Medical devices with a flexible electrode assembly coupled to an ablation tip

Abstract

Medical devices and methods for making and using medical devices are disclosed. An example medical device may include a catheter for use in cardiac mapping and/or ablation. The catheter may include an elongate catheter shaft having a distal ablation electrode region capable of ablating tissue. An electrode assembly may be coupled to the distal ablation electrode region. The electrode assembly may include a flexible circuit having one or more electrodes disposed thereon.

We claim: 
     
         1 . A catheter for use in cardiac mapping and/or ablation, the catheter comprising:
 an elongate catheter shaft having a distal ablation electrode region;   an electrode assembly coupled to the distal ablation electrode region; and   wherein the electrode assembly includes a flexible circuit having one or more electrodes disposed thereon.   
     
     
         2 . The catheter of  claim 1 , wherein the distal ablation electrode region has an opening formed therein and wherein the electrode assembly extends through the opening. 
     
     
         3 . The catheter of  claim 1 , wherein the electrode assembly includes a region that is disposed along a distal end of the distal ablation electrode region. 
     
     
         4 . The catheter of  claim 1 , wherein the electrode assembly includes a plurality of arm regions and wherein each of the arm regions includes at least one electrode. 
     
     
         5 . The catheter of  claim 4 , wherein the electrode assembly includes three or more arm regions. 
     
     
         6 . The catheter of  claim 4 , wherein the electrode assembly includes four or more arm regions. 
     
     
         7 . The catheter of  claim 1 , wherein the electrode assembly includes a mechanical locking end region that is capable of mechanically securing the electrode assembly to the distal ablation electrode region. 
     
     
         8 . The catheter of  claim 7 , wherein the distal ablation electrode region has an opening formed therein and wherein the mechanical locking end region extends through the opening. 
     
     
         9 . The catheter of  claim 1 , wherein the catheter shaft includes an inner channel, wherein the distal ablation electrode region includes a first opening and a second opening, and wherein the electrode assembly extends along the inner channel, through the first opening, along an outer surface of the distal ablation electrode region, and through the second opening. 
     
     
         10 . The catheter of  claim 1 , wherein the electrode assembly is adhesively bonded to the distal ablation electrode region. 
     
     
         11 . The catheter of  claim 1 , wherein the electrode assembly includes one or more electrode regions and one or more electrically insulated regions. 
     
     
         12 . The catheter of  claim 1 , wherein the electrode assembly extends circumferentially around the distal ablation electrode region. 
     
     
         13 . The catheter of  claim 1 , wherein the electrode assembly is designed to bow radially outward from the distal ablation electrode region. 
     
     
         14 . The catheter of  claim 1 , wherein the distal ablation electrode region includes a platinum ablation tip electrode. 
     
     
         15 . A method for manufacturing a medical device, the method comprising:
 inserting an electrode assembly into a channel formed within a distal ablation tip of a catheter;   wherein the electrode assembly includes a flexible circuit having one or more electrodes disposed thereon;   wherein the distal ablation tip includes a first opening and a second opening; and   extending the electrode assembly extends through the first opening, along an outer surface of the distal ablation tip, and through the second opening.   
     
     
         16 . A catheter for use in cardiac mapping and/or ablation, the catheter comprising:
 an elongate catheter shaft having an inner channel and a distal end region;   a distal ablation tip capable of ablating tissue disposed at the distal end region;   an electrode assembly coupled to the distal ablation tip;   wherein the electrode assembly includes a flexible circuit having one or more electrodes disposed thereon;   wherein the distal ablation electrode region includes a first opening and a second opening;   wherein the electrode assembly extends along the inner channel, through the first opening, along an outer surface of the distal ablation tip, and through the second opening.   
     
     
         17 . The catheter of  claim 16 , wherein the electrode assembly includes a region that is disposed along a distal end of the distal ablation tip. 
     
     
         18 . The catheter of  claim 16 , wherein the electrode assembly includes a plurality of arm regions and wherein each of the arm regions includes at least one electrode. 
     
     
         19 . The catheter of  claim 16 , wherein the electrode assembly includes a mechanical locking end region that is capable of mechanically securing the electrode assembly to the distal ablation tip. 
     
     
         20 . The catheter of  claim 19 , wherein the mechanical locking end region extends through the first opening, the second opening, or both.