Flexible Circuit Electrode Spline for High Density Catheter

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Solution Overview

Problem

Existing electrode assemblies for catheters, such as basket and planar catheters, face limitations in electrode density due to the number of splines and electrodes, and often apply positioning force on only one side, making it difficult to deploy in smaller target locations and limiting the precision of mapping and ablation procedures.

Innovation Solution

The method involves forming splines for electrode assemblies by coupling electrodes directly to structural members via flexible circuit substrates, allowing electrodes to be disposed on both surfaces of a single spline, thereby increasing electrode density and enabling more precise positioning force application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the number of splines is increased to increase electrode density, then the electrode density is improved, but the diameter of the electrode basket increases making it more difficult to deploy in smaller target locations

Engineering Contradiction:

Improveelectrode densityVSAvoidbasket diameter

Core Design Contradiction:

Quantity of substanceVSVolume of moving object

Solution Approach 1:

The patent applies this principle by placing electrodes on both sides of each spline structure, effectively utilizing two-dimensional space on the spline surfaces. This allows doubling the electrode count without increasing the number of splines or the overall basket diameter, thereby resolving the contradiction between electrode density and basket size.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent embeds electrodes within the three-dimensional structure of the splines by positioning them on both external surfaces of each spline. This nesting approach maximizes the use of available space within the existing basket geometry, increasing electrode density without expanding the outer dimensions.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Volume of moving object

If narrower splines are used to maintain the diameter of the electrode basket, then the basket diameter is maintained, but the electrode size is limited reducing electrode density

Engineering Contradiction:

Improvebasket diameterVSAvoidelectrode density

Core Design Contradiction:

Volume of moving objectVSQuantity of substance

Solution Approach 1:

The patent overcomes the limitation of narrow spline width by utilizing both sides of each spline for electrode placement. This two-sided configuration effectively doubles the available surface area for electrodes on each spline, maintaining basket diameter while significantly increasing electrode density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Device complexity

If electrodes are disposed on only one side of each spline, then the structure is simple, but the electrode density is limited

Engineering Contradiction:

Improvespline structure complexityVSAvoidelectrode density

Core Design Contradiction:

Device complexityVSQuantity of substance

Solution Approach 1:

The patent transitions from single-sided to double-sided electrode configuration on each spline. This utilizes the third dimension (both faces of the spline) to place electrodes, effectively doubling the electrode capacity without fundamentally changing the spline structural design, thus maintaining simplicity while increasing density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Device complexity

If positioning force is applied on only one side of the catheter, then the structure is simple, but the positioning precision is limited

Engineering Contradiction:

Improveforce application structureVSAvoidpositioning precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent applies counterbalancing forces by positioning electrodes and applying forces on both sides of the catheter structure. This creates balanced opposing forces that improve positioning stability and precision, counteracting the limitations of single-sided force application while maintaining structural simplicity.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Data Source

PatentUS20230190198A1Methods for forming a spline using a flexible circuit assembly and electrode assemblies including same

Publication Date: 2023.06.22 ST JUDE MEDICAL CARDILOGY DIV INC

AI summary

A method of forming a spline for an electrode assembly includes providing a structural member including a first surface and a second surface. The method also includes providing a flexible circuit assembly including a plurality of electrodes and at least one flexible circuit substrate having a contact surface and an outer surface opposite the contact surface. The plurality of electrodes are disposed on the outer surface of the at least one flexible circuit substrate. The method includes positioning the flexible circuit assembly relative to the structural member such that a first set of electrodes is aligned with the first surface and a second set of electrodes is aligned with the second surface. The method also includes coupling the at least one flexible circuit substrate to at least one of the structural member and the at least one flexible circuit substrate.