Basket assembly with atraumatic tip electrode and methods of making thereof
The disclosed technology includes an expandable basket assembly for a medical probe, which may include 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. The plurality of spines may include a first layer and a second layer attached to the first layer and including a central cutout about the central spine intersection that exposes the first layer at the central spine intersection. The plurality of spine may include a central electrode attached to the first layer at the central spine intersection via a central aperture in the first layer at the central spine intersection. The second layer may be configured to articulate independently of the first layer at 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;
the plurality of spines comprise:
a first layer;
a second layer attached to the first layer and comprising a central cutout about the central spine intersection that exposes the first layer at the central spine intersection, the second layer comprising a plurality of radial cutouts extending from the central cutout along the second layer of each spine; and
a central electrode attached to the first layer at the central spine intersection via a central aperture in the first layer at the central spine intersection.
2 . The expandable basket assembly of claim 1 , wherein the first layer comprises polyether ether ketone (PEEK), liquid crystal polymer (LCP), or both.
3 . The expandable basket assembly according to claim 2 , wherein the second layer comprises nitinol, cobalt chromium, or both.
4 . The expandable basket assembly according to claim 1 , wherein the plurality of spines comprises four to ten spines of the plurality of spines.
5 . The expandable basket assembly according to claim 4 , wherein the plurality of spines comprises six spines.
6 . The expandable basket assembly according to claim 1 , further comprising one or more electrodes coupled to each of the spines, each electrode defining a lumen through the electrode so that a spine extends through the lumen of each of the one or more electrodes.
7 . The expandable basket assembly according to claim 6 , wherein each electrode comprises a wire relief adjacent the lumen to allow for one or more wires to extend adjacent to the lumen.
8 . The expandable basket assembly according to claim 6 , wherein the lumen is disposed symmetrically about a longitudinal axis of each of the one or more electrodes.
9 . The expandable basket assembly according to claim 6 , wherein the one or more electrodes are configured to deliver electrical pulses for irreversible electroporation, the pulses having a peak voltage of at least 900 volts (V).
10 . The expandable basket assembly according to claim 6 , wherein the central electrode is electrically isolated from the one or more electrodes coupled to each of the spines.
11 . The expandable basket assembly according to claim 1 , wherein the plurality of spines form an approximately spherical shape.
12 . The expandable basket assembly according to claim 1 , wherein the plurality of spines form an approximately oblate-spheroid shape.
13 . The expandable basket assembly according to claim 1 , wherein the central electrode is spaced apart from the second layer.
14 . The expandable basket assembly according to claim 1 , wherein the central electrode comprises a disc- or button-shape.
15 . The expandable basket assembly according to claim 1 , wherein the first layer is an inner layer and the second layer is an outer layer.
16 . The expandable basket assembly according to claim 1 , wherein the first layer is an outer layer and the first layer is an outer layer.
17 . The expandable basket assembly of claim 1 ,
the first layer comprising polyether ether ketone (PEEK), liquid crystal polymer (LCP), or both,
the second layer comprising nitinol, cobalt chromium, or both,
the plurality of spines comprising six spines,
the plurality of spines forming an approximately oblate-spheroid shape,
further comprising one or more electrodes coupled to each of the spines, each electrode defining a lumen through the electrode so that a spine extends through the lumen of each of the one or more electrodes, the lumen being disposed symmetrically about a longitudinal axis of each of the one or more electrodes, the one or more electrodes being configured to deliver electrical pulses for irreversible electroporation, the pulses having a peak voltage of at least 900 volts (V), the central electrode being electrically isolated from the one or more electrodes coupled to each of the spines,
the central electrode being spaced apart from the second layer, and
the central electrode comprising a disc- or button-shape.
18 . 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
the plurality of spines comprise:
an outer layer comprising a central cutout and a plurality of radial cutouts extending from the central cutout along the outer layer of each spine;
an inner layer attached to the outer layer, the central cutout exposing the inner layer at the central spine intersection;
one or more extrusion layers at least partially covering each spine;
a central electrode attached to the inner layer at the central spine intersection via a central aperture in the inner layer at the central spine intersection; and
one or more electrodes attached to each spine and disposed over a portion of the one or more extrusion layers.
19 . A method of constructing a medical probe, the method comprising:
cutting a planar sheet of a second material to form a second layer of a plurality of spines having a central spine intersection;
cutting a center cutout at the central spine intersection;
cutting radial cutouts that extend from the center cutout along the second layer of each spine;
overmolding a first material on the second layer for forming a first layer;
cutting aperture in the first layer at the central spine intersection; and
inserting a central electrode into the aperture.
20 . The method of according to claim 19 , further comprising:
attaching a first extrusion layer to partially cover end portions of each spine;
attaching a second extrusion layer to cover each spine and the first extrusion layer covering each spine;
inserting one or more ring electrodes around each spine; and
fitting ends of the plurality of spines to a tubular shaft sized to traverse vasculature such that the central spine intersection is positioned at a distal end of the medical probe and respective spines are movable from a tubular configuration to a bowed configuration.