Deflectable Catheter Shaft With Nested Lumens And Unattached Coils
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Solution Overview
Problem
Existing electrophysiology catheters face challenges in transmitting torque and resisting compression during procedures, leading to potential loss of control and impaired tactile feedback due to frictional forces and spring-like energy storage, which can result in undesired catheter movement.
Innovation Solution
A deflectable catheter shaft section with a unique design featuring multiple closely spaced lumens lined with PTFE, a pull wire mechanism, and compression coils that are unattached to the catheter shaft, allowing for improved torque transmission and resistance to compression, enabling precise control and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If torque is transmitted through the catheter shaft, then the distal end can be positioned, but frictional forces cause the shaft to twist and store spring-like energy
Solution Approach 1:
The catheter shaft is divided into multiple discrete segments or sections, each capable of independent rotation or deflection. This segmentation allows torque to be transmitted in controlled increments rather than as continuous twisting, reducing energy storage and improving positional stability during navigation and procedure.
Solution Approach 2:
The catheter shaft incorporates dynamic elements such as articulated joints or flexible segments that allow controlled movement and energy dissipation. These dynamic features enable the shaft to adapt to frictional forces during advancement while maintaining operational control and preventing unwanted spring-like energy accumulation.
2Ease of operation
If the catheter shaft resists compression, then control is maintained, but excessive rigidity causes snaking and loss of tactile feedback
Solution Approach 1:
The catheter shaft employs varying local properties along its length, with more compliant sections near the distal tip for tactile feedback and navigation, and progressively stiffer sections toward the proximal end for control and compression resistance. This gradient in rigidity allows the shaft to resist overall compression while maintaining flexibility for operator feedback.
Solution Approach 2:
The shaft construction utilizes composite material structures combining elements of different mechanical properties, such as layered polymers or metal-polymer composites, to achieve optimized balance between compression resistance and flexibility. The composite structure provides controlled rigidity that prevents snaking while preserving tactile feedback capabilities.
3Volume of moving object
If multiple lumens are placed close together, then space is utilized efficiently, but manufacturing precision is required to maintain lumen integrity
Solution Approach 1:
The catheter shaft incorporates nested lumens where smaller lumens are positioned within or alongside larger lumens, maximizing space utilization within the catheter cross-section. This nesting arrangement allows multiple functional channels to coexist in close proximity while maintaining structural integrity through the hierarchical organization of lumens.
Solution Approach 2:
The multi-lumen shaft is constructed using composite material techniques that allow precise formation of multiple closely-spaced lumens within a single integrated structure. The composite manufacturing process ensures proper lumen spacing, wall thickness, and structural integrity even when lumens are positioned in close proximity to maximize space utilization.
Data Source
AI summary
A deflectable catheter shaft section is disclosed comprising an elongated body extending along a longitudinal axis and comprising a distal end and a proximal end; and a plurality of lumens extending along the longitudinal axis of the elongated body, wherein at least one of the lumens is abutting at least another one of the lumens. A catheter comprising the deflectable catheter shaft section and a method of manufacturing the deflectable catheter shaft section are also disclosed. A catheter incorporating a deflectable catheter shaft section can further comprise first and second compression coils disposed over pull wires located within the catheter, wherein the compression coils are unattached to the catheter or components thereof, but can be constrained by a shaft coupler at a distal end of each of the compression coils and by at least a portion of a handle assembly at a proximal end of each of the compression coils.