Flexible Catheter Circuit Layout for Uniform Electrode Placement
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Solution Overview
Problem
Current electrophysiology catheters face challenges in efficiently manufacturing multiple catheter tips with precise electroplated domes, particularly in achieving uniform electrode placement and effective energy delivery for ablation procedures.
Innovation Solution
A flexible circuit design for catheter tips is introduced, comprising a first segment with a base section and a second segment with a lateral wall section, along with a transition section and multiple electrode regions. This design allows for a non-planar configuration that optimizes electrode placement and energy delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for catheter tips, then production process is simpler, but manufacturing precision of electrode placement deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming the dome structure and electrode positions on a mold before electroplating. The mold includes pre-positioned electrode structures that guide precise electrode placement during the electroplating process, ensuring accurate electrode positioning without requiring complex post-processing adjustments.
Solution Approach 2:
The patent uses a mold as an intermediary tool that transfers the precise dome geometry and electrode positions to the catheter tip during electroplating. The mold acts as a mediator between the manufacturing process and the final product, ensuring consistent and precise electrode placement across multiple catheter tips produced in batches.
2Productivity
If multiple catheter tips are manufactured simultaneously, then productivity increases, but manufacturing precision of uniform electrode placement deteriorates
Solution Approach 1:
The patent applies universality by designing a single mold that can produce multiple catheter tips simultaneously through batch electroplating. The mold is configured with multiple cavity structures that each form a complete catheter tip with precisely positioned electrodes, enabling consistent production of multiple uniform products in one manufacturing cycle.
3Reliability
If complex non-planar configurations are used for flexible circuits, then energy delivery effectiveness improves, but ease of manufacture deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming the non-planar dome configuration and integrating the flexible circuit onto the molded dome structure before final assembly. The mold creates the three-dimensional dome shape with pre-positioned circuit traces and electrode connections, eliminating the need for complex post-molding circuit fabrication and assembly steps.
Data Source
AI summary
A flexible circuit including a first segment including a base section of the flexible circuit; a second segment including a lateral wall section; a transition section between the base and lateral wall sections, the transition section being at least partially positioned adjacent a shared region of the base and lateral wall sections; and one or more electrode regions including a respective electrode, the one or more electrode regions being positioned at least partially in the transition section and the second segment.