Sensor assembly tethered within catheter wall

Abstract

A distal tip assembly for an elongate medical device having an axis comprises a shaft having a proximal end portion, a distal end portion, a wall, and a central lumen extending axially between said proximal end portion and said distal end portion. The distal tip assembly further comprises a position sensor disposed in an outer sleeve such that the sensor can shift relative to the sleeve. The sleeve is disposed at least in part in the wall and is substantially fixed thereto.

1 .- 20 . (canceled) 
     
     
         21 . A method of fabricating a distal tip assembly for an elongate medical device having an axis, comprising:
 placing a sensor within an outer sleeve to form a sensor assembly;   placing said sensor assembly on a first shaft layer at a distal end portion of said elongate medical device;   applying a second shaft layer radially outward of said sensor assembly and said first shaft layer; and   subjecting said tip assembly to a reflow lamination process, wherein said first shaft layer and said second shaft layer bond to an outer surface of said outer sleeve.   
     
     
         22 . The method of  claim 21 , further comprising:
 coupling a tip electrode to an extreme distal end of said distal end portion;   placing a shape wire radially-inward of said first shaft layer;   coupling said shaft wire to said tip electrode.   
     
     
         23 . The method of  claim 22 , wherein said shape wire defines a lariat shape. 
     
     
         24 . The method of  claim 22 , wherein said the shape wire is Nitinol. 
     
     
         25 . The method of  claim 21 , wherein said outer sleeve comprises expanded polytetrafluoroethylene (ePTFE). 
     
     
         26 . The method of  claim 21 , wherein said sensor comprises a tubular core and an electrically-conductive coil wound on said core. 
     
     
         27 . An elongate medical device comprising:
 a shaft having an exterior wall and defining an axis;   an inner structure within the shaft; and   a first sensor disposed on the inner structure, wherein the first sensor is positioned between the inner structure and the exterior wall and in contact with the exterior wall, wherein the inner structure is bonded to an inner surface of the exterior wall.   
     
     
         28 . The elongate medical device of  claim 27 , wherein, said exterior wall comprises expanded polytetrafluoroethylene (ePTFE). 
     
     
         29 . The elongate medical device of  claim 27 , wherein said first sensor comprises a tubular core and an electrically-conductive coil wound on said core, said core defining a second axis. 
     
     
         30 . The elongate medical device of  claim 27 , further comprising a tip electrode coupled to a distal end portion of the shaft. 
     
     
         31 . The elongate medical device of  claim 27 , wherein the bond between the inner structure and the inner surface of the exterior wall is formed from a reflowed material. 
     
     
         32 . The elongate medical device of  claim 27 , wherein the inner structure is bonded to an inner surface of the exterior wall at a portion of the inner structure that is proximate the first sensor. 
     
     
         33 . The elongate medical device of  claim 27 , further comprising a second sensor, wherein the second sensor is located at a different location along a longitudinal axis of the elongate medical device. 
     
     
         34 . The elongated medical device of  claim 33 , further comprising a distal tip assembly comprising the first sensor and the second sensor. 
     
     
         35 . The elongate medical device of  claim 34 , wherein the distal tip assembly is formed in a curved shape. 
     
     
         36 . An elongate medical device comprising:
 a first sensor disposed on an inner structure, wherein the first sensor is positioned between the inner structure and an exterior wall and the first sensor is in contact with the exterior wall; and   a second sensor disposed on the inner structure, wherein the second sensor is positioned between the inner structure and the exterior wall and the second sensor is in contact with the exterior wall.   
     
     
         37 . The elongate medical device of  claim 36 , wherein the first sensor is located at a different longitudinal position along a longitudinal axis of the elongate medical device. 
     
     
         38 . The elongate medical device of  claim 37 , wherein the elongate medical device further comprises a distal tip assembly comprising the first sensor and the second sensor. 
     
     
         39 . The elongate medical device of  claim 38 , wherein the distal tip assembly is formed in a curved shape.