Expandable basket assemblies with linear spine patterns for improved tissue contact and methods for making thereof
The disclosed technology includes an expandable basket assembly for a medical probe, which may include a single unitary structure including a plurality of spines converging at a central spine intersection. The central spine intersection being positioned on a longitudinal axis of the expandable basket assembly at a distal end thereof. The single unitary structure may include a plurality of radial cutouts with each radial cutout defining an opening in each of the plurality of spines proximate the central spine intersection so that each opening extends for a length along each spine away from the central spine intersection.
1 . An expandable basket assembly for a medical probe, comprising:
a single unitary structure comprising a plurality of spines converging at a central spine intersection, the central spine intersection being positioned on a longitudinal axis of the expandable basket assembly at a distal end thereof; and
a plurality of radial cutouts with each radial cutout defining an opening in each of the plurality of spines proximate the central spine intersection so that each opening extends for a length along each spine away from the central spine intersection,
each cutout comprises a tadpole shaped cutout, the tadpole shaped cutout includes a head portion contiguous to a circumference of a first virtual circle with a first radius r 1 disposed about the longitudinal axis, the head portion defining a negative area approximating a second virtual circle with a second radius r 2 , the head portion connected to a slotted tail portion extending for a first length L 1 along the spine and contiguous to an inside circumference of a third virtual circle having a third radius r 3 , and
the first length of the slotted tail portion is approximately 6-10 times that of the length of the first radius r 1 of the first virtual circle.
2 . The expandable basket assembly according to claim 1 , further comprising a center aperture disposed on the central spine intersection, wherein the plurality of radial cutouts are separated from the center aperture by a portion of the central spine intersection.
3 . The expandable basket assembly of claim 1 , further comprising a center cutout disposed on the longitudinal axis to define a central negative area of a center aperture approximating a central circle including a central radius r 0 smaller than the first radius r 1 .
4 . The expandable basket assembly of claim 3 , in which the negative area of each of the tadpole shaped cutouts comprises approximately 0.2 mm-squared while the negative area of the center aperture is approximately 0.05 mm-squared so that a total negative area defined by all of the cut outs is approximately 1.4 mm-squared.
5 . The expandable basket assembly of claim 3 , wherein central void radius r 0 comprises approximately 0.13 mm, the second radius r 2 comprises approximately 0.2 mm, and the first radius r 1 comprises approximately 0.23 mm.
6 . An expandable basket assembly for a medical probe, comprising:
a single unitary structure comprising a plurality of spines converging at a central spine intersection, the central spine intersection being positioned on a longitudinal axis of the expandable basket assembly at a distal end thereof;
a plurality of radial cutouts with each radial cutout defining an opening in each of the plurality of spines proximate the central spine intersection so that each opening extends for a length along each spine away from the central spine intersection, and
a center aperture disposed on the central spine intersection, wherein the plurality of radial cutouts are separated from the center aperture by a portion of the central spine intersection,
the center aperture comprises an area of about 0.01 mm-squared to about 0.4 mm-squared,
each of the plurality of radial cutouts includes an area of about 0.1 mm-squared to about 0.55 mm-squared and each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width,
each of the plurality of radial cutouts defines a comet-shaped cutout with head portion with a slotted tapered tail extending to a proximal portion of each spine.
7 . The expandable basket assembly according to claim 6 , wherein the first width is about 0.15 mm to about 0.5 mm, the second width is about 0.05 mm to about 0.35 mm, and the third width is about 0.3 mm to about 0.7 mm, and the third portion of each spine comprises an electrode attachment slot configured to accept an electrode, the electrode attachment slot bisects each spine into two minor widths of about 0.05 mm to about 6 mm.
8 . An expandable basket assembly for a medical probe, comprising:
a single unitary structure comprising a plurality of spines converging at a central spine intersection, the central spine intersection being positioned on a longitudinal axis of the expandable basket assembly at a distal end thereof; and
a plurality of radial cutouts with each radial cutout defining an opening in each of the plurality of spines proximate the central spine intersection so that each opening extends for a length along each spine away from the central spine intersection,
a center aperture disposed on the central spine intersection, wherein the plurality of radial cutouts are separated from the center aperture by a portion of the central spine intersection,
wherein each cut out comprises two teardrop cutouts attached at their narrow portions to define a single cutout on each spine of about 0.4 mm-squared.
9 . The expandable basket assembly according to claim 6 , wherein the third portion of each spine comprises a slot that bisects each spine into two minor widths each of which comprises a width of approximately 0.1 mm to approximately 6 mm.
10 . The expandable basket assembly according to claim 6 , wherein the third portion of each spine comprises a slot that bisects each spine into two minor portions with the slot comprising a width of approximately 0.05 mm to approximately 0.55 mm and the center aperture includes a radius of approximately 0.4 mm to approximately 1.2 mm.
11 . The expandable basket assembly according to claim 8 , wherein each radial cutout comprises an ellipse shape at an end furthest from the center aperture and the ellipse shape includes a length of about 0.20 mm to about 0.55 mm and a width of about 0.1 mm to about 0.45 mm.
12 . The expandable basket assembly according to claim 1 , further comprising a center aperture disposed on the central spine intersection, wherein the plurality of radial cutouts extend from and are connected to the center aperture to form a single cutout.
13 . The expandable basket assembly according to claim 1 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the first width is about 0.15 mm to about 0.5 mm, the second width is about 0.05 mm to about 0.35 mm, and the third width is about 0.3 mm to about 0.7 mm.
14 . The expandable basket assembly according to claim 1 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the third portion of each spine comprises an electrode attachment slot configured to accept an electrode, the electrode attachment slot bisects each spine into two minor widths of about 0.05 mm to about 6 mm.
15 . The expandable basket assembly according to claim 1 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the third portion of each spine comprises a slot that bisects each spine into two minor widths each of which comprises a width of approximately 0.1 mm to approximately 6 mm.
16 . The expandable basket assembly according to claim 8 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the first width is about 0.15 mm to about 0.5 mm, the second width is about 0.05 mm to about 0.35 mm, and the third width is about 0.3 mm to about 0.7 mm.
17 . The expandable basket assembly according to claim 8 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the third portion of each spine comprises an electrode attachment slot configured to accept an electrode, the electrode attachment slot bisects each spine into two minor widths of about 0.05 mm to about 6 mm.
18 . The expandable basket assembly according to claim 8 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the third portion of each spine comprises a slot that bisects each spine into two minor widths each of which comprises a width of approximately 0.1 mm to approximately 6 mm.
19 . The expandable basket assembly according to claim 8 , each of the spines includes a first portion proximate to the central spine intersection with a first width, a second portion proximate the first portion with a second width less than the first portion, and a third portion proximate the second portion with a third width that is greater than the first width and greater than the second width, wherein the third portion of each spine comprises a slot that bisects each spine into two minor portions with the slot comprising a width of approximately 0.05 mm to approximately 0.55 mm.