Curved Flex Substrate for IVUS Catheter Strain Relief

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Solution Overview

Problem

Existing solid-state IVUS catheters face challenges with electrical cable attachment causing operational harm to electronic components, increased stiffness, and weak points due to rigidity differences, leading to potential material failure and breakage, especially during bending.

Innovation Solution

Intraluminal ultrasound imaging devices with flexible substrates featuring strain relief designs, including curved paths and conductive traces that minimize fracturing by accommodating bending, such as horseshoe, serpentine, or braided patterns, to ensure electrical connectivity and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical cable is attached close to electronic components, then electrical connection is achieved, but electronic components may be harmed and catheter stiffness increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidharm to electronic components

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The catheter is divided into distinct sections: a flexible distal section with the imaging assembly and a more proximal section with the cable attachment. This segmentation allows the cable to be attached away from sensitive electronic components while maintaining electrical connectivity, thus preventing harm to components and reducing stiffness at critical locations.

Inventive Principle:

Principle #1Segmentation

2Reliability

If electrical cable is attached close to electronic components, then electrical connection is achieved, but catheter flexibility is reduced

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidcatheter flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

3Reliability

If rigid distal imaging assembly is connected to flexible catheter body, then imaging functionality is achieved, but weak points are created susceptible to kinks and breaks

Engineering Contradiction:

Improveimaging functionalityVSAvoidresistance to kinks and breaks

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The imaging assembly is mounted on a flexible substrate that can bend and flex, allowing the rigid imaging components to be supported while the substrate absorbs mechanical stress. This flexible mounting approach prevents stress concentration at the connection point, reducing susceptibility to kinks and breaks while maintaining imaging functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

4Device complexity

If flex circuit is rolled into cylindrical shape, then compact imaging assembly is achieved, but manufacturing automation becomes difficult

Engineering Contradiction:

Improveimaging assembly compactnessVSAvoidmanufacturing automation

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The flex circuit is pre-formed with an intermediate curved region that anticipates the final cylindrical configuration. This preliminary shaping allows the circuit to be automatically formed during manufacturing without requiring complex post-assembly rolling operations, thus maintaining compactness while simplifying manufacturing automation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12465329B2Curved circuit substrate for intraluminal ultrasound imaging assembly

Publication Date: 2025.11.11 KONINKLIJKE PHILIPS NV

AI summary

An intraluminal ultrasound imaging device includes a flexible elongate member and an ultrasound imaging assembly coupled to a distal portion of the flexible elongate member. The ultrasound imaging assembly includes a flexible substrate comprising a scanner body portion, one or more control circuits mounted on the scanner body portion, and one or more transducer elements mounted on the scanner body portion. The ultrasound imaging assembly also includes an attachment portion extending proximally from the scanner body portion. The attachment portion defines a path that curves in a first direction and different second direction, and includes a plurality of conductive traces in electrical communication with the one or more control circuits. The plurality of conductive traces follows the curved path of the attachment portion, and each conductive trace comprises a pattern that bends relative to the curved path of the attachment portion.