure relate to braided sheaths for medical devices.

Background Art

[0002] Medical devices such as endoscopes or other suitable insertion devices are employed for various types of diagnostic and surgical procedures such as endoscopy, laparoscopy, arthroscopy, hysteroscopy, thoracoscopy, cystoscopy, etc. Endoscopic procedures may be performed by inserting an insertion device into a patient's body through a surgical incision or through a natural opening (e.g., the mouth, vagina, or rectum).

[0003] The insertion device includes a shaft that includes one or more lumens or working channels through the shaft. The lumen(s) are often designed to receive various devices and structures such as medical instruments (e.g., irrigation tubes, suction tubes, forceps, electrosurgical knives, brushes, RF electrodes, and / or other tools) that are operated at the distal end of the insertion device. Surgical incisions and natural openings are often narrow, and the distal end of the insertion device must be small enough to fit and operate within these spaces. Thus, the space within the distal end shaft is limited, and thus the space within the lumen is also limited.

[0004] The distal end of the insertion device may also include one or more components (lights, cameras, etc.) that require electrical wires or cables to be operated (e.g., powered, controlled, etc.) and / or to communicate with one or more proximal components (e.g., a power source, a controller, a display, etc.). These electrical wires or cables are typically housed within the shaft of the insertion device. These electrical wires or cables occupy space within the shaft and may limit the size and / or the number of lumens within the shaft. The electrical wires or cables may also increase the required size of the shaft.

[0005] The devices and methods of this disclosure may correct some of the defects described above or otherwise address other aspects of the art. [Overview of the Initiative]

[0006] Each of the embodiments disclosed herein may include one or more of the features described in relation to any of the other embodiments disclosed. An embodiment of this disclosure may relate to a medical device having a braided sheath extending along the shaft of the medical device.

[0007] Some of the exemplary devices 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 the distal end and the proximal end of the shaft. The braided sheath may include a braid. The braid may include a plurality of mechanical strands and at least one conductor which can be electrically connected and / or communically connected to an electrical device located at or near the distal end of the shaft.

[0008] The medical device may include one or more of the following embodiments: At least one conductor may be a first conductor. The braid may include a second conductor that is electrically connected to a second electrical device and / or communicates with. 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 a medical device. The medical device may be at least partially received by the lumen of the shaft. At least one of the conductors may be a coated core wire. At least one of the conductors may be a stranded wire. At least one of the conductors may be a coaxial cable.

[0009] The medical device may include a polyimide wrap layer covering a braided sheath and extending coaxially with the braided sheath. The polyimide wrap layer may include a first layer and a second layer. The first layer may be a continuous grounding surface. 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 located on either the outer surface or the inner surface, and the grounding layer of the second layer may be located on the other of the outer surface or the inner surface. One or more conductors of the second layer may be impedance-controlled conductors.

[0010] In another embodiment, the medical device may include a shaft. The shaft may include a distal end, a proximal end, and a working channel. The medical device may also include a lap layer coaxial with the shaft and located on the outer surface of the shaft. The lap layer may include one or more conductors.

[0011] The medical device may include one or more of the following features: One or more conductors may be located on either the inner surface or the outer surface of the wrap layer, and a ground layer may be located on the other of the inner and outer surfaces. One or more conductors may be configured to transmit electricity from the handle of the medical device to an electrical device in the end cap at the distal end of the shaft.

[0012] In yet another embodiment, the 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 the length of the shaft. The medical device may include an end cap containing one or more 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 end and the proximal end of the shaft. The braided sheath may include a plurality of mechanical strands. The braided sheath may also include a first conductor configured to electrically and / or communically connect the handle to one or more lights or cameras in the end cap.

[0013] 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 termination portion located at the distal end of the braided sheath. The termination portion may be housed in a flexible circuit or electrically connected to a flexible circuit.

[0014] The accompanying drawings incorporated herein and constituting part thereof illustrate examples of the present disclosure and, together with the description, help to illustrate the principles of the present disclosure. [Brief explanation of the drawing]

[0015] [Figure 1] A diagram showing an example medical device, including a magnified view of the distal portion of the medical device. [Figure 2A] Side view of the distal portion of the shaft of a medical device. [Figure 2B] A lateral cross-sectional view of a portion of the shaft shown in Figure 2A. [Figure 3A] Side view of the distal portion of the shaft of a medical device. [Figure 3B] A lateral cross-sectional view of a portion of the shaft shown in Figure 3A. [Figure 4A] Side view of the distal portion of the shaft of a medical device. [Figure 4B] A lateral cross-sectional view of a portion of the shaft shown in Figure 4A. [Figure 5] Side view of a portion of another shaft of a medical device. [Figure 6] A side view of another part of the shaft of a medical device. [Figure 7] A side view of a portion of the shaft of a medical device. [Figure 8] Side view of a portion of another shaft of a medical device. [Modes for carrying out the invention]

[0016] Hereinafter, we refer in detail to the examples of this disclosure described above and shown in the attached drawings. Wherever possible, the same reference numerals are used throughout the drawings to refer to the same or similar parts. The terms “proximal” and “distal” are used herein to refer to the relative locations of components of an exemplary medical device. Where used herein, “proximal” refers to a location relatively close to the outside of the body or relatively close to the healthcare professional using the medical device. In contrast, “distal” refers to a location further away from the healthcare professional using the medical device or closer to the inside of the body. Where used herein, the terms “comprises,” “comprising,” “having,” “includes,” “including,” or other variations thereof are intended to cover non-exclusive inclusion, such that a device or method comprising a list of elements may include other elements not explicitly listed or inherent to them, rather than including only those elements. Unless otherwise stated, the term “exemplary” is used in the sense of “example” rather than “ideal.” Where used herein, the terms “about,” “substantially,” and “approximately” indicate a range of values ​​within + / - 10% of the stated value.

[0017] Figure 1 shows an exemplary embodiment of a medical device 100. The medical device 100 includes a handle 110 and a shaft 120. The shaft 120 may be substantially tubular and may extend from the distal end 111 of the handle 110. The shaft 120 includes a proximal end 121 located at the distal end 111 of the handle 110 and a distal end 122. The shaft 120 includes a working channel 123 (at least as shown in Figure 2A) extending from the proximal end 121 to the distal end 122 of the shaft 120. In Figures 2B, 3B, and 4B, the cross-section of the shaft 120 is shown as solid, but it should be understood that the shaft 120 may be solid or hollow and / or may define multiple working channels, fluid channels, and lumens. The medical device 100 may include one or more conductors 131 that electrically connect one or more power supplies, controllers, displays, and / or other handle components of the handle 110 to appropriate electrical devices located at or near the distal end 122 of the shaft 120, or within the end cap 126. As will be discussed in detail below, the medical device 100 may include an end cap 126 with one or more electrical devices, such as, but not limited to, one or more of a lighting device or light 127, a visualization device or camera 129, etc. As will be discussed further below, the shaft 120 includes a sheath 130 having one or more conductors 131 incorporated into a braid 132 that at least partially surrounds the shaft 120, or forming the braid 132. One or more conductors 131 within the braid 132 electrically or communicatively connect one or more electrical devices of the end cap 126 (e.g., light 127, camera 129, etc.) to the handle 110, other components of the medical device 100, or other devices or systems. One or more conductors 131 may, for example, activate / power the camera 129 and facilitate bidirectional communication to transmit video or picture signals from the camera 129 to a nearby location.

[0018] The medical device 100 may receive a portion of a medical instrument (not shown) having an end effector (not shown). The working channel 123 is configured to receive at least a portion of the medical instrument. As described above, the medical device 100 may include, for example, an end cap 126 at the distal end 122 of the shaft 120. The end cap 126 includes an opening 128 that is in fluid communication with the working channel 123 when the end cap 126 is coupled to the shaft 120. In some embodiments, the end cap 126 may include one or more fluid channels 124, 125 that may be fluidly connected to one or more fluid channels (not shown) of the shaft 120. For example, the fluid channel 124 may be a fluid delivery channel, and the fluid channel 125 may be a suction or negative pressure channel.

[0019] Although not shown in FIG. 1, the sheath 130 may be disposed over or around the outer surface of the shaft 120 (FIGS. 2-4). The sheath 130 may be generally tubular and may extend from the proximal end 121 of the shaft 120 to the distal end 122 of the shaft 120, or alternatively, 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 ring portion 115 that may be positioned between the end cap 126 and the braided sheath 130.

[0020] The handle 110 may include one or more ports 112 and one or more valves 113. The ports 112 may be located on the distal portion of the handle 110. The ports 112 may be fluid-connected to a working channel 123 in the shaft 120 and an opening 128 in the end cap 126. The ports 112 may include a T-connector, a Y-connector, or another suitable connection. The ports 112 may be threaded, may be Luer components, and / or may include one or more internal flexible seals. The ports 112 may be configured to receive one or more instruments (e.g., grippers, guidewires, needles, cauterization devices, baskets, etc.). The valves 113 may be configured to actuate, for example, through one or more fluid channels in the shaft 120 which are fluid-connected to corresponding fluid channels 124, 125 in the end cap 126, to control the delivery and / or application of irrigation fluid. The handle 110 may include, or otherwise be connected to, one or more power supplies, controllers, displays, and other handle components known to those skilled in the art. For example, the umbilicus 114 may extend from the handle 110 (e.g., from the distal portion of the handle 110) and may carry, for example, wires, cables, and / or conduits for supplying power, signals, or fluids to and from the handle 110. For example, the umbilicus 114 may connect the handle 110 to one or more user interfaces, monitors, displays, etc.

[0021] 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 comprise a braid 132 comprising a plurality of elements braided together. The braid 132 may comprise a plurality of mechanical strands 133 and one or more conductors 131 (as shown in Figures 1 and 2A). Various braids and one or more conductors are shown in at least Figures 1, 2A, 4A, 5, 6, 7, and 8, each comprising any of the features of other braids or one or more conductors. The plurality of mechanical strands 133 should be understood as the non-conductive, non-electrical portion of the braided sheath 130. For example, the plurality of mechanical strands 133 provide shape, support, and / or form to the braided sheath 130. With respect to the longitudinal axis of the shaft 120, as viewed from the proximal end 121 of the shaft 120, one or more of the multiple mechanical strands 133 may be braided clockwise, and one or more of the multiple mechanical strands 133 may be braided counterclockwise. The multiple mechanical strands 133 may be configured to provide structure (e.g., rigidity and / or flexibility) to the braided sheath 130. The multiple mechanical strands 133 may also be configured to help prevent the displacement or movement of one or more members of the braid 132. The braided sheath 130 may be coated and / or otherwise encased in one or more substances or materials (not shown), such as, but not limited to, plastics, rubber, polymers, silicones, nitriles, neoprene, or other similar substances or materials known in the art. The coating and / or encasing may help prevent the conductor(s) 131 and the multiple mechanical strands 133 from moving during delivery, positioning, or other use of the medical device 100. In some embodiments, one or more of the multiple mechanical strands 133 may be welded, soldered, or otherwise fixed to one another.For example, two or more of the plurality of mechanical strands 133 may be welded, soldered, or otherwise fixedly secured together, which can serve to stabilize the plurality of mechanical strands 133 and / or the braided sheath 130.

[0022] It should be understood that including one or more conductors 131 within the braided sheath 130 rather than within the shaft 120 can serve to make one or more of the size and volume of the working channel 123 and opening 128 within 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, larger. The one or more larger channels can serve to allow larger medical instruments to be received therein, a larger volume of fluid, and a greater suction capacity. Additionally, including one or more conductors 131 within the braided sheath 130 can serve to allow one or more additional working channels and fluid channels to be disposed within the shaft 120, and / or the shaft 120 may have a smaller diameter.

[0023] Figures 1, 2A–2B, 4A–4B, and 5–8 illustrate various embodiments of exemplary medical devices, each including a braided sheath 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 of the features of any of the other braided sheaths. As shown in Figures 1, 2A, 4A, and 5–8, the 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 to or near the distal end 122 of the shaft 120. One or more conductors may be configured to send and receive signals to and from the end cap 126 or the medical device or other electrical device at the distal end 122. One or more conductors may be configured to electrically and / or communicatively connect components of the handle 110 to a medical device or electrical device at or near the distal end 122 or end cap 126 of the shaft 120. One or more conductors may be one or more single-conductor wires, one or more insulated solid-core wires, one or more stranded wires, one or more magnet wires, etc. In some embodiments, one or more conductors may be one or more cable assemblies, such as one or more coaxial cables, one or more shielded twin axial cables, and one or more ribbon cable assemblies, etc. One or more conductors may replace one or more of a plurality of mechanical strands 133, or may be further woven with a plurality of mechanical strands 133. With respect to the shaft 120, one or more conductors may be woven clockwise or counterclockwise. In some embodiments, when viewed from the proximal end 121 of the shaft 120, one of the one or more conductors may be woven in a clockwise manner with respect to the longitudinal axis of the shaft 120, and another of the one or more conductors may be woven in a counterclockwise manner. It should be understood that incorporating any number of conductors into the braided sheath in a clockwise and / or counterclockwise manner is intended within the scope of this disclosure.In embodiments including at least one of one or more conductors traveling clockwise and at least one other of one or more conductors traveling counterclockwise (see Figure 5C), this can increase the number of instances in which the two conductors cross each other over the length of the braided sheath. Nevertheless, opposite winding arrangements can help reduce instances of parallelism between each conductor. 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 of a transmission system causes an unwanted effect on another circuit or channel. Crosstalk is typically caused by unwanted capacitive coupling, inductive coupling, or conductive coupling from one circuit or channel to another. In some embodiments, the braided sheath may be configured to protect against unwanted electromagnetic transmissions traveling into and / or from the shaft 120.

[0024] Figures 2A and 2B illustrate an exemplary embodiment of the medical device 200. For example, Figure 2A shows the distal portion of the shaft 120, and Figure 2B shows a lateral cross-sectional view of a portion of the shaft 120. Although not shown, the distal portion of the shaft 120 may be connected to an end cap (e.g., end cap 126) as described above. The shaft 120 includes a braided sheath 230 that is coaxial with the shaft 120. The shaft 120 may further include an external insulating layer 239 that covers (e.g., radially surrounds) the braided sheath 230. The braided sheath 230 may have the same or all the same characteristics as the braided sheath 230 described above. The external insulating layer 239 may help limit or prevent the transmission of electricity from the braided sheath 230 and / or the shaft 120 to, for example, the environment (e.g., the patient's body). The outer insulating layer 239 may further be configured to limit or prevent electromagnetic interference from the environment to the braided sheath 230 and / or the shaft 120. The outer insulating layer 239 may extend from the proximal end 121 of the shaft 120 to the distal end 122 of the shaft 120. One or more conductors 131 of the braided sheath 230 may include one or more distal termination portions 235 extending beyond the distal termination portions 236 of a plurality of mechanical strands 133. The braided sheath 230 may include a flexible circuit 238 extending beyond the distal termination portions 236. The distal termination portions 235 may be housed within the flexible circuit 238, or otherwise electrically connected to the flexible circuit 238. In some embodiments, one or more conductors 131 may be connected to one or more copper traces (not shown) within the flexible circuit 238. In one or more embodiments, the flexible circuit 238 may be connected (e.g., plugged into) an electrical circuit or a compatible port (not shown) on a circuit board, electrically connected to an electrical device(s) on the end cap 126, or otherwise positioned at the distal end 122 of the shaft 120. In some embodiments, the shaft 120 may include a layer of insulation (not shown) between the outer surface of the shaft 120 and the braided sheath 230.

[0025] As shown in Figure 2A, one or more conductors 131 may include distal termination portions 235. One or more conductors 131 may converge to one distal termination portion 235, or each of the distal termination portions 235 may be included. A distal termination portion 235 is a portion of a conductor(s) 131 that extends distally beyond the distal termination portions 236 of a plurality of mechanical strands 133. In some embodiments, the distal termination portions 235 of a conductor(s) 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 portions 235 may be electrically connected to the electrical circuit(s) (not shown) or circuit board(s) of the end cap 126, and by extension to the electrical device of the end cap 126. The electrical circuitry or circuit board of the end cap 126 may be printed, 3D printed, chemically etched, mounted by laser direct structuring, or otherwise formed on or as the proximal opposing surface of the end cap 126 or any other surface of the end cap 126. In these embodiments, the electrical circuitry or circuit board of the end cap 126 is located inside the end cap 126 and may be electrically connected to one or more of, for example, a light 127, a camera 129, etc.

[0026] As shown in Figure 2A, the multiple mechanical strands 133 and one or more conductors 131 may be configured such that two or more of the conductors 131 intersect or otherwise overlap at predetermined points along the length of the braided sheath 230. The braided sheath 230 may be sized such that the distal ends 236 of the multiple mechanical strands 133 are positioned at two or more intersections or convergences 234 of the conductors 131. This configuration may help to allow the distal ends 235 of two or more conductors 131 to be easily housed or connected by the flexible circuit 238 and end caps 126, further minimizing the length of the circuit between the distal ends 236 and electrical devices located at or near the distal end 122 of the shaft 120. Minimizing the length of the circuit between the distal ends 236 and electrical devices can prevent the electrical wires from becoming densely packed at or near the distal end 122 of the shaft 120.

[0027] In one or more embodiments, the distal end portion 235 may be housed within a flexible circuit 238 or electrically connected to the flexible circuit 238. In some embodiments, the flexible circuit 238 may be a card-edge type flat flexible circuit that can be electrically connected to one or more electrical devices, or alternatively, electrically connected to the end cap 126 as described above. The flexible circuit 238 may extend distally from the distal end portion 236 of a plurality of mechanical strands 133. In some embodiments, the distal end portion 235 may contain 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, or be electrically connected to one or more flexible substrates (not shown) that are electrically connected to the one or more electrical devices. The one or more flexible substrates may be routed as needed within the end cap 126 to position the one or more electrical devices in desired locations.

[0028] One or more conductors 131 may include a proximal termination portion (not shown). One or more conductors 131 may converge to one proximal termination portion, or each may include its own proximal termination portion. A proximal termination portion is a portion of a conductor(s) 131 that extends proximal beyond the proximal termination portions 137 (Figure 1) of a plurality of mechanical strands 133. The proximal termination portion may be, for example, a power supply, a controller, a display, and other handle components known to those skilled in the art, but may be directly connected to the handle components of the handle 110. In some embodiments, the proximal termination portion may include the handle components of the handle 110 or be electrically connected to one or more flexible substrates (not shown) that are electrically connected to the handle components of the handle 110. In one or more embodiments, the proximal termination portion may be housed in or electrically connected to a flexible circuit (not shown), such as a card-edge type flat flexible circuit, which can be electrically connected to the handle components of the handle 110. In some embodiments, one or more conductors 131 may be connected to one or more copper traces in the flexible circuit. The flexible circuit may extend near the proximal terminations 137 of multiple mechanical strands 133. One or more conductors 131 may be electrically and / or communically connected to one or more elements within the umbilicus 114, for example, to one or more power supplies, controllers, displays, etc.

[0029] It should be understood that one or more conductors of the various braids shown in Figures 1, 4, 5, 6, 7, and 8 may include a distal termination portion and distal connection portion, as well as a proximal termination portion and proximal connection portion, similar to those described in the previous paragraph.

[0030] Figures 3A and 3B show another exemplary embodiment of the medical device 300. The shaft 120 includes a lap layer 350 coaxial with the shaft 120. The lap layer 350 may be used to create an electrical conduit, such as an electrical ground, but is not limited to this. The lap layer 350 may be used in addition to the braided sheath 230. The lap layer 350 may be used to transmit high-speed differential signals requiring inter-pair and intra-pair matching. Alternatively, or in addition, the lap layer 350 may be used for impedance control. The lap layer 350 may extend from the proximal end 121 (Figure 1) of the shaft 120 to the distal end 122 of the shaft 120. The shaft 120 may further include an insulating layer 339 covering (e.g., radially surrounding) the lap layer 350. The insulating layer 339 may extend from the proximal end 121 (Figure 1) of the shaft 120 to the distal end 122 of the shaft 120. The lap layer 350 may accommodate 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 magnet wires, etc. In some embodiments, the one or more conductors 331 may be one or more cable assemblies, such as one or more coaxial cables, one or more shielded twin-axial cables, and one or more ribbon cable assemblies, etc. The one or more conductors 331 may have any of the features of 131, 431A, 431B, 531, 631A, 631B, 731A, 731B, 831A, 831B. In some embodiments, the shaft 120 may include an insulating layer (not shown) between the outer surface of the shaft 120 and the lap layer 350.

[0031] The lap layer 350 may include a ground layer. The ground layer may be located on either the inner or outer surface of the lap layer 350, and one or more conductors 331 may be located on the other of the inner or outer surfaces of the lap layer 350. In some embodiments, one or more conductors 331 may be two or more conductors of matched length configured to transmit high-speed signals. It should be understood that length matching is necessary for certain high-speed signals. As shown in Figure 3A, one or more conductors 331 may extend linearly along the length of the lap layer 350. However, one or more conductors 331 are not limited to extending linearly along the lap layer 350. Alternatively, one or more conductors 331 may be wrapped around the surface of the lap layer 350, for example, clockwise or counterclockwise, similar to one or more conductors in the various braided sheaths disclosed herein.

[0032] One or more conductors 331 of the lap layer 350 may electrically connect and / or communicate with an electrical device positioned at or near the distal end 122 or end cap 126 of the shaft 120. The lap layer 350 may also help limit electromagnetic radiation to and from the shaft 120, as well as electromagnetic interference to and from the shaft 120. In some embodiments, the conductor(s) 331 include electrical grounding. One or more conductors 331 of the lap layer 350 may be electrically connected to a medical device at least partially received within the working channel 123 of the shaft 120. The conductor(s) 331 of the lap layer 350 may help facilitate electrical connection and / or communication between the handle components in the handle 110 and the medical device at least partially received within the working channel 123.

[0033] The distal termination portions 335 of one or more conductors 331 may extend beyond the distal termination portion 351 of the lap layer 350, or they may extend within 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 portions 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 portions 335 may be electrically connected to an electrical circuit (not shown) or circuit board (not shown) of the end cap 126 (Figure 1), and the electrical circuit or circuit board may then be electrically connected to an electrical device of the end cap 126 (Figure 1).

[0034] The electrical circuit or circuit board of the end cap 126 may be printed, 3D printed, chemically etched, or mounted by laser direct structuring on the proximal opposing surface of the end cap 126 or any other surface of the end cap 126. In one or more embodiments, the distal end portion 335 may be housed within a flexible circuit 338 or electrically connected to the flexible circuit 338. In some embodiments, the flexible circuit 338 may be a card-edge type flat flexible circuit that can be electrically connected to one or more electrical devices as described above, or alternatively, electrically connected to the end cap 126. The flexible circuit 338 may extend distally from the distal end portion 351 of the wrap layer 350. In some embodiments, the distal end portion 335 may contain 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, or electrically connected to one or more flexible substrates (not shown) that are electrically connected to said one or more electrical devices. One or more flexible substrates may be routed as needed within the end cap 126 to position one or more electrical devices in desired locations.

[0035] One or more conductors 331 of the lap layer 350 may include a proximal termination portion (not shown). One or more conductors 331 may converge to one 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 proximal to the proximal termination portion (not shown) of the lap layer 350. The proximal termination portion may be directly connected to components of the handle 110, such as, but not limited to, power supplies, controllers, displays, and other handle components known to those skilled in the art. In some embodiments, the proximal termination portion may be electrically connected to one or more flexible substrates (not shown) that include components of the handle 110 or are electrically connected to components of the handle 110. In one or more embodiments, the proximal termination portion may be housed in or electrically connected to a flexible circuit (not shown), such as a card-edge type flat flexible circuit, which can be electrically connected to the handle components of the handle 110. In some embodiments, one or more conductors 331 may be connected to one or more copper traces in the flexible circuit. The flexible circuit may extend near the proximal termination of the wrap layer 350. One or more conductors 331 may be electrically and / or communically connected to one or more elements within the umbilicus 114, for example, to one or more power supplies, controllers, displays, etc.

[0036] It should be understood that including one or more conductors 331 within the wrap layer 350 rather than within the shaft 120 may help to increase the size (e.g., cross-sectional area) of one or more of the working channels 123 and opening 128 in the end cap 126, as well as the fluid channels in the shaft 120 and the corresponding fluid channels 124, 125 in the end cap 126. One or more larger channels may help to allow larger medical instruments to be received therein, larger volumes of fluid, and greater suction capacity. In addition, including one or more conductors 331 within the wrap layer 350 may help to allow one or more additional working channels and fluid channels to be placed within the shaft 120, and / or the diameter of the shaft 120 to be smaller.

[0037] In some embodiments, one of the braided sheaths 130, 230, 430, 530, 630, 730, and 830 may be arranged to cover the lap 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, the conductors of the braided sheath and the conductors of the lap layer 350 may extend distally into the flexible circuit 338, one or more flexible substrates, or be electrically connected to the end cap 126 or a medical device. One or more flexible substrates may be routed as needed within the end cap 126 to position one or more electrical devices in desired locations. At the proximal end 121 of the shaft 120, the conductors of the braided sheath and the conductors of the lap layer 350 may extend proximal into the flexible circuit, one or more flexible substrates, or be electrically connected to components of the handle 110.

[0038] Figures 4A and 4B show yet another exemplary medical device 400, combining embodiments of the exemplary medical device 200 disclosed in Figures 2A and 2B with embodiments of the medical device 300 disclosed in Figures 3A and 3B. The shaft 120 includes a braided sheath 430. The braids 432 of the braided sheath 430 may include a plurality of mechanical strands 133 and one or more conductors 431A. The distal end portions 435 of one or more conductors 431A may extend into a flexible circuit 438. The braided sheath 430 may have some or all of the same features as the braided sheath 230 and / or braided sheath 130 described above. The shaft 120 further includes an inner insulating layer 440 covering (e.g., radially surrounding) the braided sheath 430. The inner layer 440 of the insulator may extend from the proximal end 121 (Figure 1) of the shaft 120 to the distal end 122 of the shaft 120. The shaft 120 further includes a first polyimide layer 460 covering (e.g., radially surrounding) the inner layer 440 of the insulator. 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 (Figure 1) of the shaft 120 to the distal end 122 of the shaft 120. In this disclosure, the first polyimide layer 460 and the second polyimide layer 461 may be collectively referred to as a polyimide wrap layer, i.e., the polyimide wrap layer may include or comprise multiple layers. The polyimide wrap layer may be used to transmit high-speed differential signals requiring inter-pair and intra-pair matching. The shaft 120 further includes an insulating outer layer 439 covering (e.g., radially surrounding) the second polyimide layer 461. The shaft 120 may include an insulating intermediate layer 462 between the first polyimide layer 460 and the second polyimide layer 461. It should be understood that, in addition to the insulating layers already described, the shaft 120 may include an additional insulating layer outside the second polyimide layer 461 and / or inside the first polyimide layer 460. In some embodiments, the shaft 120 may include an insulating layer (not shown) between the outer surface of the shaft 120 and the braided sheath 430.

[0039] In one or more embodiments, one of the first polyimide layer 460 or the second polyimide layer 461 may contain 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 placed on either the inner surface or the outer surface of the polyimide layer, and the one or more conductors 431B may be placed on the other of the inner surface or the outer surface of the polyimide layer.

[0040] As shown in Figure 4A, one or more conductors 431A, 431B and one of the polyimide layers 460, 461 of the braided sheath 430 may include a distal termination portion 435. The one or more conductors 431A, 431B may converge into 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(s) 431A, 431B that extends distally beyond the distal termination portions 436 of the multiple mechanical strands 133. In some embodiments, the distal termination portions 435 of the conductor(s) 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(s) 435 may be electrically connected to an electrical circuit(s) or circuit board(s)(s) of the end cap 126 (Figure 1), which may then be electrically connected to an electrical device of the end cap 126 (Figure 1). The electrical circuit(s) or circuit board(s) of the end cap 126 may be printed, 3D printed, chemically etched, or mounted by laser direct structuring on the proximal opposing surface of the end cap 126 or any other surface of the end cap 126. In one or more embodiments, the distal termination portion(s) 435 may be housed within a flexible circuit 438 or electrically connected to a flexible circuit 438. In some embodiments, one or more conductors 431A, 431B may be connected to one or more copper traces(s)(s) within the flexible circuit 438. In some aspects, the flexible circuit 438 may be a card-edge type flat flexible circuit that can be electrically connected to one or more electrical devices as described above, or alternatively, electrically connected to the end cap 126. The flexible circuit 438 may extend distally from the distal ends 436 of the multiple mechanical strands 133.In some embodiments, the distal end portion 435 may contain 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, or may be electrically connected to one or more flexible substrates (not shown) electrically connected to the one or more electrical devices. The one or more flexible substrates may be routed as needed within the end cap 126 to position the one or more electrical devices in desired locations.

[0041] As described above, one or more conductors 431A, 431B and one of the polyimide layers 460, 461 of the braided sheath 430 may include a proximal termination portion (not shown). One or more conductors 431A, 431B may converge into one proximal termination portion, or each may include its own proximal termination portion. The proximal termination portion is a portion of conductors 431A, 431B that extend proximal beyond the proximal termination portions 137 (Figure 1) of a plurality of mechanical strands 133. The proximal termination portion may be directly connected to components of the handle 110, such as, but not limited to, power supplies, controllers, displays, and other handle components known to those skilled in the art. In some embodiments, the proximal termination portion may include handle components of the handle 110, or may be electrically connected to one or more flexible substrates (not shown) electrically connected to handle components of the handle 110. In one or more embodiments, the proximal termination portion may be housed in or electrically connected to a flexible circuit (not shown), such as a card-edge flat flexible circuit, which can be electrically connected to the components of the handle 110. In some embodiments, one or more conductors 431A, 431B may be connected to one or more copper traces in the flexible circuit. The flexible circuit may extend proximal to the proximal termination portion 137 of a plurality of mechanical strands 133. One or more conductors 431A, 431B may be electrically and / or communically connected to one or more elements in the umbilicus 114, for example, to one or more power supplies, controllers, displays, etc.

[0042] The aforementioned layered arrangement of the braided sheath 430, the inner insulator layer 440, the first polyimide layer 460, the intermediate insulator layer 462, the second polyimide layer 461, and the outer insulator layer 439 can help provide numerous advantages. For example, the layered arrangement can help facilitate the separation of conductors that require impedance control from those that do not. Conductors(s) requiring impedance control (e.g., one or more conductors 431B) may be placed in either the first polyimide layer 460 or the second polyimide layer 461, and the remaining polyimide layers not containing conductors(s) requiring impedance control may be continuous ground surfaces. Conductors(s) not requiring impedance control (e.g., one or more conductors 431A) may be woven within the braided sheath 430. Separation may be required 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 grounding. The grounding distance to one or more conductors 431B and the dielectric constant of the polyimide contribute to the impedance of one or more conductors 431B. Non-impedance-controlled conductors (e.g., one or more conductors 431A) may be woven into the braid 432 as they do not require a solid grounding reference. The first polyimide layer 460 and the second polyimide layer 461 may be thin and flexible, for example, to have minimal mechanical impact on the shaft 120. It should be understood that one or more conductors 431A, 431B may have any of the characteristics of one or more conductors 131, 331, 531, 631A, 631B, 731A, 731B, 831A, 831B.

[0043] In some embodiments, one or more conductors 431B may be two or more conductors of matched length configured to transmit high-speed signals. It should be understood that length matching is necessary for certain high-speed signals. As shown in Figure 4A, one or more conductors 431B may run linearly along the polyimide layer (e.g., within the first polyimide layer 460). However, one or more conductors 431B are not limited to running linearly along or within the polyimide layer, but may instead be wound around the surface of or within the polyimide layer in a clockwise or counterclockwise manner, for example, as one or more conductors in the various braided sheaths disclosed herein.

[0044] Figure 5 shows one embodiment of an exemplary medical device including a braided sheath 530. The braided sheath 530 includes at least one conductor 531. Conductor 531 may include two conductors 531A and 531B that are intertwined together. Conductors 531A and 531B may be braided clockwise or counterclockwise around the braid 532. Conductor 531 may be a twisted pair of conductors.

[0045] Another embodiment of an exemplary medical device is shown in Figure 6. 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 twin axial cables. The conductors 631A and 631B may be intertwined together and braided clockwise or counterclockwise around a braid 632.

[0046] Figure 7 shows one embodiment of an exemplary medical device. 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, 731A may be woven together 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, arranging one of the conductors 731A, 731B to proceed clockwise around the braid 732 with respect to the longitudinal axis of the shaft 120, and arranging the other of the conductors 731A, 731B to proceed counterclockwise around the braid 732 may help limit the instances of parallelism between the two conductors 731A, 731B while allowing the conductors 731A, 731B to extend along the braided sheath 730.

[0047] Figure 8 shows another embodiment of an exemplary medical device. 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 are woven with a braid 832 and both may extend either clockwise or counterclockwise. The conductors 831A and 831B may be incorporated into the braid by an existing braiding machine by replacing one or more nonconductive strands with one or more conductors.

[0048] One aspect of the present disclosure is a method for manufacturing a braided sheath with one or more conductors, as described in the various aspects described above. Braided sheaths known in the art can be formed by the steps of: providing a plurality of spools of mechanical strands, each including a tip; positioning the spools of mechanical strands so that the tips of the spools of mechanical strands can be fed into the receiving end of a braiding machine; and operating the braiding machine to form the braided sheath. The braiding machine may be a horn gear braiding machine. The braided sheath can be formed by the steps of: providing a plurality of spools of mechanical strands; providing one or more spools of conductors, wherein the spools of mechanical strands and the spools of conductors each include a tip; positioning the spools of mechanical strands and the spools of conductors so that the tips of the spools can be fed into the receiving end of a braiding machine; and operating the braiding machine for the braided sheath. A method for manufacturing a braided sheath may further include the steps of arranging one or more spools of conductors so as to be wound counterclockwise with respect to a longitudinal axis defined by forming the braided sheath, and arranging one or more spools of conductors so as to be wound clockwise with respect to a longitudinal axis defined by forming the braided sheath. In one or more embodiments, the spools of conductors may be formed from one or more single-conductor wires, one or more insulated solid-core wires, one or more stranded wires, and the like. Alternatively, or in addition, the spools of conductors may include one or more cable assemblies, such as one or more coaxial cables and one or more shielded twin-axial cables, and combinations thereof.

[0049] As described above, removing electrical wires or cables from within the shaft and placing them within the various braided sheaths, wrap layers, and polyimide wrap layers disclosed herein may help enable larger lumens for larger instruments, more lumens for more instruments, more lumens for suction and delivery of different types of fluids, larger lumens for delivery of larger fluids, larger lumens for application of suction, smaller shaft / insertion portion diameters, and so on. Furthermore, the braided sheaths disclosed above may help reduce conductor parallelism by braiding one or more conductors clockwise and one or more other conductors counterclockwise. In addition, as shown in Figures 4A and 4B, the disclosure may help facilitate the separation of impedance-controlled and unimpedance-controlled conductors. Those skilled in the art will recognize the above-mentioned advantages as significant advances in the art.

[0050] A braided sheath, polyimide wrap layer, insulating layer, and wrap layer are shown in Figures 1 to 8 and described in this disclosure as covering an outer shaft (e.g., shaft 120), but the braided sheath, polyimide wrap layer, insulating layer, and wrap layer may be applied to an inner shaft (e.g., working channel 123) in the same or similar manner as described above with respect to shaft 120.

[0051] The principles of this disclosure are described herein with reference to exemplary examples for specific uses, but it should be understood that this disclosure is not limited thereto. Those skilled in the art and those accessing the teachings provided herein will recognize that additional modifications, uses, embodiments, and substitutions of equivalents all fall within the scope of the features described herein. Therefore, the claimed features should not be considered limited by the foregoing description.

Claims

1. shaft and A braided sheath that is coaxial with the shaft and extends along the shaft at least between the distal end and the proximal end of the shaft Equipped with, The aforementioned braided sheath includes a braid, and the braid is Multiple mechanical strands and At least one conductor is electrically connected to and / or communicatively connected to a first electrical device located at or near the distal end of the shaft. Medical devices, including those mentioned above.

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

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

4. The medical device according to claim 2, wherein both the first conductor and the second conductor are braided either 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, and the medical device is at least partially received by the lumen of the shaft.

7. The medical device according to any one of claims 1 to 6, 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 claims 1 to 9, wherein the braided sheath includes a polyimide wrap layer that covers the braided sheath and extends coaxially with the braided sheath.

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

12. The medical device according to claim 11, wherein the first layer is a continuous contact surface.

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

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