Multi-layered catheter shaft construction with embedded single axial sensors, and related methods

A catheter comprising:

• a proximal elongated section comprising a multi-layered portion with a magnetic-based sensor assembly, the proximal elongated section having only a single common lumen extending therethrough,
• a control handle proximal of the proximal elongated section, and
• a distal section distal of the proximal elongated section, the distal section comprising an electrode and a plurality of lumens,
• the multi-layered portion of the proximal elongated section comprising an assembly of a first inner layer, a braided mesh over the first inner layer, and a second layer, the second layer having a reflowed construction with an inner surface over the braided mesh and the first inner layer, the first inner layer and the second layer being of similar thermoplastic materials, and the assembly of the first inner layer, the braided mesh, and the second layer defining the single common lumen extending through the first inner layer of the proximal elongated section, and
• the magnetic-based sensor assembly of the proximal elongated section comprising:
• a first wire sensor comprising a first continuous wire with a first coil portion, a first distal portion and a first proximal portion, the first coil portion being at a first location on the second layer of the multi-layered portion of the proximal elongated section, the first distal portion and the first proximal portion of the first wire sensor extending on an outer surface of the second layer toward a proximal end of the proximal elongated section and into the control handle,
• a second wire sensor comprising a second continuous wire with a second coil portion, a second distal portion and a second proximal portion, the second coil portion being at a second location on the second layer of the multi-layered portion of the proximal elongated section, the second location being distal of the first location, the second distal portion and the second proximal portion extending on the outer surface of the second layer toward the proximal end of the proximal elongated section and into the control handle,
• a third wire sensor comprising a third continuous wire with a third coil portion, a third distal portion and a third proximal portion, the third coil portion being at a third location on the second layer of the proximal elongated section, the third location being distal of the first and second locations, the third distal portion and the third proximal portion extending on the outer surface of the second layer toward the proximal end of the proximal elongated section and into the control handle, the third distal portion and the third proximal portion of the third wire sensor extending proximally on the outer surface of the second layer underneath the first coil portion of the first wire sensor and the second coil portion of the second wire sensor,
• a first insulation sleeve mounted in circumferential surrounding relation on the second layer of the multi-layered portion between the first coil portion of the first wire sensor and segments of the second distal portion and second proximal portion of the second wire sensor that extend beneath the first coil portion of the first wire sensor, and
• a second insulation sleeve mounted in circumferential surrounding relation on the second layer of the multi-layered portion between the second coil portion of the second wire sensor and segments of the third distal portion and third proximal portion of the third wire sensor that extend beneath the second coil portion of the second wire sensor.