Method of fabricating an elongate medical device
An elongate medical device having an axis comprises an inner liner, a jacket radially outward of the liner, a braid comprising metal embedded in the jacket, a sensor, and at least one wire electrically connected to said sensor. The at least one wire is one of: embedded in the jacket and optionally disposed helically around the braid; extending longitudinally within a tube which extends generally parallel to the device axis and wherein the tube is embedded in the jacket; and disposed within a lumen, wherein the lumen extends longitudinally within the jacket.
1. A method of fabricating an elongate medical device having a longitudinal axis, comprising:
providing an elongate liner having a distal end and a proximal end;
surrounding said liner with a braid comprising metal;
placing a positioning sensor over said braid at said distal end;
disposing a longitudinally-extending element radially outward from said braid;
applying an outer layer over said braid, said sensor, and said longitudinally-extending element;
subjecting said device to a reflow lamination process;
removing said longitudinally-extending element from said device to create a lumen;
providing an electrically-conductive wire in said lumen; and
electrically coupling said wire to said sensor.
2. The method of claim 1 , wherein said longitudinally-extending element is coated with polytetrafluoroethylene (PTFE).
3. The method of claim 1 , wherein said elongate liner is provided on a mandrel.
4. The method of claim 1 , wherein said longitudinally-extending element comprises a material that has a first melting point that is higher than a second melting point of said outer layer.
5. The method of claim 1 , wherein said lumen is parallel with said longitudinal axis.
6. A method of fabricating an elongate medical device having a longitudinal axis, comprising:
providing an elongate liner having a distal end and a proximal end;
surrounding said liner with a braid comprising metal;
placing a sensor over said braid at said distal end;
disposing a wire radially outward from said braid so that said wire extends helically around said braid and around said longitudinal axis;
applying an outer layer over said braid, said sensor, and said wire; and
subjecting said device to a reflow lamination process.
7. The method of claim 6 , wherein said disposing said wire radially outward from said braid comprises disposing said wire directly on said braid.
8. The method of claim 7 , wherein said wire comprises a shielded twisted pair cable.
9. The method of claim 6 , wherein said wire comprises one of:
a shielded twisted pair cable; and
an unshielded twisted pair cable.