Flexible PCB Wrap for Medical Device Electrical Routing
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Solution Overview
Problem
The manufacturing process for medical devices like duodenoscopes and endoscopes is complicated and time-consuming due to the need to position multiple cables and wires through the lumens of the device, which also reduces the available space in these lumens.
Innovation Solution
A medical device design featuring a shaft with longitudinally extending lumens, a flexible printed circuit board (PCB) wrap around the outer surface of the shaft, and a distal end cap with electrical connections, allowing for efficient routing and connection of electrical components without occupying additional lumen space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables and wires are positioned through the lumens of the shaft, then electrical connections are achieved, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent moves the electrical connection system from the internal lumen space to the external surface of the shaft by wrapping the flexible PCB around the outer circumference. This dimensional transition eliminates the need to route cables through the lumens, thereby simplifying manufacturing and improving productivity while maintaining reliable electrical connections between the distal end cap and proximal handle
2Reliability
If cables and wires are positioned through the lumens of the shaft, then electrical connections are achieved, but the available space in the lumens is reduced
Solution Approach 1:
The patent extracts the electrical connection system from the lumen interior and relocates it to the external surface of the shaft. By removing the cables and wires from the lumen space and replacing them with an external flexible PCB wrap, the lumen volume is fully restored for its primary functions while electrical connections are maintained through the external circuit board
3Ease of manufacture
If a flexible printed circuit board wrap is used around the outer surface of the shaft, then manufacturing complexity is reduced and lumen space is increased, but device flexibility must be maintained
Solution Approach 1:
The patent employs a flexible printed circuit board wrapped around the shaft in a spiral or helical configuration. This thin film structure allows the shaft to bend and flex during use while maintaining electrical connections, as the flexible PCB can accommodate curvature changes without breaking or creating excessive tension
Data Source
AI summary
A medical device includes a shaft, a printed circuit board positioned around an outer surface of the shaft, and an end cap. The printed circuit board includes a plurality of electrical connections at a proximal end of the printed circuit board and another plurality of electrical connections at a distal end of the printed circuit board. The printed circuit board includes a plurality of communication conduits connecting electrical connections at the proximal end of the printed circuit board with respective electrical connections at the distal end of the printed circuit board. When the end cap is coupled to the shaft, (1) one or more cap lumens are in communication with one or more lumens in the shaft, and (2) the plurality of end cap electrical connections are electrically connected to the electrical connections at the distal end of the printed circuit board.