Flexible PCB Cable Assembly for Catheter Navigation
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Solution Overview
Problem
The manual process of connecting multiple wires along a catheter is labor-intensive and challenging due to the complex geometry of tight areas that catheters must navigate, requiring a more flexible and efficient electrical connection solution.
Innovation Solution
A flexible Printed Circuit Board (PCB) cable assembly is used, featuring multiple conductive traces and through slits cut between the traces, allowing for increased flexibility and ease of connection, potentially reducing manufacturing costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple wires are used to provide electrical connections along the catheter, then flexibility is improved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
Multiple separate wires are merged into a single integrated flexible PCB structure. The PCB contains multiple conductive traces that replace multiple individual wires, consolidating what would be separate connection elements into one unified component. This reduces manufacturing complexity while maintaining the electrical connection functionality.
Solution Approach 2:
The flexible PCB is segmented into multiple conductive traces that are electrically isolated from each other. Each trace functions independently like a separate wire, but they are all integrated into a single flexible substrate. This segmentation allows the PCB to replace multiple wires while maintaining individual trace functionality.
2Reliability
If multiple wires are connected at each end of the catheter, then electrical connectivity is achieved, but connection difficulty increases due to small footprint
Solution Approach 1:
Multiple connection points are merged into integrated connection pads on the flexible PCB. Instead of connecting multiple separate wires at each end, the PCB provides consolidated pads that simplify the connection process while maintaining electrical connectivity to all necessary points.
3Ease of operation
If through cuts are made along the flexible PCB between traces, then flexibility is improved, but structural integrity may be compromised
Solution Approach 1:
The flexible PCB is segmented by making through cuts between the conductive traces. These cuts divide the PCB into sections that can flex and bend more easily, particularly when the catheter needs to navigate tight or complex geometries. The segmentation is performed in the non-conductive areas between traces, preserving electrical integrity while improving mechanical flexibility.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A catheter with a distal end assembly, an elongate flexible PCB (Printed Circuit Board) being housed within a shaft of the catheter, the elongate flexible PCB extending substantially along a full length of the shaft and including a PCB distal portion including a plurality of electrical connection pads, a PCB proximal portion including a plurality of conductive traces corresponding to the plurality of electric connection pads of the PCB distal portion, a PCB median portion including a plurality of conductive traces laid longitudinally along more than 75% of a length of the elongate flexible PCB, the conductive traces continuing the conductive traces of the PCB proximal portion and electrically connected to the plurality of electrical pads of the PCB distal portion, and a plurality of slits cutting through the PCB median portion between the conductive traces and extending along the conductive traces. Related apparatus and methods are also described.