Packaging for elongate medical devices and methods of manufacture and use thereof

A holding card for holding an elongate medical device and formed of a generally planar piece of material and comprising:

• at least one relatively large tab cut into the material;
• and
• at least one relatively small tab cut into the material;
• wherein the tabs are placed for holding an elongate medical device and each have:
• a leading corner that, when the elongate medical device is held by the tabs, is towards the distal end of the elongate medical device;
• a trailing edge that, when the elongate medical device is held by the tabs, is towards the proximal end of the elongate medical device;
• and
• a second, radiused corner defining a vertex of the tab
• a first hub holding tab;
• and
• a second hub holding tab;
• wherein:
• the relatively large tab has a generally triangular form creating an angle in the range of about 30-45 degrees at the leading corner, and the relatively small tab has a generally triangular form creating an angle in the range of about 40-50 degrees at the leading corner;
• the tabs are arranged in a plurality of pairs, each pair having one small and one large tab;
• the first hub holding tab is a flap of material shaped to receive a first, proximal portion of a hub assembly through a first cutout;
• and
• the second hub holding tab is a flap of material having a notch and a second cutout, the second cutout sized to match a strain relief associated with a hub on an elongate medical device.

A method of packaging an elongate medical device:

• providing a generally planar holding card having a first surface;
• cutting a number of relatively small tabs in the holding card;
• cutting a number of relatively large tabs larger than the small tabs in the holding card;
• wherein the tabs are placed for holding the elongate medical device and each have:
• a leading corner that, when the elongate medical device is held by the tabs, is towards the distal end of the elongate medical device;
• a trailing edge that, when the elongate medical device is held by the tabs, is towards the proximal end of he elongate medical device;
• and
• a second, radiused corner defining a vertex of the tab;
• wherein the tabs are arranged in a plurality of pairs, each pair having one small and one large tab;
• pushing one of the small tabs upward with respect to the first surface causing the small tab to deflect away from the first surface, then passing a portion of a catheter shaft under the small tab, and allowing the small tab to deflect back toward the first surface;
• and
• pushing one of the large tabs upward with respect to the first surface causing the large tab to deflect away from the first surface, then passing a portion of a catheter shaft under the large tab, and allowing the large tab to deflect back toward the first surface.

Packaging for an elongate medical device comprising:

• a generally planar piece of material having a surface and including a first end and a second end;
• a relatively large tab disposed along the surface of the material, the relatively large tab including a generally triangular form including a leading corner creating an angle in the range of about 30-45 degrees, a radiused second corner defining a vertex of the tab, and a trailing edge;
• and
• a relatively small tab disposed along the surface of the material, the relatively small tab having a generally triangular form including a leading corner creating an angle in the range of about 40-50 degrees, radiused second corner defining a vertex of the tab, and a trailing edge;
• wherein the tabs are disposed along the surface such that the leading corners of the tabs are oriented towards the first end of the material, and the trailing edges of the tabs are oriented towards the second end of the material, and wherein the tabs are arranged in a plurality of pairs of one small and one large tab.

A method of making packaging for an elongate medical device, the packaging including a first end and a second end, the method comprising:

• providing a generally planar piece of material having a surface;
• cutting at least one relatively large tab into the surface of the material, the relatively large tab including a generally triangular form including a leading corner creating an angle in the range of about 30-45 degrees, a radiused second corner defining a vertex of the tab, and a trailing edge;
• and
• cutting at least one relatively small tab into surface of the material, the relatively small tab having a generally triangular form including a leading corner creating an angle in the range of about 40-50 degrees, a radiused second corner defining a vertex of the tab, and a trailing edge;
• wherein the tabs cut into the surface such that the leading corners of the tabs are oriented towards the first end of the packaging;
• and the trailing edges of the tabs are oriented towards the second end of the packaging, and wherein the tabs are arranged in a plurality of pairs of one small and one large tab.