Method of manufacturing an expandable member with substantially uniform profile

• US 20070010846A1
• Filed: 10/17/2005
• Published: 01/11/2007
• Est. Priority Date: 07/07/2005
• Status: Abandoned Application

• Current Assignee: Kyphon SARL (Medtronic Plc)
• Original Assignee: Kyphon SARL (Medtronic Plc)
• Inventors: Leung, Andrea, Palmer, Erika, Malandain, Hugues, Sand, Paul
• Application Number:
  US11/250,618
• Publication Number:
  US 20070010846A1
• Time in Patent Office: Days
• US Class Current: 606/192
• CPC Class Codes: A61B 17/3421 Cannulas
• CPC Class Codes: A61B 17/3478 Endoscopic needles, e.g. for infusion biopsy needles A61B10/0233; catheters with injection needles A61M25/0067
• CPC Class Codes: A61B 2017/00261 Discectomy
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/320048 Balloon dissectors
• CPC Class Codes: A61B 90/02 Devices for expanding tissue, e.g. skin tissue implements for holding wounds open, surgical tractors A61B17/02; implantable mammary prosthesis A61F2/12; dilators A61M29/00
• CPC Class Codes: A61M 25/1029 Production methods of the balloon members, e.g. blow-moulding, extruding, deposition or by wrapping a plurality of layers of balloon material around a mandril
• CPC Class Codes: A61M 29/00 Dilators with or without means for introducing media, e.g. remedies instruments for performing visual medical inspections of cavities or tubes of the body A61B1/00
• CPC Class Codes: A61M 29/02 Dilators made of swellable material balloon catheters for angioplasty A61M25/104

Abstract

A method includes heating a first portion of a tubular member to a first temperature greater than a temperature of a second portion of the tubular member. The first portion of the tubular member is different from the second portion of the tubular member. The tubular member is stretched after the heating such that a length of the first portion of the tubular member is associated with a width of an anulus of an intervertebral disc. After the heating and the stretching, the tubular member is disposed within a mold cavity at least until the first portion of the tubular member has a second temperature less than the first temperature and such that an outer diameter of the tubular member in a collapsed configuration is substantially constant along a longitudinal length of the tubular member.

Claims

1. A method, comprising:

heating a first portion of a tubular member to a first temperature greater than a temperature of a second portion of the tubular member, the first portion of the tubular member being different from the second portion of the tubular member;

stretching the tubular member after the heating; and

after the heating and the stretching, disposing the tubular member within a mold cavity at least until the first portion of the tubular member has a second temperature less than the first temperature and such that an outer diameter of the tubular member in a collapsed configuration is substantially constant along a longitudinal length of the tubular member.

2. The method of claim 1, wherein the first portion of the tubular member has an outer diameter after the first portion has the second temperature and when the tubular member is in an expanded configuration such that it corresponds to a size of a cannula configured to provide access to an interior of an intervertebral disc.

3. The method of claim 1, wherein the outer diameter of the tubular member in the collapsed configuration is sized to substantially correspond to a size of a proximate end of a projection configured to percutaneously access an intervertebral disc.

4. The method of claim 1, further comprising:

communicating a pressurized gas into an internal cavity of the tubular member while disposed within the mold cavity.

5. The method of claim 1, wherein the heating includes disposing at least one heat block on an outer surface of the first portion of the tubular member.

6. The method of claim 1, wherein the first portion of the tubular member includes an inner diameter after the stretching less than an inner diameter of the second portion of the tubular member.

7. The method of claim 1, wherein the first portion of the tubular member includes an outer diameter after the stretching less than an outer diameter of the second portion of the tubular member.

8. The method of claim 1, wherein the first portion of the tubular member includes an inner diameter after the first portion of the tubular member has the second temperature greater than an inner diameter of the second portion of the tubular member.

9. The method of claim 1, wherein the stretching includes exerting a tensile force on opposite end portions of the tubular member in a longitudinal direction.

10. The method of claim 1, wherein the stretching is performed such that after the stretching a wall thickness of the tubular member is associated with access of the cannula into a nucleus of an intervertebral disc when the tubular member is in an expanded configuration.

11. The method of claim 1, wherein the outer diameter of the first portion of the tubular member, after the first portion has the second temperature, is associated with percutaneous access into an anulus of an intervertebral disc when the tubular member is in a collapsed configuration.

26. The method of claim 1, wherein the stretching includes stretching the tubular member such that a length of the first portion of the tubular member is associated with a width of an anulus of an intervertebral disc.

12. An apparatus, comprising:

an elongate body defining a lumen and including a first portion, a second portion and a third portion, the second portion is disposed between the first portion and the third portion along a longitudinal length of the elongate body, an outer diameter of the elongate body in a collapsed configuration being substantially constant along the longitudinal length of the elongate body,

when in the collapsed configuration, at least a portion of the lumen associated with the second portion having a diameter larger than the diameter of the portion of the lumen associated with the first portion and the diameter of the portion of the lumen associated with the third portion.

13. The apparatus of claim 12, wherein a thickness of at least a portion of a wall of the second portion is less than a thickness of a wall of the first portion and a thickness of a wall of the third portion when the tubular body is in the collapsed configuration.

14. The apparatus of claim 12 wherein the tubular body has an expanded configuration in which the outer diameter of the tubular body at the second portion differs from the outer diameter of the tubular body at the first portion and the outer diameter of the tubular body at the third portion.

15. The apparatus of claim 12, wherein the tubular body has an expanded configuration in which an outer diameter of the tubular body at the second portion is greater than an outer diameter of the tubular body at the first portion and an outer diameter of the tubular body at the third portion.

16. The apparatus of claim 12, wherein the tubular body has an expanded configuration in which an outer diameter of the tubular body at the second portion is configured to expand an opening in an anulus of an intervertebral disc.

17. The apparatus of claim 12, wherein the tubular body has an expanded configuration in which an outer diameter of the tubular body at the second portion is sized such that it corresponds to an outer diameter of a cannula configured to provide percutaneous access to an interior of an intervertebral disc.

18. The apparatus of claim 12, wherein the outer diameter of the tubular body in the collapsed configuration is sized such that it corresponds to the size of a proximate end of a projection configured to percutaneously access an intervertebral disc.

19. The apparatus of claim 12, wherein when in the collapsed configuration a portion of the lumen associated with the first portion has a diameter substantially corresponding to a diameter associated with the third portion.

27. The apparatus of claim 12, wherein a length of the second portion of the elongate body is associated with a width of an anulus of an intervertebral disc, and the outer diameter of the elongate body in a collapsed configuration is associated with percutaneous access to an intervertebral disc.

20. A manufacturing kit, comprising:

a heating device configured to heat a first portion of an outer surface of a tubular body to a first temperature greater than a temperature of a second portion of the tubular body;

a stretching device configured to apply a tensile force on opposite end portions of the tubular body; and

a mold having a cavity configured to maintain a position of the tubular body while disposed within the mold at least until the first portion of an outer surface of the tubular body has a second temperature less than the first temperature and such that an outer diameter of the tubular body in a collapsed configuration is substantially constant along a longitudinal length of the tubular body.

21. The manufacturing kit of claim 20, further comprising:

a blower configured to communicate pressurized gas into an internal passageway of the tubular body while the tubular body is received within the mold.

22. The manufacturing kit of claim 20, wherein the heating device includes a heat block having an inner diameter and an outer diameter, the inner diameter configured to contact the outer surface of the first portion of the tubular body.

23. The manufacturing kit of claim 20, further comprising:

a plug configured to be inserted into an end of a tubular body; and

a blower configured to communicate pressurized gas into an internal passageway of the tubular body while the tubular body is received within the mold.

24. The manufacturing kit of claim 20, wherein the heating device is configured such that the temperature of the first portion of the outer surface of the tubular body is associated with a predetermined deformation of the tubular body.

25. The manufacturing kit of claim 20, wherein the outer diameter of the first portion of the outer surface of the tubular body is associated with percutaneous access into an anulus of an intervertebral disc when the tubular body is in the collapsed configuration.

28. The manufacturing kit of claim 20, wherein the stretching device is configured to apply a tensile force on opposite end portions of the tubular body such that a length of the first portion of the tubular body is associated with a width of an anulus of an intervertebral disc.