CATHETER SHEATH AND A METHOD OF MANUFACTURING

• US 20130150808A1
• Filed: 08/12/2011
• Published: 06/13/2013
• Est. Priority Date: 08/13/2010
• Status: Active Grant

• Current Assignee: Cathrx Ltd
• Original Assignee: Cathrx Ltd
• Inventors: Ogle, David, Ryan, Garrett, Partlett, Matthew
• Granted Patent: US 9,700,696 B2
• Time in Patent Office: Days
• US Class Current: 604/264
• CPC Class Codes: A61B 18/1492 having a flexible, catheter-like structure, e.g. for heart ablation A61B18/1477 takes precedence
• CPC Class Codes: A61M 25/0009 Making of catheters or other medical or surgical tubes
• CPC Class Codes: A61M 25/0012 with embedded structures, e.g. coils, braids, meshes, strands or radiopaque coils
• CPC Class Codes: A61M 25/0015 Making lateral openings in a catheter tube, e.g. holes, slits, ports, piercings of guidewire ports; Methods for processing the holes, e.g. smoothing the edges
• CPC Class Codes: A61M 25/0043 characterised by structural features
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A catheter sheath comprises a tubular member connected to a catheter handle, the tubular sheath including one or more electrical conductors and one or more electrode rings attached to the tip of the tubular member. The tubular member further includes at least one opening that allows the one or more electrical conductor to be electrically connected to the one or more electrode rings. The electrode ring is slid over the tubular member so as to cover the opening. The tubular member and the electrode ring are subjected to heat treatment by induction heating so that the material of the tubular member melts locally around the electrode ring to form a seal between the tubular member and the electrode ring.

Claims

1. A method of manufacturing a catheter sheath, comprising:

providing a tubular member of non-conductive material having a proximal end and a distal end, the tubular member further having one or more electrical conductors extending from the proximal end to the distal end within the tubular member;

forming at least one opening in an outer wall of the tubular member for accessing the one or more electrical conductors within the tubular member;

attaching at least one conductive element on the outer wall of the tubular member in electrically conductive connection with the one or more electrical conductors so that the at least one conductive element is adjacent to and surrounding the at least one opening; and

treating the tubular member and the at least one conductive element with heat by induction heating so that the tubular member melts locally around the at least one conductive element to form a seal along each edge of the at least one conductive element.

2. The method of claim 1, wherein attaching the at least one conductive element on the tubular member comprises applying a radial force.

3. The method of claim 2, wherein applying the radial force compresses the at least one conductive element so that an outer surface of the at least one conductive element lies substantially flush with the outer wall of the tubular member.

4. The method of claim 2, further comprising swaging the at least one conductive element.

5. The method of claim 1, further comprising applying a sacrificial heat-shrink member over the at least one conductive element.

6. The method of claim 1, further comprising applying a mold over the at least one conductive element.

7. The method of claim 1, wherein the one or more electrical conductors are arranged within a lumen defined by the tubular member.

8. The method of claim 1, wherein the one or more electrical conductors are arranged between an inner wall and an outer wall of the tubular member.

9. The method of claim 1, wherein the at least one conductive element includes a ring electrode snug fit about the tubular member.

19. The method of claim 3, further comprising swaging the at least one conductive element.

10. A catheter sheath, comprising:

a tubular member of non-conductive material having a proximal end and a distal end;

at least one electrical conductor extending from the proximal end to the distal end within the tubular member;

at least one opening in an outer wall of the tubular member for accessing the at least one electrical conductor within the tubular member; and

at least one conductive element on the outer wall of the tubular member, the at least one conductive element being adjacent to and surrounding the at least one opening and arranged in conductive connection with the at least one electrical conductor; and

a seal along each edge of the at least one conductive element comprising locally melted and re-solidified material of the tubular member.

11. The catheter sheath of claim 10, wherein the at least one conductive element is compressed into the tubular member.

12. The catheter sheath of claim 11, wherein an outer surface of the at least one conductive element is substantially flush with the outer wall of the tubular member.

13. The catheter sheath of claim 11, wherein the at least one conductive element is swaged into the tubular member.

14. The catheter sheath of claim 10, wherein the seal is formed by applying a sacrificial heat-shrink over the at least one conductive element while locally melting and re-solidifying the material of the tubular member.

15. The catheter sheath of claim 10, wherein the seal is formed by applying a mold over the at least one conductive element while locally melting and re-solidifying the material of the tubular member.

16. The catheter sheath of claim 10, wherein the at least one electrical conductor is located between an inner and outer wall of the tubular member.

17. The catheter sheath of claim 10, wherein the at least one electrical conductor is located longitudinally within a lumen defined by the tubular member.

18. The catheter sheath of claim 10, wherein the at least one conductive element includes a ring electrode snug fit about the tubular member.

20. The catheter sheath of claim 11, wherein the at least one conductive element is swaged into the tubular member.