Molded catheter distal end assembly and process for the manufacture thereof

The present invention includes a catheter having a molded distal end assembly that includes at least one component molded therewithin. In a preferred embodiment, the catheter end assembly includes a plurality of electrodes and lead wires that are all molded into the walls of the assembly. Each such electrode has at least one thermocouple associated with it, and the thermocouple is also molded into the walls of the assembly. In manufacturing the multi-electrode end assembly, lead wires from the coils and thermocouples are preferably spiral wound within the molded walls of the assembly to reduce the possibility that lead wires may become disconnected during manufacturing and use of the catheter. Particular core pin designs with mold blocking techniques are utilized to mold the coils and lead wires into the wall of the end assembly. The molding method is generally applicable to the manufacturing of a variety of catheter distal end components and assemblies.