Expandable catheter and related methods of manufacture and use

A medical device, comprising:

• an expandable energy delivery array reciprocally movable between a first configuration and a second configuration, the expandable energy delivery array comprising:
• a plurality of first energy transfer elements, a first proximal end piece, and a first distal end piece, wherein each of the plurality of first energy transfer elements is coupled at a proximal end to the first proximal end piece, and is coupled at a distal end to the first distal end piece, and the first proximal end piece and the first distal end piece are hollow cylinders;
• and
• a plurality of second energy transfer elements, a second proximal end piece, and a second distal end piece, wherein the plurality of first energy transfer elements alternate with the plurality of second energy transfer elements circumferentially about a longitudinal axis of the energy delivery array such that each first energy transfer element is circumferentially between two second energy transfer elements, and each second energy transfer element is circumferentially between two first energy transfer elements, wherein radially outermost portions of each of the plurality of first energy transfer elements are spaced further from the longitudinal axis of the energy delivery array than radially outermost portions of each of the plurality of second energy transfer elements, wherein each of the plurality of second energy transfer elements is coupled at a proximal end to the second proximal end piece, and is coupled at a distal end to the second distal end piece, and the second proximal end piece and the second distal end piece are hollow cylinders;
• wherein:
• the plurality of first energy transfer elements and the plurality of second energy transfer elements are electrically insulated from one another;
• the first and second proximal end pieces are separated by a first insulating element contained longitudinally between the first and second proximal end pieces;
• and
• the first and second distal end pieces are separated by a second insulating element contained longitudinally between the first and second distal end pieces.

A medical device, comprising:

• an expandable energy delivery array reciprocally movable between a first configuration and a second configuration, the expandable energy delivery array comprising:
• a first assembly having a first proximal end piece, a first distal end piece, and a plurality of first electrodes extending between the first proximal and first distal end pieces, each of the plurality of first electrodes being circumferentially offset from each other of the plurality of first electrodes;
• and
• a second assembly having a second proximal end piece, a second distal end piece, and a plurality of second electrodes extending between the second proximal and second distal end pieces, each of the plurality of second electrodes being circumferentially offset from each other of the plurality of second electrodes, wherein a distalmost portion of the second proximal end piece is proximal to both i) a proximalmost portion of the first proximal end piece and ii) proximalmost ends of each of the plurality of first electrodes, and a proximalmost portion of the second distal end piece is distal to i) a distalmost portion of the first distal end piece and ii) distalmost ends of each of the plurality of first electrodes, wherein:
• the first and second assemblies are electrically insulated from one another;
• the first and second proximal end pieces are separated by a first insulating element contained longitudinally between the first and second proximal end pieces;
• the first insulating element directly contacts a proximally-facing surface of the first proximal end piece and directly contacts a distally-facing surface of the second proximal end piece;
• the first and second distal end pieces are separated by a second insulating element contained longitudinally between the first and second distal end pieces;
• and
• the second insulating element directly contacts a distally-facing surface of the first distal end piece and directly contacts a proximally-facing surface of the second distal end piece;
• and
• an activation element configured to reciprocally move the expandable energy delivery array between the first configuration and the second configuration, wherein when the expandable energy delivery array is in the first configuration, proximal movement of the activation element is configured to move both the first and second distal end pieces proximally to cause each of the first electrodes and the second electrodes to buckle and expand radially outward.