High Density Electrode Mapping Catheter

Abstract

An integrated electrode structure can comprise a catheter shaft comprising a proximal end and a distal end, the catheter shaft defining a catheter shaft longitudinal axis. A flexible tip portion can be located adjacent to the distal end of the catheter shaft, the flexible tip portion comprising a flexible framework. A plurality of microelectrodes can be disposed on the flexible framework and can form a flexible array of microelectrodes adapted to conform to tissue. A plurality of conductive traces can be disposed on the flexible framework, each of the plurality of conductive traces can be electrically coupled with a respective one of the plurality of microelectrodes.

What is claimed is: 
     
         1 . An integrated electrode structure comprising:
 a catheter shaft comprising a proximal end and a distal end, the catheter shaft defining a catheter shaft longitudinal axis;   a flexible tip portion coupled to the distal end of the catheter shaft, the flexible tip portion comprising a flexible framework formed from a planar substrate and including an inboard understructure and an outboard understructure, the inboard and outboard understructure each having a top surface and a bottom surface;   a plurality of microelectrodes patterned onto the top surface and bottom surface of the inboard and outboard understructure so as to form a flexible top planar array of microelectrodes on the top surface of the inboard and outboard understructure and a flexible bottom planar array of microelectrodes on the bottom surface of the inboard and outboard understructure, wherein the flexible top planar array of microelectrodes is parallel with the flexible bottom planar array of microelectrodes, wherein the plurality of microelectrodes comprise a plurality of rows of longitudinally-aligned microelectrodes aligned parallel to the catheter shaft longitudinal axis; and   a plurality of conductive traces disposed on the flexible framework, each of the plurality of conductive traces electrically coupled with a respective one of the plurality of microelectrodes.   
     
     
         2 . The integrated electrode structure of  claim 1 , wherein the inboard understructure and the outboard understructure comprise a flexible printed circuit board. 
     
     
         3 . The integrated electrode structure of  claim 1 , wherein the inboard understructure and the outboard understructure are formed from a unitary piece of material. 
     
     
         4 . The integrated electrode structure of  claim 1 , wherein the inboard understructure and the outboard understructure comprise a plurality of longitudinally extending arms. 
     
     
         5 . The integrated electrode structure of  claim 4 , wherein the inboard understructure comprises a first inboard longitudinally extending arm and a second inboard longitudinally extending arm and the outboard understructure comprises a first outboard longitudinally extending arm and a second outboard longitudinally extending arm. 
     
     
         6 . The integrated electrode structure of  claim 4 , wherein the inboard understructure includes a flared head portion disposed at a distal portion of the inboard understructure. 
     
     
         7 . The integrated electrode structure of  claim 6 , wherein the outboard understructure includes a head portion disposed at a distal portion of the outboard understructure, wherein the flared head portion is disposed within the head portion. 
     
     
         8 . The integrated electrode structure of  claim 7 , wherein the flared head portion of the inboard understructure is coupled to head portion of the outboard understructure via a connective portion. 
     
     
         9 . The integrated electrode structure of  claim 1 , wherein the inboard understructure and the outboard understructure include an atraumatic edge that extends around a perimeter of the inboard understructure and the outboard understructure. 
     
     
         10 . The integrated electrode structure of  claim 1 , wherein each one of the microelectrodes patterned onto the top surface has a corresponding vertically adjacent microelectrode patterned onto the bottom surface. 
     
     
         11 . The integrated understructure of  claim 10 , wherein at least one of the microelectrodes patterned onto the bottom surface is configured for contact with tissue and to sense a bottom electrical signal, wherein at least of the microelectrodes patterned onto the top surface is configured to receive of a top electrical signal, wherein a degree of contact between the at least one of the microelectrodes on the bottom surface and the tissue is determined based on a comparison between the top electrical signal and the bottom electrical signal. 
     
     
         12 . The integrated electrode structure of  claim 10 , wherein a vertical spacing between the vertically adjacent microelectrodes is less than 3 mm. 
     
     
         13 . The integrated electrode structure of  claim 10 , wherein the plurality of microelectrodes comprise raised microelectrodes that extend above a surface of the flexible framework. 
     
     
         14 . The integrated electrode structure of  claim 10 , wherein the plurality of microelectrodes have a longitudinal length in a range from 0.1 mm to 5 mm and a lateral width in a range from 0.1 mm to 5 mm. 
     
     
         15 . The integrated electrode structure of  claim 1 , wherein the plurality of conductive traces are disposed on the top surface of the inboard understructure and outboard understructure and the bottom surface of the inboard understructure and outboard understructure. 
     
     
         16 . The integrated electrode structure of  claim 15 , wherein each of the plurality of conductive traces is aligned parallel to the catheter shaft longitudinal axis. 
     
     
         17 . The integrated understructure of  claim 15 , wherein each of the plurality of conductive traces are routed around alternating sides of a preceding microelectrode. 
     
     
         18 . The integrated understructure of  claim 15 , wherein the plurality of conductive traces comprise multiple layers of patterned conductive traces formed on the flexible framework, wherein each patterned conductive trace layer is separated from another patterned conductive trace layer by a dielectric material. 
     
     
         19 . The integrated electrode structure of  claim 15 , further comprising a dielectric material disposed between each of the plurality of conductive traces and the flexible framework, wherein the dielectric material covers an outer facing surface of each of the plurality of conductive traces. 
     
     
         20 . The integrated understructure of  claim 1 , further comprising a mounting portion coupled to the inboard understructure and the outboard understructure, wherein the mounting portion includes a plurality of contact pads electrically coupled with the plurality of microelectrodes via the plurality of conductive traces. 
     
     
         21 . The integrated understructure of  claim 21 , wherein the plurality of conductive pads are staggered longitudinally toward a proximal end of the mounting portion and laterally toward the catheter shaft longitudinal axis. 
     
     
         22 . An integrated electrode structure comprising:
 a catheter shaft comprising a proximal end and a distal end;   a flexible tip portion coupled to the distal end of the catheter shaft, the flexible tip portion comprising a flexible framework formed from a planar substrate;   a plurality of microelectrodes patterned onto a top surface and a bottom surface of the flexible framework so as to form a flexible top planar array of microelectrodes and a flexible bottom planar array of microelectrodes, wherein the flexible top planar array of microelectrodes is parallel with the flexible bottom planar array of microelectrodes, wherein each microelectrode in the flexible top planar array and the flexible bottom planar array are longitudinally aligned with one another when the flexible tip portion is in an expanded configuration; and   a plurality of conductive traces disposed on the flexible framework, each of the plurality of conductive traces electrically coupled with a respective one of the plurality of microelectrodes.