Flexible Catheter Circuit Layout for Easier Testing and Assembly
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Solution Overview
Problem
The complexity and cost of manufacturing small form-factor electronic components for intravascular catheters are increased due to their small size, which complicates the integration of electronic components like ultrasound transducers and electronics packages within the catheter tips.
Innovation Solution
A flexible electronic circuit design featuring a plurality of leaves with bonded proximal and distal sections and loose intermediate sections, equipped with conductive connector pads and test connector pads, allows for the integration of ultrasound transducers and electronics packages, and includes a method of manufacturing that simplifies the connection and testing of these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If small form-factor electronic components are used in catheter tips, then the catheter size is reduced, but the manufacturing complexity and cost increase
Solution Approach 1:
The circuit is divided into multiple leaves that are bonded together in sections. The proximal and distal sections have leaves bonded together to form a compact structure, while the intermediate section has loose leaves that can be fanned out to provide access to connection points, enabling modular assembly and testing
Solution Approach 2:
The circuit transitions from a two-dimensional planar layout to a three-dimensional structure by bonding leaves together in stacked configurations at the proximal and distal ends, while maintaining loose leaves in the intermediate section for connection access
2Volume of moving object
If small form-factor electronic components are used in catheter tips, then the catheter size is reduced, but the manufacturing cost increases
Solution Approach 1:
The leaves are pre-bonded in proximal and distal sections during manufacturing, creating a compact structure that simplifies subsequent assembly. Test connection points are also pre-positioned on the loose intermediate leaves, enabling efficient testing before final catheter assembly
Solution Approach 2:
The loose intermediate leaves automatically provide access to connection points and test pads without requiring additional manipulation or disassembly steps, allowing self-contained testing and connection operations
3Strength
If leaves are bonded together throughout the entire circuit, then structural integrity is improved, but flexibility and access to connection points are reduced
Solution Approach 1:
Different sections of the circuit have different bonding characteristics: proximal and distal sections have leaves bonded together for structural integrity, while the intermediate section has loose leaves for flexibility and connection access
4Adaptability or versatility
If leaves are kept loose throughout the entire circuit, then flexibility is improved, but structural integrity and compactness are reduced
Solution Approach 1:
Different sections of the circuit have different bonding characteristics: proximal and distal sections have leaves bonded together for structural integrity, while the intermediate section has loose leaves for flexibility and connection access
Data Source
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AI summary
A flexible electronic circuit includes a plurality of leaves having a proximal section, a distal section, and an intermediate section. The plurality of leaves are bonded to each other within the distal section and loose within the the intermediate section. The intermediate section also includes conductive connector pads for a wiring harness. A plurality of test connector pads are disposed on the plurality of leaves within the proximal section. The leaves within the proximal section may also be bonded to each other, for example in a ribbon or stepped configuration, in order to facilitate connection to testing apparatus. Once the circuit is tested, the proximal section can be served from the intermediate section prior to installation of the circuit into a medical device, such as an intracardiac echocardiography catheter.