Intraluminal Flex Circuit for Durable Guidewire Sensor Connections
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Solution Overview
Problem
Existing intravascular guidewires with sensors face issues of fine-gauge electrical wires being prone to damage during handling, leading to poor electrical connectivity and increased manufacturing complexity due to their delicate nature and circular cross-section.
Innovation Solution
The use of flex circuits, which are formed separately and applied to the guidewire, providing a flatter profile and thicker polymer coating, reducing damage and improving electrical/mechanical performance by eliminating the need for multi-filar bundles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fine-gauge electrical wires with circular cross-section are used, then electrical connectivity is achieved, but the wires are prone to damage during handling and have limited space due to small outer diameter
Solution Approach 1:
The patent replaces traditional fine-gauge circular electrical wires with a flex circuit that has a flat profile. The flex circuit consists of a flexible substrate with conductive traces formed on its surface, eliminating the need for circular cross-section wires. This flat configuration provides mechanical durability while maintaining electrical connectivity, directly resolving the contradiction between reliability and susceptibility to damage during handling.
2Reliability
If fine-gauge electrical wires are used, then electrical connection is provided, but manufacturing complexity increases due to delicate nature requiring careful handling
Solution Approach 1:
The flex circuit with its flat profile and integrated conductive traces eliminates the need for delicate multi-filar bundles. The flexible substrate provides structural support and electrical pathways in a single integrated component, significantly simplifying the manufacturing process by reducing the number of delicate parts that require careful assembly and handling.
3Reliability
If multi-filar bundles are used, then electrical communication is achieved, but the circular cross-section occupies space and limits outside diameter
Solution Approach 1:
The patent transitions from a three-dimensional circular cross-section configuration to a two-dimensional flat profile configuration. The flex circuit lays out conductive traces on the surface of a flexible substrate, effectively moving the electrical communication pathways from a volumetric circular arrangement to a planar arrangement. This dimensional change reduces the outside diameter while maintaining electrical communication capability.
4Reliability
If ribbons or multi-filar conductor bundles are used, then electrical connection is provided, but they add stiffness and local torques to the guidewire
Solution Approach 1:
The flex circuit's flat, thin-profile construction provides electrical connection without the bulk and stiffness of traditional ribbons or multi-filar bundles. The flexible substrate allows the circuit to conform to the guidewire's curvature and movement, eliminating unwanted stiffness and local torques while maintaining reliable electrical connection between the sensor and proximal connector.
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 proximal portion comprising a proximal core member and a proximal electrical conductor. The proximal core member includes a distal end. The flexible elongate member includes a distal portion coupled to the proximal portion, wherein the distal portion comprises a distal core member, a sensor, and a distal electrical conductor coupled to the sensor. The distal core member includes a proximal end. The flexible elongate member includes a flex circuit positioned over the distal end of the proximal core member and the proximal end of the distal core member. The flex circuit includes a proximal portion coupled to the proximal electrical conductor and a distal portion coupled to the distal electrical conductor such that the proximal electrical conductor is in electrical communication with the sensor via the flex circuit and the distal electrical conductor.