Flat wire coil wire guide with twisted contraction

1. A wire guide comprising:

an elongated solid core mandrel with a length, and a uniform diameter over a majority of the length;

a flat wire formed into a flat wire coil that, when at rest, defines a rest inner diameter that is greater than the uniform diameter, and an entire coil length of the flat wire coil matches the length of the elongated solid core mandrel;

the elongated solid core mandrel being received in the flat wire coil;

the flat wire coil being attached to the elongated solid core mandrel at a distal attachment location and a proximal attachment location;

the distal attachment location being closer to a distal end of the elongated solid core mandrel than to the proximal attachment location, which is closer to a proximal end of the elongated solid core mandrel than to the distal attachment location;

wherein the flat wire is in tension between the proximal attachment location and the distal attachment location so that the flat wire coil has a reduced inner diameter, which is smaller than the rest inner diameter, between the proximal attachment location and the distal attachment location, and such that a winding gap between adjacent turns of the flat wire coil is unchanged from a rest winding gap of the flat wire coil when at rest.

2. The wire guide of claim 1 wherein the flat wire has a rectangular cross section.

3. The wire guide of claim 1 wherein the elongated solid core mandrel terminates with a distal tapered segment; and

the distal attachment location is proximal to the distal tapered segment.

4. The wire guide of claim 1 including a rounded cap attached to a distal end of the flat wire coil and attached to the distal end of the elongated solid core mandrel.

5. The wire guide of claim 1 wherein the tension in the flat wire corresponds to a predetermined range of torque stress between the elongated solid core mandrel and the flat wire coil about a common longitudinal axis.

6. The wire guide of claim 1 wherein a radial gap between an external surface of the elongated core mandrel and an inner surface of the flat wire coil is less than one order of magnitude smaller than the uniform diameter.

7. A wire guide comprising:

an elongated solid core mandrel with a length, and a uniform diameter over a majority of the length;

a flat wire formed into a flat wire coil that, when at rest, defines a rest inner diameter that is greater than the uniform diameter, and an entire coil length of the flat wire coil matches the length of the elongated solid core mandrel;

the elongated solid core mandrel being received in the flat wire coil;

the flat wire coil being attached to the elongated solid core mandrel at a distal attachment location and a proximal attachment location;

the distal attachment location being closer to a distal end of the elongated solid core mandrel than to the proximal attachment location, which is closer to a proximal end of the elongated solid core mandrel than to the distal attachment location;

wherein the flat wire is in tension between the proximal attachment location and the distal attachment location so that the flat wire coil has a reduced inner diameter, which is smaller than the rest inner diameter, between the proximal attachment location and the distal attachment location;

wherein the flat wire coil defines a rest winding gap between adjacent turns of the flat wire coil when at rest; and

the flat wire coil is in a compressed state between the proximal attachment location and the distal attachment location and defines a reduced winding gap, which is smaller than the rest winding gap.

8. A method of making a wire guide that includes an elongated solid core mandrel with a length, and a uniform diameter over a majority of the length; a flat wire formed into a flat wire coil that, when at rest, defines a rest inner diameter that is greater than the uniform diameter, and an entire coil length of the flat wire coil matches the length of the elongated solid core mandrel; the elongated solid core mandrel being received in the flat wire coil; the flat wire coil being attached to the elongated solid core mandrel at a distal attachment location and a proximal attachment location; the distal attachment location being closer to a distal end of the elongated solid core mandrel than to the proximal attachment location, which is closer to a proximal end of the elongated solid core mandrel than to the distal attachment location; wherein the flat wire is in tension between the proximal attachment location and the distal attachment location so that the flat wire coil has a reduced inner diameter, which is smaller than the rest inner diameter, between the proximal attachment location and the distal attachment location, the method comprising the steps of:

sliding the elongated solid core mandrel into the flat wire coil;

attaching the flat wire coil to the elongated solid core mandrel at the distal attachment location;

torquing the elongated solid core mandrel in a direction with respect to the flat wire coil that puts tension in the flat wire of the flat wire coil and reduces the inner diameter of the flat wire coil from the rest inner diameter to the reduced inner diameter;

attaching the flat wire coil to the elongated solid core mandrel at the proximal attachment location while retaining the tension in the flat wire; and

the distal attachment location being closer to the distal end of the elongated solid core mandrel than to the proximal attachment location, which is closer to the proximal end of the elongated solid core mandrel than to the distal attachment location;

wherein the torquing step is performed without moving a proximal end of the flat wire coil relative to the elongated solid core mandrel along a longitudinal axis.

9. The method of claim 8 including a step of compressing the flat wire coil toward the distal attachment location prior to the attaching at the proximal attachment location.

10. The method of claim 9 wherein the torquing and compressing steps are performed at least partially simultaneously.

11. The method of claim 9 wherein a winding gap defined between two turns of the flat wire coil is reduced responsive to the compressing step.

12. The method of claim 8 wherein the step of attaching at the proximal attachment location includes positioning hot liquid solder material in a winding gap defined between two turns of the flat wire coil.

13. The method of claim 8 including measuring a torque during the torquing step; and

the torquing step is stopped at a predetermined torque magnitude.

14. The method of claim 8 wherein the inner diameter of the flat wire coil is reduced responsive to the torquing step.

15. The method of claim 8 wherein an interference contact between the elongated solid core mandrel and the flat wire coil is increased responsive to the torquing step.