Integrated polymer and braid for intravascular catheters

• US 20030028173A1
• Filed: 08/06/2001
• Published: 02/06/2003
• Est. Priority Date: 08/06/2001
• Status: Active Grant

• Current Assignee: Boston Scientific Scimed, Inc. (Boston Scientific Corporation)
• Original Assignee: Scimed Life Systems Incorporated (Boston Scientific Corporation)
• Inventors: Forsberg, Andrew
• Granted Patent: US 6,635,047 B2
• Time in Patent Office: Days
• US Class Current: 604/527
• CPC Class Codes: A61M 25/0045 multi-layered, e.g. coated coating materials A61L29/08
• CPC Class Codes: A61M 25/005 with embedded materials for reinforcement, e.g. wires, coils, braids
• CPC Class Codes: A61M 25/0053 having a variable stiffness along the longitudinal axis, e.g. by varying the pitch of the coil or braid
• CPC Class Codes: A61M 25/0054 with regions for increasing flexibility

Abstract

An intravascular catheter including a reinforcement layer having a plurality of interwoven metal wire members and polymer members. The polymer members are thermally processed to permeate the metal wire members to form a polymeric layer having an orientation which is interwoven with the metal wire members.

Claims

1. An intravascular catheter comprising an elongate shaft including a reinforcement layer having a plurality of braided metal wire members and a polymer material permeating the metal wire members, wherein the polymer material has an orientation which is interwoven with the metal wire members.

2. An intravascular catheter as in claim 1, further comprising an inner polymeric layer defining a lumen extending therethrough, with the reinforcement layer covering the inner polymeric layer.

3. An intravascular catheter as in claim 2, further comprising an outer polymeric layer covering the reinforcement layer.

4. An intravascular catheter as in claim 3, wherein the polymer material of the reinforcement layer thermally fuses to the outer polymer layer.

5. An intravascular catheter as in claim 3, wherein the polymer material of the reinforcement layer and the outer polymeric layer comprise thermally bondable polymeric materials.

6. An intravascular catheter as in claim 5, wherein the polymer material of the reinforcement layer and the outer polymeric layer comprise the same polymeric material.

7. An intravascular catheter comprising an elongate shaft including a reinforcement layer having a plurality of interwoven metal wire members and polymer members, wherein the polymer members are thermally processed to permeate the metal wire members.

8. An intravascular catheter as in claim 7, wherein the polymer members have a larger cross-sectional area than the metal wire members.

9. An intravascular catheter as in claim 7, wherein the polymer members have a cumulative cross-sectional area sufficient to at least partially encase the metal wire members.

10. An intravascular catheter as in claim 7, wherein the polymer members have a cumulative cross-sectional area sufficient to fully encase the metal wire members.

11. An intravascular catheter as in claim 7, wherein the elongate shaft has a length and a wall thickness, and wherein the polymer members have a pic count per unit length which varies along the length of the elongate shaft to thereby vary the wall thickness thereof.

12. An intravascular catheter as in claim 7, wherein the elongate shaft has a length and a stiffness, and wherein the polymer members have a durometer which varies along the length of the elongate shaft to thereby vary the stiffness thereof.

13. An intravascular catheter as in claim 7, further comprising an inner polymeric layer defining a lumen extending therethrough, with the reinforcement layer covering the inner polymeric layer.

14. An intravascular catheter as in claim 13, further comprising an outer polymeric layer covering the reinforcement layer.

15. An intravascular catheter as in claim 14, wherein the polymer members thermally fuse to the outer polymer layer.

16. An intravascular catheter as in claim 14, wherein the polymer members and the outer polymeric layer comprise thermally bondable polymeric materials.

17. An intravascular catheter as in claim 16, wherein the polymer members and the outer polymeric layer comprise the same polymeric material.

18. A method of making an intravascular catheter, comprising:

braiding a plurality of metal wire members with a plurality of polymer members; and

thermally processing the polymer members to permeate the metal wire members.

19. A method of making an intravascular catheter as in claim 18, wherein the polymer members have a cumulative cross-sectional area sufficient to at least partially encase the metal wire members after thermal processing.

20. A method of making an intravascular catheter as in claim 18, wherein the polymer members have a cumulative cross-sectional area sufficient to fully encase the metal wire members after thermal processing.

21. A method of making an intravascular catheter as in claim 18, wherein the polymer members are braided to have a pic count per unit length which varies to thereby vary the wall thickness of the catheter.

22. A method of making an intravascular catheter as in claim 18, wherein the polymer members are extruded to have a durometer which varies to thereby vary the stiffness of the catheter.

23. A method of making an intravascular catheter as in claim 18, further comprising the act of forming an inner polymeric layer and braiding the reinforcement layer thereon.

24. A method of making an intravascular catheter as in claim 23, further comprising the step of forming an outer polymeric layer over the reinforcement layer.