Flex Circuit Around Core Wire for Guidewire Torque Response
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Solution Overview
Problem
Existing intravascular guidewires with fine-gauge electrical wires are prone to damage during manufacturing due to their delicate nature, leading to poor electrical connectivity and increased space occupancy, which affects the device's mechanical performance and torque response.
Innovation Solution
The use of flex circuits around the core wire, which are formed separately and applied to the guidewire, provides improved electrical and mechanical performance by reducing damage, allowing for a larger outside diameter and lower electrical resistance, and eliminating issues associated with multi-filar bundle handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fine-gauge electrical wires are used for sensor transmission, then electrical connectivity is achieved, but the wires are prone to damage during manufacturing and have circular cross-section occupying space with small outer diameter
Solution Approach 1:
The patent replaces traditional fine-gauge electrical wires with a flex circuit that has a flat profile. This substitution eliminates the circular cross-section wires that are difficult to handle during manufacturing, while maintaining electrical connectivity through conductive traces on the flex circuit substrate.
Solution Approach 2:
The patent employs a flex circuit with a flat, thin-film structure instead of traditional wires. The flex circuit includes a flexible substrate with conductive traces that provide electrical connectivity while being easier to manufacture and less prone to damage during handling.
2Reliability
If circular cross-section wires are used, then electrical connectivity is provided, but they occupy space with very small outer diameter affecting mechanical performance
Solution Approach 1:
The patent transitions from circular cross-section wires to a flat-profile flex circuit. This dimensional change from circular to flat geometry reduces the space occupied by the electrical connection system while maintaining connectivity, allowing for a larger outside diameter distal core wire.
3Reliability
If multi-filar bundles are used for electrical connection, then electrical communication is achieved, but they add stiffness and local torques affecting straightness and torque response
Solution Approach 1:
The patent uses a flat-profile flex circuit instead of multi-filar bundles. The flex circuit's thin-film structure provides electrical communication without adding the stiffness and local torques that multi-filar bundles introduce, thereby improving the device's straightness and torque response characteristics.
4Reliability
If larger outside diameter core wire is used, then electrical resistance is reduced, but space occupancy increases
Solution Approach 1:
The patent employs a flat-profile flex circuit that allows for a larger outside diameter distal core wire by eliminating the space occupied by circular cross-section wires. This dimensional change enables lower electrical resistance while managing the overall device profile effectively.
Data Source
AI summary
An intraluminal device includes a flexible elongate member configured to be positioned within a body lumen of a patient. The flexible elongate member includes a distal portion comprising a distal core member and a sensor. The distal core member includes a length between a distal end and a proximal end. The flexible elongate member includes a proximal portion comprising a proximal electrical conductor. The flexible elongate member includes a flex circuit positioned around a majority of the length of the distal core member. The flex circuit includes a distal portion coupled to the sensor and a proximal portion coupled to a proximal electrical conductor such that the proximal electrical conductor is in electrical communication with the sensor via the flex circuit.