Medical devices including high strength bond joints and methods of making same

A method of forming an ablation catheter comprising a catheter shaft and an electrode tip assembly, the method comprising:

• providing an electrode tip assembly including a tip stem on a proximal end and a wire bundle attached to the tip stem;
• providing tubing located in a catheter shaft;
• introducing an adhesive onto a circumference of the tip stem and onto the wire bundle and tubing;
• and
• introducing the tip stem and wire bundle into a distal end of the catheter shaft, such that a distal end of the tubing is separated from the tip stem of the electrode tip assembly along a longitudinal direction of the catheter shaft, and wherein the adhesive extends past the tip stem to encapsulate and fill at least a part of the tubing towards a proximal end of the catheter shaft.

A method of forming an ablation catheter comprising a catheter shaft and an electrode tip assembly, the method comprising:

• introducing an orifice into a distal end of the catheter shaft;
• providing an electrode tip assembly including a tip stem on a proximal end and a wire bundle attached to the tip stem and introducing a first adhesive onto a circumference of the tip stem and onto the wire bundle;
• introducing the tip stem and wire bundle into the distal end of a catheter shaft;
• and
• introducing a second adhesive into the orifice on the distal end of the catheter shaft.