Flexible Sensor Arrays on Soft Catheters for Cardiac Mapping
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Solution Overview
Problem
Existing cardiac mapping and ablation devices face challenges in conforming to the complex anatomy of the heart chamber, leading to suboptimal outcomes due to limited spatiotemporal resolution and mechanical non-conformability, particularly in treating atrial fibrillation (AFib).
Innovation Solution
Development of soft robotic devices with flexible, stretchable circuits and multi-electrode sensor arrays that can conform to the heart chamber's structure, using scalable fabrication methods to integrate flexible circuits on soft actuators, allowing for precise mapping and sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional rigid cardiac mapping devices are used, then device structure is simple and manufacturing is easy, but the device cannot conform to the complex anatomy of the heart chamber, leading to suboptimal mapping precision
Solution Approach 1:
The patent employs flexible circuit boards with serpentine conductive traces and thin-film sensor arrays that can bend and conform to the complex three-dimensional geometry of the heart chamber. The flexible substrate allows the device to adapt to anatomical variations while maintaining sensor contact, directly resolving the contradiction between mapping precision and device complexity.
Solution Approach 2:
The device incorporates expandable structures that can transition from a compressed delivery state to an expanded sensing configuration within the heart chamber. This dynamic transformation allows the device to achieve optimal conformability and mapping precision after deployment, while maintaining a simple delivery profile that reduces initial complexity.
2Reliability
If soft robotic devices with flexible circuits are developed, then sensor contact to heart chamber improves to 85-90%, but fabrication complexity increases due to integration of flexible circuits on soft actuators
Solution Approach 1:
The patent integrates the flexible circuit board, sensor array, and soft actuator into a unified structure where the circuit board is directly mounted on the actuator surface. This merging of components simplifies the overall fabrication process by reducing the number of separate assembly steps while maintaining the high sensor contact reliability of 85-90%.
Solution Approach 2:
The fabrication process utilizes parameter changes in the flexible circuit board materials, such as transitioning from rigid to flexible states during manufacturing, and adjusting thermal or mechanical properties during assembly. These parameter changes enable easier integration of the flexible circuits onto the soft actuator without compromising the final sensor contact reliability.
3Measurement precision
If multi-electrode sensor arrays are used for near-field sensing, then mapping resolution improves, but device complexity and difficulty of fabrication increase
Solution Approach 1:
The sensor array is segmented into multiple independent electrode elements distributed across the flexible circuit board. Each electrode can be independently fabricated using standard PCB techniques, and the segmented structure allows the array to conform to curved surfaces while maintaining high spatiotemporal resolution for precise cardiac mapping.
Solution Approach 2:
The flexible circuit board serves multiple functions simultaneously: it provides structural support for the sensor array, enables electrical connections between electrodes, allows mechanical conformability to the heart chamber, and facilitates signal transmission. This multi-functionality reduces overall device complexity despite the high resolution requirements of the multi-electrode array.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The soft robotic devices achieve robust near-field sensing with 85-90% sensor contact to the heart chamber, improving mapping accuracy and reducing mechanical response issues, thereby enhancing treatment efficacy.
Implementation Method 1
applying, within each region of the one or more regions, thermal energy via a heat source to a surface of the PCB within the region such that insulation material of the insulation layer is removed from the region
Data Source
AI summary
Methods for fabricating flexible/stretchable circuits can include identifying one or more regions of a printed circuit board (PCB) for selectively removing insulation material. The PCB can include one or more electrically conductive structures arranged on an insulation layer. The method can include applying, within each region of the one or more regions, thermal energy via a heat source to a surface of the PCB within the region such that insulation material of the insulation layer is removed from the region while a portion of the insulation layer beneath the one or more electrically conductive structures is maintained. The flexible/stretchable circuit can be laminated on a soft actuator to form a soft robotic device.