BRAIDED SHEATHS FOR MEDICAL DEVICES

A medical device includes a shaft and a braided sheath. The braided sheath is coaxial with the shaft and at least extends along the shaft between a distal end of the shaft and a proximal end of the shaft. The braided sheath includes a braiding. The braiding includes a plurality of mechanical strands and at least one conductor configured to deliver energy to or convey signals to and from an electrical device positioned at or near the distal end of the shaft.

TECHNICAL FIELD

Aspects of the present disclosure generally relate to medical devices and procedures. In particular, aspects of the present disclosure relate to braided sheaths for medical devices

BACKGROUND

Medical devices, such as endoscopes or other suitable insertion devices, are employed for a variety of types of diagnostic and surgical procedures, such as endoscopy, laparoscopy, arthroscopy, gynoscopy, thoracoscopy, cystoscopy, etc. Endoscopic procedures may be carried out by inserting an insertion device into a patient's body through a surgical incision, or via a natural orifice (e.g., mouth, vagina, or rectum).

The insertion device includes a shaft that includes one or more lumens or working channels therethough. A lumen (or lumens) may often receive various devices and structures such as medical instruments (e.g. irrigation tubes, aspiration tubes, forceps, electrosurgical knives, brushes, RF electrodes, and/or other tools) designed to be operated at a distal end of an insertion device. Surgical incisions and natural orifices are often narrow, and the distal end of the insertion device must be small enough to fit and operate within these spaces. Accordingly, space is limited within the shaft of the distal end, and thus space is also limited in the lumen(s).

The distal end of the insertion device may also include one or more components (lights, cameras, etc.), which require electrical wires or cables in order to be actuated (e.g., powered, controlled, etc.) and/or to be in communication with one or more proximal components (e.g., power sources, controllers, displays, etc.). These electrical wires or cables are ordinarily contained within the shaft of the insertion device. These electrical wires or cables take up space within the shaft, which may limit a size of a lumen within the shaft and/or a number of lumens within the shaft. The electrical wires or cables may also increase a necessary size of the shaft.

The devices and methods of the present disclosure may rectify some of the deficiencies described above or otherwise address other aspects of the art.

SUMMARY

Each of the aspects disclosed herein may include one or more of the features described in connection with any of the other disclosed aspects. Aspects of the disclosure may related to medical devices with braided sheaths extending along the shafts of said medical devices.

Some of the exemplary devices or methods herein may include any of the following features. A medical device may include a shaft and a braided sheath. The braided sheath may be coaxial with the shaft and may extend at least along the shaft between a distal end of the shaft and a proximal end of the shaft. The braided sheath may include a braiding. The braiding may include: a plurality of mechanical strands and at least one conductor that may be electrically connected and/or communicatively connected to an electrical device positioned at or near the distal end of the shaft.

The medical device may include one or more of the following aspects. The at least one conductor may be a first conductor. The braiding may include a second conductor electrically connected and/or communicatively connected to a second electrical device. The first conductor may be braided clockwise along the braided sheath, and the second conductor may be braided counterclockwise along the braided sheath. The first conductor and second conductor may be both braided clockwise or counter clockwise. The first conductor and second conductor may be electrically connected to an end cap. One of the conductors may be connected to a medical instrument. The medical instrument may be at least partially received by a lumen of the shaft. At least one of the conductors may be a coated core wire. At least one of the conductors may be a stranded wire. At least one of the conductors may be a coaxial cable.

The medical device may include a polyimide wrap layer that covers the braided sheath and extends coaxially with the braided sheath. The polyimide wrap layer may include a first layer and a second layer. The first layer may be a continuous ground plane. The second layer may include one or more conductors. The second layer may include an exterior surface and an interior surface. The one or more conductors of the second layer may be disposed on one of the exterior surface and the interior surface, and a ground layer of the second layer may be disposed on the other of the exterior surface and interior surface. The one or more conductors of the second layer may be impedance controlled conductors.

In another aspect, a medical device may include a shaft. The shaft may include a distal end, a proximal end, and a working channel. The medical device may include a wrap layer coaxial with the shaft and disposed on an outer surface of the shaft. The wrap layer may include one or more conductors.

The medical device may include one or more of the following features. The one or more conductors may be disposed on one of an interior surface of the wrap layer and an exterior surface of the wrap and a ground layer is disposed on the other of the interior surface and the exterior surface. The one or more conductors may be configured to transfer electricity from a handle of the medical device to an electrical device of an end cap at the distal end of the shaft.

In yet another aspect, a medical device may include a handle and a shaft extending from the handle. The shaft may include a proximal end and a distal end. The shaft may include a working channel extending a length of the shaft. The medical device may include an end cap including one or more lights or cameras. The medical device may include a braided sheath coaxial with the shaft and extending along at least an exterior of the shaft between the distal end of the shaft and the proximal end of the shaft. The braided sheath may include a plurality of mechanical strands. The braided sheath may also include a first conductor configured to electrically and/or communicatively connect the handle to one or more lights or cameras in the end cap.

The medical device may include one or more of the following features. The braided sheath may include a second conductor. The first conductor and the second conductor may each include a termination portion positioned at a distal end of the braided sheath. The termination portions may be contained within or electrically connected to a flexible circuit.

DETAILED DESCRIPTION OF THE FIGURES

Reference will now be made in detail to examples of the present disclosure described above and illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

The terms “proximal” and “distal” are used herein to refer to the relative positions of the components of an exemplary medical device. When used herein, “proximal” refers to a position relatively closer to the exterior of the body or closer to a medical professional using the medical device. In contrast, “distal” refers to a position relatively further away from the medical professional using the medical device, or closer to the interior of the body. As used herein, the terms “comprises,” “comprising,” “having,” “includes,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion, such that a device or method that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent thereto. Unless stated otherwise, the term “exemplary” is used in the sense of “example” rather than “ideal.” As used herein, the terms “about,” “substantially,” and “approximately,” indicate a range of values within +/−10% of a stated value.

FIG.1illustrates aspects of an exemplary medical device100. Medical device100includes a handle110and a shaft120. Shaft120may be generally tubular, and may extend from a distal end111of handle110. Shaft120includes a proximal end121that is positioned at distal end111of handle110and a distal end122. Shaft120includes a working channel123(as seen at least inFIG.2A) that extends from proximal end121of shaft120to distal end122of shaft120. InFIGS.2B,3B, and4B, a cross-section of shaft120is shown as being a solid, however it should be understood that shaft120may be a solid, or hollow, and/or may define multiple working channels, fluid channels and lumens. Medical device100may include one or more conductors131that electrically connect one or more power sources, controllers, displays, and/or other handle components of handle110to appropriate electrical devices positioned at or near a distal end122of shaft120or within an end cap126. As discussed in detail below, medical device100may include end cap126with one or more electrical devices, such as but not limited to one or more of an illumination device or light127, a visualization device or camera129. As will further be discussed below, shaft120includes a sheath130with one or more conductors131incorporated into or forming a braiding132that at least partially surrounds shaft120. One or more conductors131in braiding132electrically or communicatively connect the one or more electrical devices (e.g., light127, camera129, etc.) of end cap126to handle110, to other components of medical device100, or to other devices or systems. One or more conductors131may facilitate two way communication, for example, to activate/power camera129, and also convey video or picture signals proximally from camera129.

Medical device100may receive a portion of a medical instrument (not shown) with an end effector (not shown). Working channel123is configured to receive at least a portion of medical instrument. As mentioned, medical device100may include end cap126, for example, at distal end122of shaft120. End cap126includes an opening128, which is in fluid communication with working channel123when end cap126is coupled to shaft120. In some aspects, end cap126may include one or more fluid channels,124,125, which may be fluidly connected to one or more fluid channels (not shown) of shaft120. For example, fluid channel124may be a fluid delivery channel, and fluid channel125may be a suction or negative pressure channel.

Although not shown inFIG.1, sheath130may be disposed over or around an outer surface (FIGS.2-4) of shaft120. Sheath130may be generally tubular and may extend from proximal end121of shaft120to distal end122of shaft120or, alternatively, may extend from distal end111of handle110to distal end122of shaft120. Shaft120may include a distal ring portion115that may be positioned between end cap126and braided sheath130.

Handle110may include one or more ports112and one or more valves113. Port(s)112may be positioned on a distal portion of handle110. Port(s)112may be fluidly connected to working channel123in shaft120and with opening128of end cap126. Port(s)112may include a T-connector, a Y-connector, or another appropriate connection. Port(s)112may be threaded, may be a Luer component, and/or may include one or more internal flexible seals. Port(s)112may be configured to receive one or more instruments (e.g. graspers, guide wires, needles, cautery devices, baskets, etc.) One or more valves113may be configured to be actuated to control the delivery of irrigation fluid and/or application of suction, for example, through one or more fluid channels of shaft120that are fluidly connected with corresponding fluid channels124,125of end cap126. Handle110may include or otherwise be coupled to one or more power sources, controllers, displays, and other handle components known to one skilled in the art. For example, an umbilicus114may extend from handle110(e.g., from a distal portion of handle110) and may carry wires, cables, and/or conduits for providing, for example, power, signals, or fluids to and/or from handle110. For example, umbilicus114may connect handle110to one or more user interfaces, monitors, displays, etc.

In one or more embodiments, sheath130is a braided sheath. Sheath130may extend from distal end111of handle110to distal end122of shaft120. Sheath130may comprise braiding132that includes a plurality of elements braided together. Braiding132may include a plurality of mechanical strands133and one or more conductors131(as shown inFIGS.1and2A). The various braidings and one or more conductors, shown in at leastFIGS.1,2A,4A,5,6,7and8, may include any of the features of the other braidings or one or more conductors, respectively. Plurality of mechanical strands133should be understood as being the non-conductive, non-electrical portions of braided sheath130. For example, plurality of mechanical strands133provide shape, support, and/or form to braided sheath130. Relative to a longitudinal axis of shaft120, when viewed from proximal end121of shaft120, one or more of plurality of mechanical strands133may be braided in a clockwise manner, and one or more of plurality of mechanical strands133may be braided in a counter clockwise manner. Plurality of mechanical strands133may be configured to provide structure (e.g., rigidity and/or flexibility) to braided sheath130. Plurality of mechanical strands133may also be configured to help prevent the dislocation or movement of one or more members of braiding132. Braided sheath130may be coated and/or otherwise encased in one or more substances or materials (not shown), such as but not limited to plastic, rubber, polymer, silicone, nitrile, neoprene, or other similar substances or materials known in the art. The coating and/or encasing may help to prevent conductor(s)131and plurality of mechanical strands133from moving during the delivery, positioning, or other usage of medical device100. In some embodiments, one or more of plurality of mechanical strands133may be welded, soldered, or otherwise affixed to one another. For example, two or more of plurality of mechanical strands133may be welded, soldered, or otherwise affixed together, which may help to stabilize plurality of mechanical strands133and/or braided sheath130.

It should be understood that the inclusion of one or more conductors131within braided sheath130, instead of within shaft120, may help to allow for one or more of working channel123and opening128in end cap126, and the fluid channels of shaft120and corresponding fluid channels124,125of end cap126to be greater in size and volume. One or more larger channels may help to allow for larger medical instruments to be received therein, larger volumes of fluid, and for greater suction capabilities. Additionally, the inclusion of one or more conductors131within braided sheath130may help to allow for one or more additional working channels and fluid channels to be disposed within shaft120and/or shaft120may be smaller in diameter.

FIGS.1,2A-2B,4A-4B, and5-8depict various aspects of exemplary medical devices that include the respective braided sheaths130,230,430,530,630,730,830. It should be understood that any of braided sheaths130,230,430,530,630,730,830may have any of the features of any of the other braided sheaths. As seen inFIGS.1,2A,4A, and5-8, the various braidings may include one or more conductors131,431A,531,631A,631B,731A,731B,831A,831B. The one or more conductors may be configured to deliver energy at or near distal end122of shaft120. The one or more conductors may be configured to transmit signals to and from the medical instrument or other electrical devices of end cap126or at distal end122. The one or more conductors may be configured to electrically connect and/or communicatively connect components of handle110to the medical instrument or electrical devices at or near distal end122of shaft120or end cap126. The one or more conductors may be one or more single conductor wires, one or more coated solid core wires, one or more stranded wires, one or more magnet wires, etc. In some aspects, the one or more conductors may be one or more cable assemblies, such as but not limited to one or more coaxial cables, one or more shielded twin axial cables, and one or more ribbon cable assemblies. The one or more conductors may replace one or more of plurality of mechanical strands133, or may be additionally interwoven with plurality of mechanical strands133. Relative to shaft120, the one or more conductors may be woven in a clockwise or counter clockwise manner. In some embodiments, relative to a longitudinal axis of shaft120when viewed from proximal end121of shaft120, one of the one or more conductors may be woven in a clockwise manner and another one of the one or more conductors may be woven in a counter clockwise manner. It should be understood that incorporating any number of conductors into braided sheath in a clockwise and/or counter clockwise manner is contemplated within the scope of this disclosure. In embodiments that include at least one of the one or more conductors travelling in a clockwise manner and another at least one of the one or more conductors travelling in a counter clockwise manner (seeFIG.5C), this may increase the number of instances that the two conductors cross over each other across a length of the braided sheath. Nevertheless, the opposite winding arrangement may help to decrease instances of parallelism of the respective conductors. Limiting parallelism of the conductors may help to reduce cross-talk between conductors. Cross-talk is defined as any phenomenon by which a signal transmitted on one circuit or channel of a transmission system creates an undesired effect in another circuit or channel. Cross-talk is usually caused by undesired capacitive, inductive, or conductive coupling from one circuit or channel to another. In some embodiments, the braided sheath may be configured to protect against unwanted electromagnetic transmissions traveling to and/or traveling from shaft120.

FIGS.2A and2Bdepict aspects of an exemplary medical device200. For example,FIG.2Aillustrates a distal portion of shaft120, andFIG.2Billustrates a lateral cross-sectional view of a portion of shaft120. Although not shown, a distal portion of shaft120may be coupled to an end cap (e.g., end cap126), as discussed above. Shaft120includes a braided sheath230that is coaxial with shaft120. Shaft120may further include an exterior insulation layer239covering (e.g., radially surrounding) braided sheath230. Braided sheath230may have the same of or all of the same features as braided sheath230as described above. Exterior insulation layer239may help to limit or prevent the transfer of electricity from braided sheath230and/or shaft120, for example, to the environment (e.g., the patient's body). Exterior insulation layer239may be further configured to limit or prevent electromagnetic inference from the environment to braided sheath230and/or shaft120. Exterior insulation layer239may extend from proximal end121of shaft120to distal end122of shaft120. One or more conductors131of braided sheath230may include one or more distal termination portion(s)235that extend(s) beyond a distal termination236of plurality of mechanical strands133. Braided sheath230may include a flexible circuit238that extends beyond distal termination236. Distal termination portion235may be contained in or otherwise electrically connected to flexible circuit238. In some embodiments, one or more conductors131may be connected to one or more copper traces (not shown) within flexible circuit238. In one or more embodiments, flexible circuit238may be coupled to (e.g., plugged into) a compatible port (not shown) of an electrical circuit, or circuit board, and electrically connected to the electrical device(s) of end cap126or otherwise positioned at distal end122of shaft120. In some embodiments, shaft120may include a layer of insulation (not shown) between an outer surface of shaft120and braided sheath230.

As shown inFIG.2A, one or more conductors131may include a distal termination portion235. One or more conductors131may converge into one distal termination portion235, or may each include a respective distal termination portion235. Distal termination portion235is a portion of conductor(s)131that extends distally beyond a distal termination236of plurality of mechanical strands133. In some embodiments, distal termination portion235of conductor(s)131may be directly connected to electrical devices positioned at or near distal end122of shaft120. In one or more embodiments, distal termination portion(s)235may be electrically connected to electrical circuits (not shown) or a circuit board (not shown) of end cap126and by extension the electrical devices of end cap126. The electrical circuits or circuit board of end cap126may be printed, 3-D printed, chemically etched, implemented by laser direct structuring, or otherwise formed onto or as a proximal facing surface of end cap126or any other surface of end cap126. In these aspects, the electrical circuits or circuit board of end cap126may be internal to end cap126, for example, electrically connected to one or more of light127, camera129, etc.

As seen inFIG.2A, plurality of mechanical strands133and one or more conductors131may be configured so that two or more of conductors131intersect, or otherwise overlap, at predetermined points along a length of braided sheath230. Braided sheath230may be sized so that distal termination236of plurality of mechanical strands133is positioned at an intersection or convergence234of two or more of conductors131. This configuration may help to allow for distal termination portion(s)235of the two or more conductors131to be more easily contained or connected to flexible circuit238and end cap126, and may further minimize a length of a circuit between the distal termination236and an electrical device positioned at or near distal end122of shaft120. Minimizing the lengths of circuits between distal termination236and electrical devices may prevent the crowding of electrical wires at or near distal end122of shaft120.

In one or more embodiments, distal termination portion235may be contained in or electrically connected to flexible circuit238. In some aspects, flexible circuit238may be a card-edge type flat flexible circuit that may be electrically connected to one or more electrical devices or alternatively may be electrically connected to end cap126as described above. Flexible circuit238may extend distally from distal termination236of plurality of mechanical strands133. In some embodiments, distal termination portion235may be electrically connected to one or more flex boards (not shown) that contain or are electrically connected to one or more electrical devices positioned at or near distal end122of shaft120or electrically connected to end cap126, as described above. The one or more flex boards may be routed as needed within end cap126to place the one or more electrical devices in desirable locations.

One or more conductors131may include a proximal termination portion (not shown). One or more conductors131may converge into one proximal termination portion or each include their own proximal termination portion. The proximal termination portion is a portion of conductor(s)131that extends proximally beyond a proximal termination137(FIG.1) of plurality of mechanical strands133. The proximal termination portion may be directly connected to handle components of handle110, for example, such as but not limited to power sources, controllers, displays, and other handle components known to one skilled in the art. In some embodiments, the proximal termination portion may be electrically connected to one or more flex boards (not shown) that contain or are electrically connected to handle components of handle110. In one or more embodiments, the proximal termination portion may be contained in or electrically connected to a flexible circuit (not shown), for example, a card-edge type flat flexible circuit, that may be electrically connected to the handle components of handle110. In some embodiments, one or more conductors131may be connected to one or more copper traces within the flexible circuit. The flexible circuit may extend proximally of proximal termination137of plurality of mechanical strands133. One or more conductors131may be electrically and/or communicatively coupled to one or more elements in umbilicus114, for example, to connect to one or more power sources, controllers, displays, etc.

It should be understood that the one or more conductors of the various braidings shown inFIGS.1,4,5,6,7,8may include similar distal termination portions and distal connections and proximal termination portions and proximal connections as described in the preceding paragraphs.

FIGS.3A and3Billustrate aspects of another exemplary medical device300. Shaft120includes a wrap layer350that is coaxial with shaft120. Wrap layer350may be used to create an electrical conduit, such as but not limited to an electrical ground. Wrap layer350may be used in addition to braided sheath230. Wrap layer350may be used for transmitting high-speed differentials signals that require inter and intra pair matching. Alternatively or additionally, wrap layer350may be used for impedance control. Wrap layer350may extend from proximal end121(FIG.1) of shaft120to distal end122of shaft120. Shaft120may further include an insulation layer339covering (e.g., radially surrounding) wrap layer350. Insulation layer339may extend from proximal end121(FIG.1) of shaft120to distal end122of shaft120. Wrap layer350may contain one or more conductors331. One or more conductors331may be one or more single conductor wires, one or more coated solid core wires, one or more stranded wires, one or more magnet wires, etc. In some aspects, one or more conductors331may be one or more cable assemblies, such as but not limited to one or more coaxial cables, one or more shielded twin axial cables, and one or more ribbon cable assemblies. One or more conductors331may have any of the features of131,431A,431B,531,631A,631B,731A,731B,831A,831B. In some embodiments, shaft120may include a layer of insulation (not shown) between an outer surface of shaft120and wrap layer350.

Wrap layer350may include a ground layer. The ground layer may be disposed on one of an interior surface and an exterior surface of wrap layer350, and one or more conductors331may be disposed on the other of the interior surface and exterior surface of wrap layer350. In some embodiments, one or more conductors331may be two or more matched-length conductors configured to transmit high-speed signals. It should be understood that for certain high-speed signals, length matching is necessary. As shown inFIG.3A, one or more conductors331may extend linearly along a length of wrap layer350. However, one or more conductors331are not limited to extending linearly along wrap layer350. Alternatively, one or more conductors331may wind around a surface of wrap layer350, for example, in a clockwise or counterclockwise manner similarly to the one or more conductors of the various braided sheaths disclosed in this disclosure.

One or more conductors331of wrap layer350may electrically connect and/or communicatively connect the handle components of handle110with the electrical devices positioned at or near distal end122of shaft120or end cap126. Wrap layer350may also help to limit electromagnetic emissions and electromagnetic inference to and from shaft120. In some embodiments, conductor(s)331include an electrical ground. One or more conductors331of wrap layer350may be electrically connected to a medical instrument at least partially received within a working channel123of shaft120. Conductor(s)331of wrap layer350may help to facilitate electrical connection and/or communication between the handle components within handle110and the medical instrument at least partially received within working channel123.

A distal termination portion335of one or more conductors331may extend beyond a distal termination351of wrap layer350may extend into a flexible circuit338. In some embodiments, one or more conductors331may be connected to one or more copper traces (not shown) within flexible circuit338. In some embodiments, distal termination portion335of one or more conductors331may be directly connected to electrical devices positioned at or near distal end122of shaft120. In one or more embodiments, distal termination portion335may be electrically connected to electrical circuits (not shown) or a circuit board (not shown) of end cap126(FIG.1), and the electrical circuits or the circuit board may then be electrically connected to the electrical devices of end cap126(FIG.1).

The electrical circuits or circuit board of end cap126may be printed, 3-D printed, chemically etched, implemented by laser direct structuring onto a proximal facing surface of end cap126or any other surface of end cap126. In one or more embodiments, distal termination portion335may be contained in or electrically connected to flexible circuit338. In some aspects, flexible circuit338may be a card-edge type flat flexible circuit that may be electrically connected to one or more electrical devices or, alternatively, may be electrically connected to end cap126, as described above. Flexible circuit338may extend distally from distal termination351of wrap layer350. In some embodiments, distal termination portion335may be electrically connected to one or more flex boards (not shown) that contain or are electrically connected to one or more electrical devices positioned at or near distal end122of shaft120or electrically connected to end cap126, as described above. The one or more flex boards may be routed as needed within end cap126to place the one or more electrical devices in desirable locations.

One or more conductors331of wrap layer350may include a proximal termination portion (not shown). One or more conductors331may converge into one proximal termination portion or each include their own proximal termination portion. The proximal termination portion is a portion of the one or more conductors331that extends proximally beyond a proximal termination (not shown) of wrap layer350. The proximal termination portion may be directly connected to components of handle110, for example, such as but not limited to power sources, controllers, displays, and other handle components known to one skilled in the art. In some embodiments, the proximal termination portion may be electrically connected to one or more flex boards (not shown) that contain or are electrically connected to components of handle110. In one or more embodiments, the proximal termination portion may be contained in or electrically connected to a flexible circuit (not shown), for example, a card-edge type flat flexible circuit, that may be electrically connected to the handle components of handle110. In some embodiments, one or more conductors331may be connected to one or more copper traces within the flexible circuit. The flexible circuit may extend proximally of the proximal termination of wrap layer350. One or more conductors331may be electrically and/or communicatively coupled to one or more elements in umbilicus114, for example, to connect to one or more power sources, controllers, displays, etc.

It should be understood that the inclusion of one or more conductors331within wrap layer350instead of within shaft120may help to allow for one or more of working channel123and opening128in end cap126, and the fluid channels of shaft120and corresponding fluid channels124,125of end cap126to be greater in size (e.g., in cross-sectional area). One or more larger channels may help to allow for larger medical instruments to be received therein, larger volumes of fluid, and for greater suction capabilities. Additionally, the inclusion of one or more conductors331within wrap layer350may help to allow for one or more additional working channels and fluid channels to be disposed within shaft120and/or for shaft120to be smaller in diameter.

In some embodiments, any of the braided sheaths130,230,430,530,630,730,830may be disposed over wrap layer350and extend from proximal end121of shaft120to distal end122of shaft120. At distal end122of shaft120, the conductors of the braided sheath and wrap layer350may distally extend into flexible circuit338, one or more flex boards, or be electrically connected to end cap126or a medical instrument. The one or more flex boards may be routed as needed within end cap126to place the one or more electrical devices in desirable locations. At proximal end121of shaft120, the conductors of the braided sheath and wrap layer350may proximally extend into a flexible circuit, one or more flex boards, or be electrically connected to components of handle110.

FIGS.4A and4Bdepict aspects of yet another exemplary medical device400that combines aspects of exemplary medical device200disclosed inFIGS.2A and2Bwith aspects of medical device300disclosed inFIGS.3A and3B. Shaft120includes a braided sheath430. Braiding432of braided sheath430may include a plurality of mechanical strands133and one or more conductors431A. A distal termination portion435of one or more conductors431A may extend into a flexible circuit438. Braided sheath430may have some of or all of the same features as braided sheath230and/or braided sheath130as described above. Shaft120further includes an interior layer of insulation440covering (e.g., radially surrounding) braided sheath430. Interior layer of insulation440may extend from proximal end121(FIG.1) of shaft120to distal end122of shaft120. Shaft120further includes a first polyimide layer460covering (e.g., radially surrounding) interior layer of insulation440. Shaft120also include a second polyimide layer461covering (e.g., radially surrounding) first polyimide layer460. First polyimide layer460and second polyimide layer461may extend from proximal end121(FIG.1) of shaft120to distal end122of shaft120. Within this disclosure, first polyimide layer460and second polyimide layer461may be referred to collectively as the polyimide wrap layer, that is, the polyimide wrap layer may include or comprise a plurality of layers. The polyimide wrap layer may be used for transmitting high-speed differentials signals that require inter and intra pair matching. Shaft120further includes an exterior layer of insulation439that covers (e.g., radially surrounds) second polyimide layer461. Shaft120may include an intermediate layer of insulation462between first polyimide layer460and second polyimide layer461. It should be understood that shaft120may include additional layers of insulation exterior to second polyimide layer461and/or interior to first polyimide layer460, in addition to those insulation layers already discussed. In some embodiments, shaft120may include a layer of insulation (not shown) between an outer surface of shaft120and braided sheath430.

In one or more embodiments, one of first polyimide layer460or second polyimide layer461may include one or more conductors431B and the other of the first polyimide layer460and second polyimide layer461may be a ground layer. The polyimide layer with the one or more conductors431B may include a ground layer. The ground layer may be disposed on one of an interior surface of the polyimide layer and an exterior surface of the polyimide layer and the one or more conductors431B are disposed on the other of the interior surface of the polyimide layer and the exterior surface of the polyimide layer.

As shown inFIG.4A, one or more conductors431A,431B of braided sheath430and one of polyimide layers460,461may include a distal termination portion435. One or more conductors431A,431B may converge into one distal termination portion435, or may each include a respective distal termination portion435. Distal termination portion435includes a portion of respective conductor(s)431A,431B that extends distally beyond a distal termination436of plurality of mechanical strands133. In some embodiments, distal termination portion435of conductor(s)431A,431B may be directly connected to electrical devices positioned at or near distal end122of shaft120. In one or more embodiments, distal termination portion(s)435may be electrically connected to electrical circuits (not shown) or a circuit board (not shown) of end cap126(FIG.1), and the electrical circuits or the circuit board may then be electrically connected to the electrical devices of end cap126(FIG.1). The electrical circuits or circuit board of end cap126may be printed, 3-D printed, chemically etched, implemented by laser direct structuring onto a proximal facing surface of end cap126or any other surface of end cap126. In one or more embodiments, distal termination portion435may be contained in or electrically connected to a flexible circuit438. In some embodiments, one or more conductors431A,431B may be connected to one or more copper traces (not shown) within flexible circuit438. In some aspects, flexible circuit438may be a card-edge type flat flexible circuit that may be electrically connected to one or more electrical devices or alternatively may be electrically connected to end cap126as described above. Flexible circuit438may extend distally from distal termination436of plurality of mechanical strands133. In some embodiments, distal termination portion435may be electrically connected to one or more flex boards (not shown) that contain or are electrically connected to one or more electrical devices positioned at or near distal end122of shaft120or electrically connected to end cap126, as described above. The one or more flex boards may be routed as needed within end cap126to place the one or more electrical devices in desirable locations.

As mentioned above, one or more conductors431A,431B of braided sheath430and one of polyimide layers460,461may include a proximal termination portion (not shown). One or more conductors431A,431B may converge into one proximal termination portion or each include their own proximal termination portion. The proximal termination portion is a portion of conductor(s)431A,431B that extends proximally beyond a proximal termination137(FIG.1) of plurality of mechanical strands133. The proximal termination portion may be directly connected to components of handle110, for example, such as but not limited to power sources, controllers, displays, and other handle components known to one skilled in the art. In some embodiments, the proximal termination portion may be electrically connected to one or more flex boards (not shown) that contain or are electrically connected to handle components of handle110. In one or more embodiments, the proximal termination portion may be contained in or electrically connected to a flexible circuit (not shown), for example, a card-edge type flat flexible circuit, that may be electrically connected to the components of handle110. In some embodiments, one or more conductors431A,431B may be connected to one or more copper traces within the flexible circuit. The flexible circuit may extend proximally of proximal termination137of plurality of mechanical strands133. The one or more conductors431A,431B may be electrically and/or communicatively coupled to one or more elements in the umbilicus114, for example, to connect to one or more power sources, controllers, displays, etc.

The above-described layered arrangement of braided sheath430, interior layer of insulation440, first polyimide layer460, intermediate layer of insulation462, second polyimide layer461, and exterior layer of insulation439may help to provide numerous advantages. For example, the layered arrangement may help to facilitate the segregation of conductors that require impedance control and conductors that do not require impedance control. Conductor(s) (e.g. one or more conductors431B) that do require impedance control may be placed in either first polyimide layer460or second polyimide layer461, with the remaining polyimide layer not containing the conductor(s) requiring impedance control may be a continuous ground plane. Conductor(s) (e.g. one or more conductors431A) that do not require impedance control may be interwoven within braided sheath430. The segregation may be necessary for conductors that require impedance control. First polyimide layer460and second polyimide layer461are two conducting layers, one for the impedance controlled signal conductors and the other layer for a ground plane. The ground plane distance to one or more conductors431B and the dielectric constant of the polyimide contributes to the impedance of one or more conductors431B. The non-impedance controlled conductors (e.g., one or more conductors431A) may be interwoven in braiding432because a solid ground reference is not necessary. First polyimide layer460and second polyimide layer461may be thin and flexible, for example, so as to have minimal mechanical impact on shaft120. It should be understood that one or more conductors431A,431B may be any of the features of one or more conductors131,331,531,631A,631B,731A,731B,831A,831B.

In some embodiments, one or more conductors431B may be two or more matched-length conductors configured to transmit high-speed signals. It should be understood that for certain high-speed signals, length matching may be necessary. As shown inFIG.4A, one or more conductors431B may travel linearly along the polyimide layer (for example within first polyimide layer460). However, one or more conductors431B are not limited to traveling linearly along or within the polyimide layer, but instead may wind around on a surface of or within the polyimide layer in a clockwise or counterclockwise manner, for example, in a similar manner as the one or more conductors of the various braided sheaths disclosed in this disclosure.

FIG.5illustrates an aspect of an exemplary medical device that includes a braided sheath530. Braided sheath530includes at least one conductor531. Conductor531may include two conductors531A,531B intertwined together. Conductors531A,531B may be braided clockwise or counter clockwise about a braiding532. Conductor531may be a twisted pair of conductors.

Another aspect of an exemplary medical device is shown inFIG.6. The medical device includes a braided sheath630. Braided sheath630may include two conductors631A,631B. The two conductors631A,631B may be a twin axial cable. Conductors631A,631B intertwined together and may be braided clockwise or counter clockwise about a braiding632.

An aspect of an exemplary medical device is shown inFIG.7. The medical device includes a braided sheath730. Braided sheath730may include a first conductor731A and a second conductor731B. The two conductors731A,731A may be interwoven with a braiding732. First conductor731A may be braided clockwise, and second conductor731B may be braided counter clockwise. Relative to a longitudinal axis of shaft120, when viewed from proximal end121of shaft120, arranging one of conductors731A,731B to travel clockwise about braiding732and the other of conductors731A,731B to travel counter clockwise about braiding732may help to limit instances of parallelism between the two conductors731A,731B, while conductors731A,731B extend along braided sheath730.

FIG.8illustrates another aspect of an exemplary medical device. The medical device includes a braided sheath830. Braided sheath830may include two conductors831A,831B. The two conductors831A,831B may be interwoven with braiding832and both extend in either clockwise or counter-clockwise. The conductors831A,831B may be incorporated into braidings by existing braiding machines by replacing one or more non-conductive strands with one or more conductors.

An aspect of the present disclosure is a method of manufacturing braided sheath with one or more conductors, as described in various aspects above. Braided sheaths known in the art may be formed by providing a plurality of spools of mechanical strands, the spools of mechanical strands each including a leading end, arranging the spools of mechanical strands so that leading ends of the spools of mechanical strands may be fed into a receiving end of a braiding machine, and actuating the braiding machine to form the braided sheath. The braiding machine may be a horn gear braiding machine. A braided sheath may be formed by providing a plurality of spools of mechanical strands, providing one or more spools of conductor, wherein the spools of the mechanical strands and spools of conductors each include a leading end, arranging the spools of mechanical strands and spools of conductors so that the leading ends of the spools may be fed into a receiving end of a braiding machine, actuating the braiding machine to for braided sheath. The method of manufacturing the braided sheath may further comprise arranging one or more spools of conductor to be wound counter-clockwise relative to a longitudinal axis defined by a forming braided sheath and arranging one or more spools of conductor to be wound clockwise relative to the longitudinal axis defined by the forming braided sheath. In one or more embodiments, the spools of conductors may be formed of one or more single conductor wires, one or more coated solid core wires, one or more stranded wires, etc. Alternatively or additionally, the spools of conductors may include one or more cable assemblies, such as, but not limited to, one or more coaxial cables and one or more shielded twin axial cables, and combinations thereof.

As discussed above, removing the electrical wires or cables from within the shaft and disposing the electrical wires or cables in the various braided sheaths, wrap layers and polyimide wrap layers disclosed herein may help to allow for larger lumens for larger instruments, more lumens for more instruments, more lumens for delivery of suction and different types of fluid, larger lumen(s) for delivery of greater amounts of fluid(s), larger lumen(s) for application of suction, smaller shaft/insertion portion diameters, etc. Further, the braided sheaths disclosed above may help to reduce parallelism of conductors by braiding one or more conductors clockwise and one or more other conductors counter clock-wise. Additionally, as disclosed inFIGS.4A and4B, the present disclosure may help to facilitate the segregation of impedance controlled conductors and non-impedance controlled conductors. One skilled in the art would recognize the above described benefits as significant advancements in the art.

Although, the braided sheaths, polyimide wrap layers, insulation layers, and wrap layer are shown inFIGS.1-8and discussed in this disclosure as covering an external shaft (for example, shaft120), the braided sheaths, polyimide wrap layers, insulation layers, and wrap layer may be applied to internal shafts (for example, working channel123) in the same or similar manners as discussed above with respect to shaft120.

While principles of this disclosure are described herein with reference to illustrative examples for particular applications, it should be understood that the disclosure is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, embodiments, and substitution of equivalents all fall within the scope of the features described herein. Accordingly, the claimed features are not to be considered as limited by the foregoing description.