Electrode assembly including plated emitters
An electrode assembly including an elongate body, a proximal emitter, and a distal emitter. A discharge port may be in fluid communication with a lumen of the elongate body. The proximal and distal emitters are formed by plating a metal an outer surface of the elongate body that is polymeric. A portion of the elongate body forms an insulative spacer between the proximal and distal emitters. A distal cap may be coupled to the elongate body, formed from conductive material, and arranged in electrical communication with the distal emitter. A distal lead, a thermocouple, and/or a hypotube may be disposed within the lumen to form an electrical pathway with the distal cap. A sheath may be disposed over a portion of the proximal emitter, and a radiopaque marker may be coupled to the proximal emitter. Methods of fabricating the electrode assembly are also disclosed.
1 . An electrode assembly comprising:
an elongate body formed from a flexible polymer comprising an outer surface opposite an inner surface defining a lumen and a discharge port in fluid communication with the lumen;
a proximal emitter formed from plating a metal on a first portion of the outer surface;
a distal emitter formed from plating the metal or another metal on a second portion of the outer surface; and
a proximal lead extending through the lumen and coupled to the proximal emitter through the discharge port,
wherein the first portion and the second portion are spaced apart from one another such that the flexible polymer of the elongate body forms a flexible insulative spacer between the proximal emitter and the distal emitter.
2 . The electrode assembly of claim 1 , wherein at least one of the proximal emitter and the distal emitter comprises a first layer of copper or nickel adhered to the flexible polymer, and a second layer of gold or platinum plated on the first layer.
3 . The electrode assembly of claim 1 , further comprising a distal cap coupled to a distal end of the elongate body, wherein the distal cap is formed from conductive material and arranged in electrical communication with the distal emitter.
4 . The electrode assembly of claim 3 , wherein the electrical communication between the distal cap and the distal emitter is formed from electrodepositing the metal on the distal end of the elongate body.
5 . The electrode assembly of claim 3 , wherein the distal cap is at least partially secured within the lumen, and wherein the distal emitter is further formed from electrodepositing the metal on the inner surface of the elongate body.
6 . The electrode assembly of claim 3 , further comprising a distal lead extending through the lumen and in electrical communication with the distal cap.
7 . The electrode assembly of claim 3 , further comprising:
a thermocouple extending through the lumen and arranged in thermal communication with the distal cap; and
a hypotube extending through the lumen and comprising a closed distal end coupled to the distal cap, wherein the thermocouple is disposed within the hypotube.
8 . The electrode assembly of claim 7 , further comprising a jacket disposed the thermocouple so as to electrically insulate the thermocouple from the hypotube.
9 . The electrode assembly of claim 7 , wherein the elongate body further defines an infusion port in fluid communication with the lumen to-define a fluid pathway between the inner surface of the elongate body and the hypotube.
10 . The electrode assembly of claim 1 , further comprising a sheath coaxially disposed over a portion of the proximal emitter, wherein the sheath is formed from non-conductive material such that an exposed portion of the plated metal defines the proximal emitter.
11 . The electrode assembly of claim 10 , further comprising a proximal lead arranged in electrical communication with the proximal emitter and extending proximally between the sheath and the outer surface of the elongate body.
12 . The electrode assembly of claim 11 , further comprising a radiopaque marker band securing the proximal lead to the proximal emitter.
13 . The electrode assembly of claim 1 , wherein the lumen extends longitudinally within a portion of the elongate body and further extends radially outward to the discharge port.
14 . An electrode assembly comprising:
an elongate body comprising an outer surface opposite an inner surface defining a first lumen, a second lumen fluidly separated from the first lumen, and a discharge port in fluid communication with the second lumen, wherein the elongate body is formed from non-conductive material;
a proximal emitter formed from plating a metal on a first portion of the outer surface, wherein the plated metal defines a discharge port in fluid communication with the second lumen; and
a distal emitter formed from plating the metal or another metal on a second portion of the outer surface, wherein the first portion and the second portion are spaced apart from one another such that the elongate body forms an insulative spacer between the proximal emitter and the distal emitter,
wherein the first lumen defines a fluid pathway for fluid received from a fluid source to be discharged through the discharge port, and the second lumen defines an electrical pathway for electrical components of the electrode assembly.
15 . The electrode assembly of claim 14 , further comprising a proximal lead extending through the first lumen and coupled to the proximal emitter.
16 . The electrode assembly of claim 15 , wherein the proximal lead is coupled to the proximal emitter through the discharge port.
17 . The electrode assembly of claim 14 , wherein the electrical components comprise a distal lead extending through the second lumen and coupled to the distal emitter through a hole in the elongate body.
18 . The electrode assembly of claim 17 , wherein the electrical components comprise a thermocouple extending through the second lumen together with the distal lead.
19 . The electrode assembly of claim 14 , wherein the first lumen extends longitudinally within a portion of the elongate body and further extends radially outward to the discharge port.
20 . An electrode assembly comprising: an elongate body formed from a flexible polymer comprising an outer surface opposite an inner surface defining a lumen and a discharge port in fluid communication with the lumen; a proximal emitter formed from plating a metal on a first portion of the outer surface; a distal emitter formed from plating the metal or another metal on a second portion of the outer surface, wherein the first portion and the second portion are spaced apart from one another such that the flexible polymer of the elongate body forms a flexible insulative spacer between the proximal emitter and the distal emitter; and a proximal lead coupled to the proximal emitter, wherein the lumen extends longitudinally within a portion of the elongate body and further extends radially outward to the discharge port, and wherein the proximal lead is disposed within the lumen.