Methods of fabricating a catheter shaft having one or more guidewire ports

• US 6,409,863 B1
• Filed: 06/12/2000
• Issued: 06/25/2002
• Est. Priority Date: 06/12/2000
• Status: Expired due to Term

• Current Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Original Assignee: Scimed Life Systems Incorporated (Boston Scientific Corporation)
• Inventors: Williams, Brett A., Stivland, Timothy M., Prindle, Katherine M.
• Primary Examiner(s): Aftergut, Jeff H.
• Assistant Examiner(s): Musser, Barbara J.
• Application Number:
  US09/591,753
• Time in Patent Office: 743 Days
• Field of Search: 604/96.01, 604/102.01, 604/102.02, 604/102.03, 604/523, 604/524, 604/527, 606/191, 606/194, 606/198, 156/198, 156/211, 156/256, 156/257, 156/272.8, 156/293, 156/294, 156/308.2
• US Class Current: 156/198
• CPC Class Codes: A61B 5/0084 for introduction into the body, e.g. by catheters A61B5/1459 takes precedence
• CPC Class Codes: A61M 25/0009 Making of catheters or other medical or surgical tubes
• CPC Class Codes: A61M 25/0014 Connecting a tube to a hub
• CPC Class Codes: Y10T 156/1005 by inward collapsing of portion of hollow body
• CPC Class Codes: Y10T 156/1026 with slitting or removal of material at reshaping area prior to reshaping
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]

Abstract

A method of fabricating a catheter shaft having one or more guidewire ports is disclosed. A method in accordance with the present invention includes the steps of cutting the wall of a first shaft portion to create an opening defined by the wall of the first shaft portion, inserting the proximal end of an inner member through the opening defined by the wall of the first shaft portion, inserting the distal end of the inner member into the lumen of a second shaft portion, inserting the bonding end the second shaft portion into a lumen defined by first shaft portion, and bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion.

Claims

1. A method of forming a catheter shaft having a guidewire port, the method comprising the steps of;

providing a first shaft portion having a bonding portion disposed proximate a bonding end thereof, an ancillary end, and a lumen extending therethrough;

providing a second shaft portion having a bonding portion disposed proximate a bonding end thereof, an ancillary end, and a lumen extending therethrough;

providing an inner member having a proximal end, a distal end, and a lumen extending therebetween;

slitting a wall of the first shaft portion to create an opening defined by the wall of the first shaft portion;

inserting the proximal end of the inner member through the opening defined by the wall of the first shaft portion;

inserting the distal end of the inner member into the lumen of the second shaft portion;

inserting the bonding end of the second shaft portion into a lumen defined by bonding portion of the first shaft portion such that the bonding portion of the first shaft portion overlays the bonding portion of the second shaft portion; and

bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion.

2. The method of claim 1, further including the step of applying heat and pressure to an outer surface of the bonding area of the first shaft portion.

3. The method of claim 1, further including the step of positioning a generally tubular sleeve so that it overlays the bonding area of the first shaft portion.

4. The method of claim 1, further including the steps of positioning a generally tubular sleeve so that it overlays the bonding area of the first shaft portion, and applying heat and pressure to an outer surface of the sleeve.

5. The method of claim 1, further including the step of deforming the bonding end of the first shaft portion to form a flare.

6. The method of claim 1, wherein the first shaft portion includes a support member comprising a plurality of filaments.

7. The method of claim 1, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to electromagnetic waves.

8. The method of claim 1, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to a hot fluid.

9. The method of claim 1, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion.

10. The method of claim 1, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion with a laser beam.

11. The method of claim 1, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the steps of rotating the first shaft portion and the second shaft portion and directing a laser beam toward the bonding portion of the first shaft portion and the bonding portion of the second shaft portion.

12. The method of claim 1, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to hot air.

13. A method of forming a catheter shaft segment having a guidewire port, the method comprising the steps of:

providing a first shaft portion having a bonding portion disposed proximate a bonding end thereof, an ancillary end, and a lumen extending therethrough;

the first shaft portion comprising a support member encased in a substrate material, the support member having a plurality of filaments;

providing a second shaft portion having a bonding portion disposed proximate a bonding end thereof, an ancillary end, and a lumen extending therethrough;

providing an inner member having a proximal end, a distal end, and a lumen extending therebetween;

slitting a wall of the first shaft portion to create an opening defined by the wall of the first shaft portion;

inserting the proximal end of the inner member through the opening defined by the wall of the first shaft portion;

inserting the distal end of the inner member into the lumen of the second shaft portion;

inserting the bonding end of the second shaft portion into a lumen defined by the bonding portion of the first shaft portion such that the bonding portion of the first shaft portion overlays the bonding portion of the second shaft portion;

inserting a first mandrel into the lumen of the first shaft portion;

inserting a second mandrel into the lumen of the inner member;

applying pressure to an outer surface of the bonding portion of the first shaft portion; and

heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to form a bond therebetween.

14. The method of claim 13, further including the step of positioning a generally tubular sleeve so that it overlays the bonding area of the first shaft portion.

15. The method of claim 13, further including the step of deforming the bonding end of the first shaft portion to form a flare.

16. The method of claim 13, wherein the second shaft portion includes a support member comprising a plurality of filaments.

17. The method of claim 13, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to electromagnetic waves.

18. The method of claim 13, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to hot fluid.

19. The method of claim 13, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the step of directing a laser beam toward the bonding portion of the first shaft portion and the bonding portion of the second shaft portion.

20. The method of claim 13, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the steps of rotating the first shaft portion and the second shaft portion and directing a laser beam toward the bonding portion of the first shaft portion and the bonding portion of the second shaft portion.

21. The method of claim 13, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to hot air.

22. A method of forming a catheter shaft segment having a guidewire port, the method comprising the steps of,

providing a first shaft portion having a bonding portion disposed proximate a bonding end thereof, an ancillary end, and a lumen extending therethrough;

providing a second shaft portion having a bonding portion disposed proximate a bonding end thereof, an ancillary end, and a lumen extending therethrough;

providing an inner member having a proximal end, a distal end, and a lumen extending therebetween;

deforming the bonding end of the first shaft portion to form a flare;

slitting a wall of the first shaft portion to create an opening defined by the wall of the first shaft portion;

inserting the proximal end of the inner member through the opening defined by the wall of the first shaft portion;

inserting the distal end of the inner member into the lumen of the second shaft portion;

inserting the bonding end of the second shaft portion into a lumen defined by bonding portion of the first shaft portion such that the bonding portion of the first shaft portion overlays the bonding portion of the second shaft portion;

inserting a first mandrel into the lumen of the first shaft portion;

urging the first mandrel further so that a portion thereof is disposed within the lumen of the second shaft portion;

inserting a second mandrel into the lumen of the inner member;

positioning a generally tubular sleeve so that it overlays the bonding portion of the first shaft portion;

applying pressure to an outer surface of the sleeve;

removing the pressure applied to the outer surface of the sleeve; and

heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to form a bond therebetween.

23. The method of claim 22, wherein the first shaft portion includes a support member comprising a plurality of filaments.

24. The method of claim 22, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to electromagnetic waves.

25. The method of claim 22, wherein the step of heating the bonding portion of the fist shaft portion and the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to a hot fluid.

26. The method of claim 23, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the step of directing a laser beam toward the bonding portion of the first shaft portion and the bonding portion of the second shaft portion.

27. The method of claim 22, wherein the step of heating the bonding portion of the first shaft portion and the bonding portion of the second shaft portion includes the steps of rotating the first shaft portion and the second shaft portion and directing a laser beam toward the bonding portion of the first shaft portion and the bonding portion of the second shaft portion.

28. The method of claim 22, wherein the step of bonding the bonding portion of the first shaft portion to the bonding portion of the second shaft portion includes the step of exposing the bonding portion of the first shaft portion and the bonding portion of the second shaft portion to hot air.