Standalone Flex Circuit for Kink-Resistant Intravascular Imaging

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Solution Overview

Problem

Manufacturing an intravascular ultrasound imaging device that can efficiently traverse the human body is challenging due to rigid components at the distal portion, which increase the likelihood of kinking when steered through vasculature.

Innovation Solution

The intravascular imaging device incorporates a flex circuit positioned directly around a flexible elongate member, eliminating the need for a rigid support structure, and includes layers of transducers and acoustic backing material for improved flexibility and operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a rigid support structure is used at the distal portion of the imaging device, then structural stability is improved, but flexibility and ability to navigate tortuous vasculature deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidability to navigate tortuous vasculature

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid support structures with a flexible circuit board that has a thin profile, allowing the imaging device to bend and conform to tortuous vasculature while maintaining structural integrity. The flexible circuit board serves as both a structural support and a functional component for mounting transducers and electronics.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical parameters of the support structure by using materials and designs that provide flexibility while maintaining adequate structural stability. This includes using flexible substrates with appropriate thickness, material composition, and mechanical properties to achieve the desired balance between stability and navigability.

Inventive Principle:

Principle #35Parameter changes

2Strength

If rigid components are positioned at the distal portion of the device, then structural support is improved, but the likelihood of kinking during steering increases

Engineering Contradiction:

Improvestructural supportVSAvoidrisk of kinking

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The flexible circuit board is designed with sufficient flexibility to prevent kinking during device steering while providing the necessary structural support. The thin film structure allows the device to bend smoothly around curves in the vasculature without creating stress concentrations that would lead to kinking.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs dynamic design principles where the flexible circuit board can adapt its shape and flexibility based on the mechanical forces applied during steering. The structure maintains structural support when needed but can flex and conform to prevent kinking under operational conditions.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If the flex circuit is positioned around a rigid support structure, then electrical component mounting is improved, but device flexibility deteriorates

Engineering Contradiction:

Improveelectrical component mountingVSAvoiddevice flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The flexible circuit board serves as both the support structure and the mounting platform for electrical components. The thin flexible substrate allows transducers, electronics, and other components to be mounted directly on it, maintaining ease of manufacture while providing the flexibility needed to navigate tortuous vasculature.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible circuit board performs multiple functions simultaneously: it provides structural support, serves as a mounting platform for electrical components, and enables device flexibility for navigation. This multi-functional design eliminates the need for separate rigid support structures while maintaining all necessary functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 flexible design allows the device to navigate tortuous anatomy more effectively, reducing the risk of kinking and enhancing operational efficiency.

Implementation Method 1

a layer including acoustic backing material that facilitates operation of the transducers

Methodology Applied

Scientific EffectAcoustic backing: Acoustics

Data Source

PatentUS20250325247A1Standalone flex circuit for intravascular imaging device and associated devices, systems, and methods

Publication Date: 2025.10.23 PHILIPS IMAGE GUIDED THERAPY CORP

AI summary

An intravascular imaging device is provided. In some embodiments, the intravascular imaging device includes a flexible elongate member sized and shaped for insertion into a vessel of a patient, the flexible elongate member having a proximal portion and a distal portion; and an imaging assembly disposed at the distal portion of the flexible elongate member, the imaging assembly including a flex circuit positioned directly around the flexible elongate member. In some embodiments, a method of assembling an intravascular imaging device includes obtaining a flex circuit including a first layer having a plurality of transducers and a second layer having an acoustic backing material; and positioning the flex circuit directly around a distal portion of a flexible elongate member.