Flexible Multi-Arm Catheter with Diametrically Opposed Sensing Electrodes

A manufacturing method, comprising:

• patterning electrodes and conductive lines on multiple flexible circuit boards;
• laminating pairs of the flexible circuit boards, with a layer of tensile material sandwiched between the circuit boards of each pair, so as to form flexible spines;
• and
• mounting the multiple flexible spines at a distal end of a shaft, wherein the multiple flexible spines have respective first ends that are connected to a distal end of the shaft and respective second ends that are free-standing and unanchored, wherein the spines are bent proximally such that the second ends are more proximal than the first ends, and wherein a tensile layer included in each of the flexible spines is configured to cause the flexible spines to bend proximally.

A manufacturing method, comprising:

• patterning electrodes and conductive lines on multiple flexible circuit boards;
• and
• folding the flexible circuit boards along respective longitudinal axes of the circuit boards, over one or more fibers made of a tensile material, such that the fibers become sandwiched between two diametrically opposing facets of the patterned flexible boards, so as to form flexible spines;
• and
• mounting the multiple flexible spines at a distal end of a shaft, wherein the multiple flexible spines have respective first ends that are connected to a distal end of the shaft and respective second ends that are free-standing and unanchored, wherein the spines are bent proximally such that the second ends are more proximal than the first ends, and wherein a tensile layer included in each of the flexible spines is configured to cause the flexible spines to bend proximally.

A medical instrument, comprising:

• a catheter shaft extending along a longitudinal axis from a proximal end to a distal end;
• multiple flexible spines extending out of the catheter shaft toward the distal end, each flexible spine includes:
• a respective first end that is connected to the distal end of the catheter shaft and respective second end that is free-standing and unanchored;
• a first plurality of electrodes disposed on a surface of the spine facing the longitudinal axis;
• and
• a second plurality of electrodes disposed on a surface of the spine facing away from the longitudinal axis;
• and
• a tensile member disposed between the first and second plurality of electrodes having tensile strength greater than 895 MPa.