Stitched-Wire Planar Catheter Circuit for Conformal Cardiac Mapping
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Solution Overview
Problem
Existing cardiac mapping catheters face challenges in conforming closely to complex cardiac anatomy, collecting data efficiently, and maintaining electrode contact with irregular tissue surfaces while being collapsible and atraumatic, often requiring stiff internal structures that hinder manipulation and are prone to breakage and delamination.
Innovation Solution
A flexible circuit with a bio-compatible substrate and conductive wire routed along the substrate using a stitch pattern, integrated into a medical probe with a planar framework, allowing for electrode connection on one side and enhanced flexibility, collapsibility, and reduced risk of delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If stiff internal structural members are used to maintain predetermined configuration, then structural stability is improved, but flexibility and ability to conform to tissue surfaces deteriorates
Solution Approach 1:
The patent employs a flexible substrate (thin film) as the base structure for the circuit board, replacing traditional rigid substrates. This flexible substrate can be made of biocompatible materials and is capable of conforming to irregular tissue surfaces while maintaining electrical connectivity through flexible traces and conductive elements embedded within the film structure.
Solution Approach 2:
The patent uses composite material structures combining flexible substrates with conductive materials (such as conductive polymers, metal traces, or conductive particles embedded in the substrate). This composite approach provides both mechanical flexibility and electrical conductivity, allowing the circuit to adapt to tissue contours while maintaining functional integrity.
2Adaptability or versatility
If flexible probe tips are used to improve conformability, then adaptability to tissue surfaces is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent integrates multiple functions into a single flexible circuit board structure that combines electrical connectivity, mechanical flexibility, and tissue contact capabilities in one component. The flexible substrate serves as both the structural support and the mounting surface for electrodes, eliminating the need for separate rigid support structures and reducing assembly complexity.
Solution Approach 2:
By using thin-film flexible substrates and trace technologies, the patent achieves conformability without requiring complex multi-layered probe tip structures. The flexible traces and conductive elements are embedded within the thin film, simplifying manufacturing compared to traditional multi-component flexible probe assemblies.
3Measurement precision
If flexible probe tips are used to enhance mapping resolution, then measurement precision is improved, but reliability of electrical connections deteriorates due to breakage and delamination
Solution Approach 1:
The patent employs composite material structures where conductive elements are embedded within or coated upon the flexible substrate using adhesive layers or co-extrusion processes. This integration ensures that conductive traces and electrodes maintain reliable electrical connections even when the flexible probe tip bends or deforms during use, preventing delamination and connection failures.
Solution Approach 2:
The patent replaces traditional rigid mechanical connection methods (such as wire bonding or soldering to rigid substrates) with flexible integrated connection systems where conductive traces and electrodes are directly formed on the flexible substrate. This substitution eliminates weak mechanical joints and reduces the risk of breakage and delamination while maintaining electrical connectivity.
4Stability of the object's composition
If rigid catheter structures are used to maintain configuration, then structural stability is improved, but ease of manipulation and withdrawal deteriorates
Solution Approach 1:
The patent designs a flexible catheter system where the circuit board and probe tip can dynamically adapt their shape and configuration in response to manipulation forces and tissue contact. The flexible substrate and embedded conductive elements allow the catheter to be easily maneuvered, advanced, and withdrawn through vascular access points while maintaining electrical functionality throughout the dynamic range of motion.
Data Source
AI summary
A flexible circuit is herein disclosed. The flexible circuit is intended for insertion into an internal body cavity of a patient. The flexible circuit includes a flexible substrate comprising a bio-compatible material and extending along a substrate plane, a plurality of electrodes disposed on the flexible substrate, and a conductive wire routed along the flexible substrate and connected to one or more of the plurality electrodes by a stitch pattern.