Electrode-carrying catheter and method of making same

Abstract

An electrode-carrying catheter has elongate, flexible tubing defining a proximal end, a distal end, and an electrically insulative outer tubular layer intermediate the ends, the tubing including a flexible electrically conductive core of wire and a flexible non-conductive core-covering layer of plastic about the core. At least one electrically conductive ring electrode is crimped on and flush with the outer tubular surface. In order to conduct electrical signals between the proximal end and each of the ring electrodes, a longitudinally-spaced plurality of flexible electrically conductive wires are helically wound around and at least partially into the core-covering layer. The wound wires define a removed section beneath a segment of each of the ring electrodes to enable electrical contact between a respective one of the wound wires and a respective one of the ring electrodes An electrically conductive flexible flat ribbon is disposed intermediate each of the ring electrodes and the tubing, each ribbon being electrically and physically joined to a respective one of the wound wires and wrapped about the outer tubular surface, each of the ring electrodes being crimped onto a respective one of the ribbons and the outer tubular surface.

I claim: 
     
       1. An electrode-carrying catheter, comprising: (A) elongate, flexible tubing defining a proximal end, a distal end, and an electrically insulative outer tubular layer intermediate said ends, said tubing including a flexible electrically conductive core of wire and a flexible non-conductive core-covering layer of plastic about said core;   (B) at least one electrically conductive ring electrode crimped on and flush with said outer tubular layer, and   (C) conducting means for conducting electrical signals between said proximal end and each of said at least one ring electrode, said conducting means including, intermediate said core and said outer tubular layer, a longitudinally-spaced plurality of flexible electrically conductive wires helically wound around and at least partially into said core-covering layer and insulated from one another at least by said core-covering layer and from the environment at least by said outer tubular layer, said outer tubular layer defining a removed section beneath a segment of each of said at least one ring electrode to enable electrical contact between a respective one of said wound wires and a respective one of said at least one ring electrode, said conducting means further including electrically conductive flexible flat means disposed intermediate each of said at least one ring electrode and said tubing for providing electrical communication between one of said at least one ring electrode and one of said wound wires, each of said flat means being electrically and physically joined to a respective one of said wound wires and wrapped about said outer tubular layer, each of at least one ring electrode being crimped onto a respective one of said flat means and said outer tubular layer.   
     
     
       2. The catheter of claim 1 wherein said flat means is joined to said wound wires by welding. 
     
     
       3. The catheter of claim 1, wherein said core-covering layer is softer than said outer tubular layer. 
     
     
       4. The catheter of claim 1, wherein said core-covering layer is over-extruded over said core, and said outer tubular layer is over-extruded over said wound wires and said core-covering layer. 
     
     
       5. The catheter of claim 1, wherein said flat means is a flat copper ribbon having a pair of opposed ends, said ribbon being electrically and physically joined at one end to a respective one of said wound wires, wrapped under tension completely about said outer tubular layer, and physically joined at the other end to itself. 
     
     
       6. The catheter of claim 1, wherein said core is a stranded and twisted configuration of annealed stainless steel wire having an appreciable torsional strength and a slow return after lateral bending. 
     
     
       7. The catheter of claim 1 wherein said core-covering layer and said outer tubular layer are formed of polyurethane. 
     
     
       8. The catheter of claim 1 wherein each of said wound wires is covered with electrical insulation, and said electrical insulation covering each wound wire defines a removed section beneath one of said at least one electrode. 
     
     
       9. The catheter of claim 1 wherein said at least one electrode are platinum with a minor proportion of iridium. 
     
     
       10. The catheter of claim 1 wherein each of said at least one ring electrode is crimped onto said flat means and said outer tubular layer at at least 24 crimp points. 
     
     
       11. The catheter of claim 1 wherein said at least one ring electrode crimped onto said flat means and said outer tubular layer are also welded to said flat means, and said outer tubular layer is reformed about said at least one ring electrode. 
     
     
       12. The catheter of claim 1 wherein said core has an extension projecting distally from said distal end, and an electrically conductive end electrode is crimped distally onto said core extension and is proximally crimped onto and radially flush with said outer tubular layer. 
     
     
       13. The catheter of claim 1 wherein, said wound wires include electrical insulation thereabout, and said outer tubular layer and said electrical insulation about said wound wires define said removal section. 
     
     
       14. An electrode-carrying catheter, comprising: (A) elongate, flexible tubing defining a proximal end, a distal end, and an electrically insulative outer tubular layer intermediate said ends, said tubing including a flexible electrically conductive core of wire and a flexible non-conductive core-covering layer of plastic about said core, said core being a stranded and twisted configuration of annealed stainless steel wire having an appreciable torsional strength and a slow return after lateral bending, said core-covering layer being softer than said outer tubular layer and over-extruded over said core;   (B) at least one electrically conductive ring electrode crimped on and flush with said outer tubular layer; and   (C) conducting means for conducting electrical signals between said proximal end and each of said at least one ring electrode, said conducting means including, intermediate said core and said outer tubular layer, a longitudinally-spaced plurality of flexible electrically conductive wires helically wound around and at least partially into said core-covering layer and insulated from one another at least by said core-covering layer and insulated from one another at least by said core-covering layer and from the environment at least by said outer tubular layer, said outer tubular layer defining a removed section beneath a segment of each of said at least one ring electrode to enable electrical contact between a respective one of said wound wires and a respective one of said at least one ring electrode, said conducting means further including electrically conductive flexible flat means disposed intermediate each of said at least one ring electrode and said tubing for providing electrical communication between one of said at least one ring electrode and one of said wound wires, each of said flat means being a flat copper ribbon having a pair of opposed ends, said ribbon being electrically physically joined by welding at one end to a respective one of said wound wires, wrapped under tension completely about said outer tubular layer, and physically joined by welding at the other end to itself, each of said at least one ring electrode being crimped onto a respective one of said flat means and said outer tubular layer, said at least one ring electrode crimped onto sad flat means and said outer tubular layer being also welded to said flat means, and said outer tubular layer being reformed about said at least one ring electrode, said outer tubular layer being over-extruded over said wound wires and said core-covering layer,   said core having an extension projecting distally from said distal, end and an electrically conductive and electrode being crimped distally onto said core extension and proximally crimped onto and radially flush with said outer tubular layer.   
     
     
       15. The catheter of claim 14 wherein, said wound wires include electrical insulation thereabout, and said outer tubular layer and said electrical insulation about said wound wires define said removed section. .Iadd. 
     
     
       16.  An electrode-carrying catheter, comprising: (A) elongate, flexible tubing defining a proximal end, a distal end, and an electrically insulative outer tubular layer intermediate said ends, said tubing including a flexible electrically conductive core of wire and a flexible non-conductive core-covering layer about said core;   (B) at least one electrically conductive ring electrode crimped on and flush with said outer tubular layer; and   (C) conducting means for conducting electrical signals between said proximal end and each of said at least one ring electrode, said conducting means including, intermediate said core and said outer tubular layer, a longitudinally-spaced plurality of flexible electrically conductive wires helically wound around and at least partially into said core-covering layer and insulated from one another at least by said core-covering layer and from the environment at least by said outer tubular layer, said outer tubular layer defining a removed section beneath a segment of each of said at least one ring electrode to enable electrical contact between a respective one of said wound wires and a respective one of said at least one ring electrode, said conducting mean further including electrically conductive flexible flat means disposed intermediate each of said at least one ring electrode and said tubing for providing electrical communication between one of said at least one ring electrode and one of said wound wires, each of said flat means being electrically and physically joined to a respective one of said wound wires, and wrapped about said outer tubular layer, each of at least one ring electrode being crimped onto a respective one of said flat means and said outer tubular layer. .Iaddend..Iadd.17. The catheter of claim 16 wherein said flat means is joined to said wound wires by welding. .Iaddend..Iadd.18. The catheter of claim 16 wherein said core-covering layer is softer than said outer tubular layer. .Iaddend..Iadd.19. The catheter of claim 16 wherein said core-covering layer is over-extruded over said core, and said outer tubular layer is over-extruded over said wound wires and said core-covering layer. .Iaddend..Iadd.20. The catheter of claim 16 wherein said flat means is a flat copper ribbon having a pair of opposed ends, said ribbon being electrically and physically joined at one end to a respective one of said wound wires, wrapped under tension completely about said outer tubular layer, and physically joined at the other end to itself. .Iaddend..Iadd.21. The catheter of claim 16 wherein said core is a stranded and twisted configuration of annealed stainless steel wire having an appreciable torsional strength and a slow return after lateral bending. .Iaddend..Iadd.22. The catheter of claim 16 wherein said core-covering layer and said outer tubular layer are formed of polyurethane. .Iaddend..Iadd.23. The catheter of claim 16 wherein each of said wound wires is covered with electrical insulation, and said electrical insulation covering each wound wire defines a removed section beneath one of said at least one electrode. .Iaddend..Iadd.24. The catheter of claim 16 wherein said at least one electrode is platinum with a minor proportion of iridium. .Iaddend..Iadd.25. The catheter of claim 16 wherein each said at least one ring electrode is crimped onto said flat means and said outer   
     
     
        tubular layer at at least 24 crimp points. .Iaddend..Iadd.26.  The catheter of claim 16 wherein said at least one ring electrode crimped onto said flat means and said outer tubular layer are also welded to said flat means, and said outer tubular layer is reformed about said at least one ring electrode. .Iaddend..Iadd.27. The catheter of claim 16 wherein said core has an extension projecting distally from said distal end, and an electrically conductive end electrode is crimped distally onto said core extension and is crimped proximally onto and radially flush with said outer tubular layer. .Iaddend..Iadd.28. The catheter of claim 16 wherein said wound wires include electrical insulation thereabout, and said outer tubular layer and said electrical insulation about said wound wires define said removed section. .Iaddend..Iadd.29. An electrode-carrying catheter, comprising: (A) elongate, flexible tubing defining a proximal end, a distal end, and an electrically insulative outer tubular layer intermediate said ends, said tubing including a flexible non-conductive core-covering layer about said core, said core being a stranded and twisted configuration of annealed stainless steel wire having an appreciable torsional strength and a slow return after lateral bending, said core-covering layer being softer than said outer tubular layer and over-extruded over said core;   (B) at least one electrically conductive ring electrode crimped on and flush with said outer tubular layer; and   (C) conducting means for conducting electrical signals between said proximal end and each of said at least one ring electrode, said conducting means including, intermediate said core and said outer tubular layer, a longitudinally-spaced plurality of flexible electrically conductive wires helically wound around and at least partially into said core-covering layer and insulated from one another at least by said core-covering layer and insulated from one another at least by said core-covering layer and from the environment at least by said outer tubular layer, said outer tubular layer defining a removed section beneath a segment of each of said at least one ring electrode to enable electrical contact between a respective one of said wound wires and a respective one of said at least one ring electrode, said conducting means further including electrically conductive flexible flat means disposed intermediate each of said at least one ring electrode and said tubing for providing electrical communication between one said at least one ring electrode and one of said wound wires, each of said flat means being a flat cooper ribbon having a pair of opposed ends, said ribbon being electrically physically joined by welding at one end to a respective one of said wound wires, wrapped under tension completely about said outer tubular layer, and physically joined by welding at the other end to itself, each of said at least one ring electrode being crimped onto a respective one of said flat means and said out tubular layer, said at least one ring electrode crimped onto said flat means and said outer tubular layer being also welded to said flat means, and said outer tubular layer being reformed about said at least one ring electrode, said outer tubular layer being over-extruded over said wound wires and said core-covering layer;   said core having an extension projecting distally from said distal end and an electrically conductive end electrode being crimped distally onto said core extension and proximally crimped onto and radially flush with said   
     
     
        outer tubular layer. .Iaddend..Iadd.30.  The catheter of claim 29 wherein said wound wires include electrical insulation thereabout, and said outer tubular layer and said electrical insulation about said wound wires define said removed section. .Iaddend.