Laser direct structured connection for intravascular device

Abstract

The invention generally relates to intravascular imaging catheters and methods of making catheters for imaging systems. The invention provides a connector for an imaging catheter that includes a unitary body with very thin electrical contacts that are formed on the surface of the body. Due to the scale of the contacts, the connector operates essentially as a single unitary piece of material. Each of the leads may be less than about 100 μm wide and less than about 8 μm thick, and further the leads may be spaced apart by less than about 160 μm.

What is claimed is: 
     
         1 . A connector for a medical imaging device, the connector comprising:
 an extended body having a proximal end and a distal end, wherein the extended body comprises a thermoplastic doped with an organo-metal complex;   a conductive contact disposed on a surface of the proximal end; and   a conductive lead extending along a length of the body and in electrical contact with the conductive contact.   
     
     
         2 . The connector of  claim 1 , wherein the conductive contact is less than about 10 μm thick. 
     
     
         3 . The connector of  claim 1 , wherein the conductive lead comprises a metal trace on a surface of the body, the metal trace being less than about 150 μm wide and less than about 10 μm thick. 
     
     
         4 . The connector of  claim 1 , wherein the proximal end substantially defines a cylindrical member and the conductive contact is on an outer surface of the cylindrical member. 
     
     
         5 . The connector of  claim 4 , wherein the conductive contact defines a ring extending around the cylindrical member. 
     
     
         6 . The connector of  claim 1 , wherein the proximal end substantially defines a cylindrical hollow and the conductive contact is on an inner surface of the cylindrical hollow. 
     
     
         7 . The connector of  claim 6 , wherein the conductive contact defines a ring extending around an inside surface of the cylindrical hollow. 
     
     
         8 . The connector of  claim 1 , wherein the device further comprises a plurality of conductive contacts disposed on the surface of the proximal end and each in electrical contact with one of a plurality of conductive leads extending along a length of the body. 
     
     
         9 . The connector of  claim 8 , further comprising a male form factor plug configured so that if inserted into a corresponding jack the plug may be rotated with respect to the jack while maintaining constant electrical contact from each of the conductive leads to corresponding conductors in the jack. 
     
     
         10 . The connector of  claim 1 , further comprising an intravascular imaging catheter. 
     
     
         11 . The connector of  claim 1 , further comprising a plurality of conductive leads extending along the length of the body, wherein each of the leads are less than about 150 μm wide and less than about 10 μm thick, and further wherein the plurality of leads are spaced apart by less than about 200 μm. 
     
     
         12 . The connector of  claim 11 , wherein each of the leads are less than about 110 μm wide and less than about 8 μm thick, and further wherein the plurality of leads are spaced apart by less than about 160 μm. 
     
     
         13 . The connector of  claim 1 , wherein the conductive contact is less than about 5 μm thick and the conductive lead is disposed on a surface of the body and is less than about 5 μm thick. 
     
     
         14 . The connector of  claim 13 , wherein the conductive contact is less than about 3 μm thick and the conductive lead is less than about 3 μm thick. 
     
     
         15 . A method of making a connector for a medical imaging device, the method comprising:
 molding a thermoplastic doped with an metal-organic complex into an extended body having a proximal end and a distal end;   irradiating an area of a surface of the body with a laser to make a metal from the metal-organic complex available at the surface; and   depositing a conductor metal on the area to provide a conductive contact at the proximal end.   
     
     
         16 . The method of claim, further comprising depositing the metal to a thickness not greater than about 10 μm. 
     
     
         17 . The method of  claim 15 , further comprising depositing the conductor metal on the area to provide a conductive lead extending along the extended body. 
     
     
         18 . The method of  claim 15 , further comprising configuring the extended body as a male form factor plug so that if inserted into a corresponding jack the plug may be rotated with respect to the jack while maintaining constant electrical contact from each of the conductive leads to corresponding conductors in the jack. 
     
     
         19 . The method of  claim 17 , further comprising creating a conductive lead comprising a metal trace on a surface of the body, the metal trace being less than about 150 μm wide and less than about 10 μm thick. 
     
     
         20 . The method of  claim 15 , wherein the proximal end substantially defines a cylindrical hollow and the area is on an inner surface of the cylindrical hollow.