Flexible elongate member having one or more electrical contacts

• US 20050091833A1
• Filed: 08/23/2004
• Published: 05/05/2005
• Est. Priority Date: 03/03/1999
• Status: Active Grant

• Current Assignee: Daniel A. Brunicardi, Gary P. Rizzuti, Horst F. Kiepen, Michael J Eberle
• Original Assignee: Daniel A. Brunicardi, Gary P. Rizzuti, Horst F. Kiepen, Michael J Eberle
• Inventors: Eberle, Michael J., Kiepen, Horst F., Brunicardi, Daniel A., Rizzuti, Gary P.
• Granted Patent: US 7,676,910 B2
• Time in Patent Office: Days
• US Class Current: 29/594
• CPC Class Codes: A61B 2562/227 Sensors with electrical connectors
• CPC Class Codes: A61B 5/0215 by means inserted into the body catheters A61M25/00
• CPC Class Codes: A61M 25/09 Guide wires
• CPC Class Codes: Y10S 439/909 Medical use or attached to human body
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49005 Acoustic transducer
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor

Abstract

A flexible elongate member such as a pressure guide wire (1000) includes an electrical device such as a pressure sensor (1002). The pressure sensor (1002) is electrically connected to conductive bands (304), (306) and (308) located on electrical connector (300). The electrical connector is attached to core wire (602) and shaft or hypotube (704). The use of electrical connector (300) helps minimize the assembly time of pressure guide wire (1000), as well as minimize some of the assembly problems associated with prior art designs such as pressure guide wire (100).

Claims

1. A method for making a flexible elongate member for insertion into humans or animals, the method comprising the steps of:

first forming a flexible member having proximal and distal ends;

second forming a circuit carrier comprising a substantially cylindrical electrical connector with at least one conductive band, the electrical connector having a first end portion that is flush with a second end portion;

first attaching an electrical device in proximity to the distal end of the flexible member;

interconnecting an electrical conductor to the electrical device;

third forming an electrically conductive bond between the electrical conductor and a conductive path on the circuit carrier comprising the at least one conductive band; and

second attaching the substantially cylindrical electrical connector in proximity to the proximal end of the flexible member.

2. A method as defined in claim 1, wherein the circuit carrier is formed comprising the steps of:

providing a substantially flat substrate with the at least one conductive band, the substantially flat substrate having a first end portion and the second end portion;

reshaping the first end portion so that it is flush with the second end portion forming the substantially cylindrical electrical connector with the conductive band on its outer surface; and

bonding the first end portion and the second end portion in the area where the first end portion is flush with the second end portion.

3. A method as defined in claim 1, wherein the electrical device is a sensor and the flexible elongate member forms a guide wire.

4. A method as defined in claim 1, wherein the electrical device is a flow sensor and the flexible elongate member forms a flow guide wire.

5. A method as defined in claim 1, wherein the electrical device is an ultrasonic transducer and the flexible elongate member forms an intravascular ultrasound guide wire.

6. A method as defined in claim 1, wherein the circuit carrier is formed comprising the steps of:

forming a tubular member having an outer surface; and

forming the at least one conductive band on the outer surface of the tubular member such that the tubular member and the at least one conductive band form the substantially cylindrical electrical connector.

7. A method as defined in claim 1, further comprising the steps of:

forming an extension portion on the circuit carrier;

electrically connecting the electrical conductor to the at least one conductive band such that the electrically conductive bond is formed on the extension portion of the circuit carrier.

17. A method as defined in claim 2, wherein the electrical device is a sensor and the flexible elongate member forms a guide wire.

18. A method as defined in claim 2, wherein the electrical device is a flow sensor and the flexible elongate member forms a flow guide wire.

19. A method as defined in claim 2, wherein the electrical device is an ultrasonic transducer and the flexible elongate member forms an intravascular ultrasound guide wire.

20. A method as defined in claim 2, further comprising the steps of:

forming an extension portion on the circuit carrier;

electrically connecting the electrical conductor to the at least one conductive band such that the electrically conductive bond is formed on the extension portion of the circuit carrier.

8. A method for making a cardiovascular guide wire, the method comprising the steps of:

first forming a core wire having a proximal and distal end;

second forming a circuit carrier comprising a substantially cylindrical electrical connector with at least one conductive band;

the electrical connector having a first end portion that is flush with a second end portion;

first attaching an electrical device in proximity to the distal end of the core wire;

interconnecting an electrical conductor to the electrical device;

third forming an electrically conductive bond between the electrical conductor and a conductive path on the circuit carrier comprising the at least one conductive band; and

second attaching the substantially cylindrical electrical connector in proximity to the proximal end of the core wire.

9. A method as defined in claim 8, wherein the circuit carrier is formed comprising the steps of:

providing a substantially flat substrate with the at least one conductive band, the substantially flat substrate having a first end portion and the second end portion;

reshaping the first end portion so that it is flush with the second end portion forming the substantially cylindrical electrical connector with the conductive band on its outer surface; and

bonding the first end portion and the second end portion in the area where the first end portion is flush with the second end portion.

10. A method as defined in claim 8, wherein the circuit carrier is formed comprising the steps of:

providing a substantially flat substrate with the at least one conductive band, the substantially flat substrate having a first end portion and a second end portion;

reshaping the first end portion so that it is flush with the second end portion forming the substantially cylindrical electrical connector with the conductive band on its outer surface; and

bonding the first end portion to the second end portion.

11. A method as defined in claim 8, wherein the circuit carrier is formed comprising the steps of:

forming a tubular member having an outer surface; and

forming the at least one conductive band on the outer surface of the tubular member such that the tubular member and the at least one conductive band form the substantially cylindrical electrical connector.

12. A method as defined in claim 8 wherein the guide wire further comprises a hypotube and further comprising the steps of running the electrical conductor inside the hypotube and coupling the hypotube to the substantially cylindrical electrical connector.

13. A method as defined in claim 12, wherein the hypotube further includes a window and the substantially cylindrical connector includes an extension portion, further comprising the steps of:

forming the electrical bond connection between the electrical conductor and the at least one conductive band on the extension portion; and

bringing the hypotube and the substantially cylindrical electrical connector together with the window and the extension portion in substantial registration prior to coupling the substantially cylindrical electrical connector and the hypotube.

14. A method as defined in claim 8, wherein the electrical device is a pressure sensor.

15. A method as defined in claim 8, wherein the electrical device is a blood flow sensor.

16. A method as defined in claim 8, wherein the electrical device is an ultrasound transducer.