Balloon catheters with flexible conducting wires and related methods of use and manufacture

1. A medical device, the medical device comprising:

an elongate shaft having a proximal end region, a distal end region, and a lumen extending therebetween;

an expandable member coupled to the distal end region of the elongate shaft, wherein the expandable member is an inflatable cylindrical balloon;

one or more electrical conductors extending from the proximal end region to the expandable member, the one or more electrical conductors having a distal end region secured directly to an outer surface the expandable member; and

one or more energy delivery regions positioned on the expandable member and coupled to the one or more electrical conductors;

wherein the one or more energy delivery regions are formed from a distal portion of the one or more electrical conductors;

wherein the one or more electrical conductors are each at least partially coated with an insulator;

wherein the one or more energy delivery regions are defined by one or more regions of the one or more electrical conductors that are free of the insulator;

wherein at least a portion of the one or more regions of the one or more electrical conductors that are free of the insulator is wound in a serpentine manner; and

wherein the at least the portion of the one or more regions of the one or more electrical conductors that are free of the insulator is wound in the serpentine manner extending along a length of the inflatable cylindrical balloon.

2. The medical device of claim 1 , wherein the one or more electrical conductors extend along an outer surface of the elongate shaft and an outer surface of the expandable member.

3. The medical device of claim 1 , wherein the one or more electrical conductors extend within the lumen of the elongate shaft along at least a portion of a length of the elongate shaft and an outer surface of the expandable member.

4. The medical device of claim 1 , wherein the one or more electrical conductors are adhesively secured to the expandable member.

5. The medical device of claim 1 , wherein the one or more electrical conductors are thermally bonded to the expandable member.

6. The medical device of claim 1 , wherein the one or more electrical conductors are solvent bonded to the expandable member.

7. The medical device of claim 1 , wherein the insulator comprises a polyethylene terephthalate (PET), a polyamide, a polyester, a polyurethane, a fluoropolymer, or a polyimide.

8. The medical device of claim 1 , wherein the one or more energy delivery regions comprise radiofrequency electrodes.

9. The medical device of claim 1 , wherein the one or more energy delivery regions comprise at least two energy delivery regions and wherein the at least two energy delivery regions comprise a bipolar pair.

10. A medical device, the medical device comprising:

an elongate shaft having a proximal end region, a distal end region, and a lumen extending therebetween;

an inflatable cylindrical balloon coupled to the distal end region of the elongate shaft; and

one or more wire conductors having a proximal end and a distal end and covered with an insulating material, the one or more wire conductors extending from the proximal end region of the elongate shaft to an outer surface of the inflatable cylindrical balloon, wherein at least a portion of the one or more wire conductors is wound in a serpentine manner and is free from the insulating material defining one or more energy delivery regions adjacent the distal end of the one or more wire conductors and wherein the at least the portion of the one or more wire conductors is wound in the serpentine manner extending along a length of the inflatable cylindrical balloon.

11. The medical device of claim 10 , wherein the insulating material comprises a polyethylene terephthalate (PET), a polyamide, a polyester, a polyurethane, a fluoropolymer, or a polyimide.

12. The medical device of claim 10 , further comprising one or more temperature sensors.

13. The medical device of claim 12 , wherein the one or more temperature sensors comprise thermistors.

14. The medical device of claim 10 , wherein the one or more energy delivery regions comprise at least two energy delivery regions and wherein the at least two energy delivery regions comprise a bipolar pair.

15. A medical device, comprising:

an elongate shaft having a proximal end region, a distal end region, and a lumen extending therebetween;

an inflatable cylindrical balloon coupled to the distal end region of the elongate shaft;

one or more round wire conductors having a proximal end and a distal end and covered with an insulating material, the one or more round wire conductors extending from the proximal end region of the elongate shaft to the inflatable cylindrical balloon, wherein at least a portion of the one or more round wire conductors is wound in a serpentine manner and free from the insulating material defining one or more energy delivery regions adjacent the distal end of the one or more wire conductors; and

one or more temperature sensors positioned adjacent to at least one of the one or more energy delivery regions;

wherein the one or more energy delivery regions comprise at least two energy delivery regions and wherein the at least two energy delivery regions are arranged in bipolar pairs and wherein the at least the portion of the one or more round wire conductors is wound in the serpentine manner extending along a length of the inflatable cylindrical balloon.

16. The medical device of claim 15 , wherein the one or more round wire conductors extend along an outer surface of the elongate shaft and an outer surface of the inflatable cylindrical balloon.

17. The medical device of claim 15 wherein the one or more round wire conductors extend within the lumen of the elongate shaft along at least a portion of a length of the elongate shaft and an outer surface of the inflatable cylindrical balloon.