PUSH/PULL WIRE ANCHOR

• US 20090235511A1
• Filed: 06/05/2009
• Published: 09/24/2009
• Est. Priority Date: 06/09/2005
• Status: Active Grant

• Current Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Original Assignee: Enpath Medical, Inc. (Integer Holdings Corporation Inc)
• Inventors: Honebrink, Brian, Fischer, Brian
• Granted Patent: US 8,056,207 B2
• Time in Patent Office: Days
• US Class Current: 29/515
• CPC Class Codes: A61M 2025/015 Details of the distal fixation of the movable mechanical means
• CPC Class Codes: A61M 25/0147 with movable mechanical means, e.g. pull wires
• CPC Class Codes: Y10T 29/49906 Metal deforming with nonmetallic bonding
• CPC Class Codes: Y10T 29/49925 Inward deformation of aperture or hollow body wall

Abstract

A method for making a deflectable catheter includes positioning a positioning a flexible element along a catheter liner. A flexible element distal portion extends along at least a portion of a deflectable distal end portion of the catheter liner. At least one anchor is engaged to the flexible element distal portion. The anchor extends at least part way around the flexible element distal portion. An encapsulant is positioned around at least the flexible element distal portion and the deflectable distal end portion. The method further includes squeezing the encapsulant around the flexible element distal portion and the anchor, wherein the encapsulant forms at least a portion of a sidewall of the deflectable distal end portion and at least the anchor is within the sidewall, and the encapsulant is adapted to transmit pushing and pulling forces from the at least one anchor to the deflectable distal end portion, and the tension strength and compression strength of the flexible element and the at least one anchor are at least as strong as the encapsulant tension strength and compression strength.

Claims

1. A method for making a catheter comprising:

positioning a flexible element along a catheter liner, and a flexible element distal portion extends along at least a portion of a deflectable distal end portion of the catheter liner;

engaging at least one anchor to the flexible element distal portion, and the at least one anchor extends at least part way around the flexible element distal portion;

positioning an encapsulant around at least the flexible element distal portion and the deflectable distal end portion; and

squeezing the encapsulant around the flexible element distal portion and the anchor, wherein the encapsulant forms at least a portion of a sidewall of the deflectable distal end portion and at least the anchor is within the sidewall, and the encapsulant is adapted to transmit pushing and pulling forces from the at least one anchor to the deflectable distal end portion, and the tension strength and compression strength of the flexible element and the at least one anchor are at least as strong as the encapsulant tension strength and compression strength.

2. The method for making the catheter of claim 1 further comprising positioning a braided sheath around the catheter liner, the flexible element and the anchor.

3. The method for making the catheter of claim 2 further comprising positioning the encapsulant around the catheter liner and the braided sheath, and squeezing the encapsulant includes squeezing the encapsulant through the braided sheath and squeezing the encapsulant around the catheter liner to form the sidewall.

4. The method of claim 1, wherein engaging the at least one anchor to the flexible element distal portion includes deforming an engaging portion of the anchor, wherein the engaging portion includes a clamp, and the clamp grasps the flexible element distal portion.

5. The method of claim 4, wherein deforming the anchor includes crimping the clamp at a plurality of points along the clamp.

6. The method of claim 1, wherein engaging the at least one anchor to the flexible element distal portion includes forming at least one flared projection tapering toward an engaged portion of the anchor and the flexible element, and squeezing the encapsulant includes filling the flared projection with the encapsulant.

7. The method of claim 6, wherein forming at least one flared projection includes flaring at least one of the flexible element distal portion and the at least one anchor.

8. The method of claim 1, further comprising engaging a marker band substantially adjacent to the deflectable distal end portion, wherein the marker band is distal relative to the at least one anchor.

9. The method of claim 8, further comprising welding the flexible element distal portion to the marker band.

10. The method of claim 9, further comprising substantially preventing fracture of the flexible element adjacent to the marker band.

11. The method of claim 1, further comprising flaring at least one of the flexible element distal portion and the at least one anchor.

12. A method for making a catheter comprising:

securing at least one anchor to a flexible element distal portion of a flexible element, the anchor extending at least part way around the flexible element distal portion, securing the anchor including;

deforming an engaging portion of the anchor around the flexible element distal portion to grasp the flexible element distal portion, and

forming at least one flared projection at one or both of an anchor proximal end or an anchor distal end, and the flexible element distal portion is at least partially received within the flared projection;

encapsulating the anchor and the flexible element distal portion within an encapsulant including filling the flared projection with the encapsulant; and

forming a catheter sidewall of a catheter body with the encapsulant, the anchor and the flexible element distal portion within the catheter sidewall of a deflectable distal end portion of the catheter body, and the flexible element extends from the deflectable distal end portion toward a proximal end portion of the catheter.

13. The method for making the catheter of claim 12, wherein encapsulating the anchor and the flexible element distal portion includes squeezing the encapsulant around the anchor and the flexible element distal portion.

14. The method for making the catheter of claim 13 further comprising positioning the flexible element and the anchor along a catheter liner including a delivery lumen.

15. The method for making the catheter of claim 14, wherein squeezing the encapsulant and forming the catheter sidewall includes squeezing the encapsulant over the catheter liner to form the sidewall.

16. The method for making the catheter of claim 13, wherein squeezing the encapsulant and forming the catheter sidewall includes squeezing the encapsulant through a braided sheath positioned around at least the anchor and the flexible element distal portion.

17. The method for making the catheter of claim 12, wherein forming at least one flared projection includes forming a tapered flared projection that tapers toward the engaging portion.

18. The method for making the catheter of claim 12, wherein forming at least one flared projection includes forming a flared projection extending annularly away from the flexible element, and the flared projection includes a conical geometry.

19. The method for making the catheter of claim 12, wherein deforming the engaging portion of the anchor includes clamping the engaging portion around the flexible element distal portion.

20. The method for making the catheter of claim 12, wherein forming the catheter sidewall includes forming the catheter sidewall with the encapsulant and a tension strength and a compression strength of the flexible element and the anchor are greater than an encapsulant tension strength and an encapsulant compression strength.

23. The method for making the catheter of claim 20, wherein filling the tapered portion includes filling the proximal tapered portion and the distal tapered portion.

21. A method for making a catheter comprising:

positioning an anchor in a non-deformed configuration around a flexible element distal portion of a flexible element;

clamping an engaging portion of the anchor onto the flexible element distal portion, the clamped anchor in a deformed configuration;

forming one or more projections extending from the engaging portion, the one or more projections including a tapered portion that tapers toward the engaging portion;

squeezing an encapsulant around the anchor and the flexible element to form a sidewall of a catheter body, the catheter body having a deflectable distal end portion, and the anchor and the flexible element are within the sidewall and surrounded by the encapsulant at the deflectable distal end portion; and

filling the tapered portion with the encapsulant, and the encapsulant is adapted to transmit tension and compression from the anchor to the deflectable distal end portion

22. The method for making the catheter of claim 21, wherein forming one or more projections includes:

forming a proximal projection including a proximal tapered portion tapering toward the engaging portion, and

forming a distal projection including a distal tapered portion tapering toward the engaging portion.

24. The method for making the catheter of claim 21, wherein forming one or more projections includes forming a projection extending radially away from the engaging portion.

25. The method for making the catheter of claim 21, wherein forming one or more projections includes flaring at least one projection annularly away from the flexible element, and the projection includes a conical geometry.

26. The method for making the catheter of claim 21, wherein clamping the engaging portion includes crimping the engaging portion at a plurality of points, the plurality of points engaged with the flexible element distal portion.

27. The method for making the catheter of claim 21, wherein positioning the anchor includes positioning a tube around the flexible element distal portion.

28. The method for making the catheter of claim 21, wherein squeezing the encapsulant around the anchor and the flexible element to form the sidewall includes squeezing the encapsulant through a braided sheath positioned around at least the anchor and the flexible element distal portion.