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US 6,027,863 AGranted
Method for manufacturing a tubular medical device
AssigneeIntraTherapeutics, Inc.
InventorJames V. Donadio, III
Life of this patent
Estimating the term…
Abstract
Manufacturing processes for apparatus, including slotted hypotube, for use as a catheter, a guidewire, a catheter sheath for use with catheter introducers or a drug infusion catheter/guidewire are disclosed. The manufacturing process includes creating a pattern of slots or apertures in a flexible metallic tubular member, by processes including but not limited to, electrostatic discharge machining (EDM), chemical milling, ablation and laser cutting. These slots or apertures may be cut completely or partially through the wall of the flexible metallic tubular member. These manufacturing processes may include the additional step of encasing the flexible metallic member such that a fluid tight seal is formed around the periphery of the tubular member.
Claims29
A method for producing a flexible tubular medical device comprising:
- providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;
- providing a light source;
- applying a photoresist to at least a portion of the outer surface of the tubular element;
- providing a pattern mask intermediate the tubular element and the light source;
- exposing the photoresist by directing light from the light source through the pattern mask, and generating relative movement between the tubular element and the light source such that an exposed pattern and an unexposed pattern are generated on the outer surface of the tubular element;
- developing the photoresist to remove first regions of the photoresist that correspond to one of the exposed and unexposed patterns;
- and
- removing first portions of the tubular element that correspond to the first regions of the photoresist such that the tubular element is provided with a desired pattern, the desired pattern including a plurality of apertures that extend completely through the tubular element between an inner and outer diameter of the tubular element, the plurality of apertures being arranged and configured for providing the tubular element with a desired flexibility suitable for intravascular operations.
5 more elements
A method for producing a flexible tubular medical device comprising:
- a. providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;
- b. providing a light source;
- c. creating a pattern on the tubular element by:
- 1. applying photoresist to at least a portion of the outer surface of the tubular element;
- 2. providing a mask intermediate the tubular element and the light source, said mask being curved, at least a portion of said curvature including a pattern defining a plurality of locations translucent to light from the light source;
- 3. placing said tubular element into contact with said mask such that a curvature of said mask receives said tubular element along a first partial arc;
- 4. activating said light source to expose areas of the photoresist on the tubular element that are located along said first partial arc;
- 5. developing the photoresist on the tubular element such that first portions of the photoresist are removed from the tubular element while second portions of the photoresist remain on the tubular element, the first portions and the second portions corresponding to their respective exposure from the light source;
- and
- d. removing segments of the tubular element corresponding to the first portions of the photoresist such that the tubular element is provided with a desired pattern, the desired pattern including a plurality of apertures that extend completely through the tubular element between an inner and outer diameter of the tubular element, the plurality of apertures being arranged and configured for providing the tubular element with a desired flexibility suitable for intravascular operations.
7 more elements
A method for producing a flexible tubular medical device comprising:
- a. providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;
- b. providing a light source;
- c. creating a pattern on the tubular element by:
- 1. applying a photoresist to at least a portion of the outer surface of the tubular element;
- 2. providing a mask intermediate the tubular element and the light source, at least a portion of the mask including a predetermined pattern formed of predetermined locations translucent to light from the light source;
- 3. placing a portion of said mask, said portion including a pattern having a plurality of locations translucent to light from the light source, into contact with said tubular element along a partial arc of said tubular element;
- 4. activating said light source to expose areas of the photoresist along said partial arc of said tubular element;
- 5. developing the photoresist on the tubular element such that first portions of the photoresist are removed from the tubular element while second portions of the photoresist remain on the tubular element, the first portions and the second portions corresponding to their respective exposure from the light source;
- and
- d. removing segments of the tubular element corresponding to the first portions of the photoresist such that the tubular element is provided with a desired pattern, the desired pattern including a plurality of apertures that extend completely through the tubular element between an inner and outer diameter of the tubular element, the plurality of apertures being arranged and configured for providing the tubular element with a desired flexibility suitable for intravascular operations.
7 more elements
A method for producing a flexible tubular medical device comprising:
- providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;
- providing a light source;
- applying a photoresist to at least a portion of the outer surface of the tubular element;
- providing a glass pattern mask intermediate the tubular element and the light source;
- exposing the photoresist by directing light from the light source through the pattern mask such that an exposed pattern and an unexposed pattern are generated on the outer surface of the tubular element;
- developing the photoresist to remove first regions of the photoresist that correspond to one of the exposed and unexposed patterns;
- and
- removing first portions of the tubular element that correspond to the first regions of the photoresist such that the tubular element is provided with a desired pattern, the desired pattern including a plurality of apertures that extend completely through the tubular element between an inner and outer diameter of the tubular element, the plurality of apertures being arranged and configured for providing the tubular element with a desired flexibility suitable for intravascular operations.
5 more elements
A method for producing a flexible tubular medical device comprising:
- providing a tubular element sized for vascular insertion in a human body, the tubular element including an outer surface;
- providing a light source;
- applying a photoresist to at least a portion of the outer surface of the tubular element;
- providing a pattern mask intermediate the tubular element and the light source;
- exposing the photoresist by directing light from the light source through the pattern mask such that an exposed pattern and an unexposed pattern are generated on the outer surface of the tubular element, wherein the exposed and unexposed patterns are generated by rotating the tubular element relative to the light, and moving the pattern mask across the tubular element in coordination with the rotation of the tubular element;
- developing the photoresist to remove first regions of the photoresist that correspond to one of the exposed and unexposed patterns;
- and
- removing first portions of the tubular element that correspond to the first regions of the photoresist such that the tubular element is provided with, a desired pattern, the desired pattern including a plurality of apertures that extend completely through the tubular element between an inner and outer diameter of the tubular element, the plurality of apertures being arranged and configured for providing the tubular element with a desired flexibility suitable for intravascular operations.
5 more elements
A method for producing a tubular medical device comprising:
- providing a tubular element including a circumferential outer surface defined by at least first and second separate partial arc surfaces;
- providing a light source;
- applying a photoresist to the first and second partial arc surfaces of the tubular element;
- providing a pattern mask intermediate the tubular element and the light source,
- generating an exposure pattern on the photoresist by:
- facing the first partial arc surface toward the light source;
- exposing the photoresist on the first partial arc surface by directing light from the light source through the pattern mask and onto the photoresist that covers the first partial arc surface;
- rotating the tubular element such that the second partial arc surface faces the light source;
- moving the pattern mask relative to the tubular element;
- and
- exposing the photoresist on the second partial arc surface by directing light from the light source through the pattern mask and onto the photoresist that covers the second partial arc surface;
- developing the photoresist;
- and
- removing portions of the tubular element that correspond to the exposure pattern generated on the outer surface of the tubular element.
11 more elements
Dependencies are inferred from the claim text.