Catheter and method of manufacture
AssigneeSt. Jude Medical, Atrial Fibrillation Divison, Inc.
InventorsChad A. Thorstenson, James D. Savage
Life of this patent
Estimating the term…
Abstract
The instant invention relates generally to introducer catheters used to help deliver catheters or other medical devices to locations within the human body. In particular, the instant invention relates to large diameter introducer catheters (introducer catheters with lumens greater than about 6 French) having increased strength, flexibility, and kink resistance. Introducer catheters according to the teachings herein may also include curved distal ends and flared (that is, funnel-like) transition sections within their lumens.
Claims9
An introducer catheter having a distal end and a proximal end, the introducer catheter comprising:
- a tubular polymeric inner liner having a lumen diameter of at least about 8 French;
- a torque transfer layer surrounding at least a portion of the inner liner, the torque transfer layer comprising at least two flat wires braided into a wire mesh;
- an outer sheath of a melt-processable polymer formed over the torque transfer layer, wherein the outer sheath includes a distal segment and a proximal segment, the proximal segment having a higher durometer than the distal segment;
- and
- at least one flat pull wire disposed longitudinally between the distal end and the proximal end of the introducer catheter, wherein the at least one flat pull wire is connected to a pull ring,
- wherein the outer sheath is formed over a first tubular member, wherein the first tubular member is external to the torque transfer layer, and wherein the at least one flat pull wire is disposed within the first tubular member.
A method of manufacturing an introducer catheter having a distal end and a proximal end, the method comprising:
- forming a tubular polymeric inner liner about a mandrel, the mandrel having an outer diameter of at least about 8 French;
- forming a torque transfer layer over at least a portion of the inner liner, the torque transfer layer including a plurality of flat wires braided into a wire mesh;
- placing a preformed pull wire lumen over the torque transfer layer;
- forming an outer sheath about the torque transfer layer, the outer sheath including at least a distal segment and a proximal segment, wherein each of the distal segment and the proximal segment comprises a melt-processable polymer, and wherein a hardness characteristic of the proximal segment is greater than a hardness characteristic of the distal segment, and wherein the melting point of the outer sheath is lower than the melting point of the preformed pull wire lumen;
- subjecting the inner liner, the torque transfer layer, and the outer sheath to a reflow lamination process, wherein the outer sheath bonds to the torque transfer layer and the inner liner;
- and
- removing the mandrel.
An introducer catheter having a distal end and a proximal end, the introducer catheter comprising:
- a tubular polymeric inner liner having a lumen diameter of at least about 8 French;
- a torque transfer layer surrounding at least a portion of the inner liner, the torque transfer layer comprising at least two flat wires braided into a wire mesh;
- an outer sheath of a melt-processable polymer formed over the torque transfer layer, wherein the outer sheath includes a distal segment and a proximal segment, the proximal segment having a higher durometer than the distal segment;
- and
- at least one flat pull wire disposed longitudinally between the distal end and the proximal end of the introducer catheter, wherein the at least one flat pull wire is connected to a pull ring,
- wherein the at least one flat pull wire is external to the torque transfer layer and is surrounded by a lumen within the outer sheath.
Dependencies are inferred from the claim text.