Sensor mounted flexible guidewire

1. A medical device, comprising:

a corewire having a proximal end and a distal end, said distal end terminating at a distal tip;

a sensor assembly comprising a sensor core and a sensor;

one or more wires electrically coupled with the sensor; and

an electrical interconnect, disposed at said corewire proximal end, configured to be electrically coupled with said one or more wires to provide an electrical connection between said sensor and an external device;

wherein said sensor core comprises a proximal end, a distal end, and a bore in said proximal end, and further wherein said corewire distal tip is disposed within said bore in said sensor core, further wherein said corewire proximal end is proximal of said sensor core proximal end further wherein said sensor core defines a longitudinal axis extending from said sensor core proximal end to said sensor core distal end and said sensor core has a radially-outermost surface, said sensor mounted on said radially-outermost surface.

2. The medical device of claim 1 , wherein said corewire includes a first portion having a first diameter and a second portion located at said distal end having a second diameter that is less than said first diameter, and further wherein said distal tip is a part of said second portion of said corewire.

3. The medical device of claim 1 , wherein said sensor comprises an electromagnetic field detector comprising a coil wound on said sensor core.

4. The medical device of claim 1 , further comprising at least one of a polymer layer, a metallic layer, and a tubular spring covering at least a portion of at least one of said sensor core and said corewire.

5. A method of manufacturing a medical device, the method comprising:

providing a sensor core configured to have a sensor mounted on said sensor core, said sensor core defining a longitudinal axis extending from a proximal end to a distal end, said sensor core having a radially-outermost surface;

providing a corewire having a proximal end and a distal end, said distal end terminating in a distal tip;

mounting a sensor onto said radially-outermost surface of said sensor core;

forming a bore in said proximal end of said sensor core; and

inserting a portion of said corewire into said bore; and

rigidly coupling said corewire with said sensor core with said distal tip of said corewire disposed in said bore.

6. The method of claim 5 , wherein said forming a bore comprises drilling said bore into said first end of said sensor core.

7. The method of claim 5 , further comprising covering at least a portion of at least one of said corewire and said sensor core with at least one of an elastic polymer material, a metallic material, and a tubular spring.

8. The method of claim 7 , wherein said polymer material comprises a heat shrink tube, said method further comprising the step of applying heat to said polymer material.

9. The method of claim 5 , wherein said corewire is a first corewire, and said forming a bore further comprises forming a bore in said distal end of said sensor core, said method further comprising:

providing a second corewire; and

inserting said second corewire into said bore in said distal end of said sensor core such that a proximal end of said second corewire is disposed in said bore in said distal end of said sensor core.

10. The method of claim 9 , wherein said bore in said sensor core proximal end is continuous with said bore in said sensor core distal end.

11. A medical device, comprising:

a non-hollow corewire having a proximal end and a distal end, said proximal end terminating in a proximal tip and said distal end terminating in a distal tip;

a sensor assembly comprising a sensor core and a sensor; and

at least one of a polymer layer, a metallic layer, and a tubular spring covering at least a portion of at least one of said sensor core and said corewire;

wherein said sensor core comprises a first end, a second end, and a bore in said first end, and further wherein one of said corewire distal tip and said corewire proximal tip is disposed within said bore in said sensor core, further wherein said sensor core defines a longitudinal axis extending from said first end to said second end and said sensor core has a radially-outermost surface, said sensor mounted on said radially-outermost surface.

12. The medical device of claim 11 , wherein said corewire includes a first portion having a first diameter and a second portion located at said distal end having a second diameter that is less than said first diameter, and further wherein said distal tip is a part of said second portion of said corewire.

13. The medical device of claim 11 , wherein said sensor comprises an electromagnetic field detector comprising a coil wound on said sensor core.

14. The medical device of claim 11 , wherein said corewire is cylindrical.

15. The medical device of claim 11 , wherein said corewire is a first corewire, and said sensor core further comprises a bore in said second end, the medical device further comprising a second non-hollow corewire comprising a proximal end and a distal end, one of said second corewire proximal end and said second corewire distal end disposed within said bore in said second end of said sensor core.

16. The medical device of claim 15 , wherein said bore in said sensor core first end is continuous with said bore in said sensor core second end.

17. The medical device of claim 15 , wherein said bore in said sensor core first end is not continuous with said bore in said sensor core second end.

18. The medical device of claim 15 , wherein said first corewire and said second corewire are cylindrical.

19. A medical device, comprising:

a non-hollow corewire having a proximal end and a distal end; and

a sensor assembly comprising a sensor core and a sensor;

wherein said sensor core comprises a first end, a second end, and a bore in said first end, and further wherein one of said corewire distal end and said corewire proximal end is disposed within said bore in said sensor core, further wherein said sensor core defines a longitudinal axis extending from said first end to said second end and said sensor core has a radially-outermost surface, said sensor mounted on said radially-outermost surface;

wherein one of said corewire distal end and said corewire proximal end is bonded to said sensor core with adhesive.

20. The medical device of claim 19 , wherein said corewire is a first corewire, said bore is a blind bore, and said sensor core further comprises a blind bore in said second end, the medical device further comprising a second non-hollow corewire comprising a proximal end and a distal end, one of said second corewire proximal end and said second corewire distal end disposed within said blind bore in said second end of said sensor core, said blind bore in said first end of said sensor core not being continuous with said blind bore in said second end of said sensor core.

21. The medical device of claim 19 , wherein said corewire includes a first portion having a first diameter and a second portion located at said distal end having a second diameter that is less than said first diameter, and further wherein said second portion of said corewire is disposed within said bore in said sensor core.

22. The medical device of claim 19 , wherein said corewire is cylindrical.

23. The medical device of claim 1 , wherein said interconnect is electrically coupled with said one or more wires.