Push-pull wire anchor

• US 7,553,305 B2
• Filed: 06/09/2005
• Issued: 06/30/2009
• 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
• Primary Examiner(s): Eisenberg; Rebecca E
• Application Number:
  US11/149,079
• Publication Number:
  US 20070005008A1
• Time in Patent Office: 1,482 Days
• Field of Search: 604/95.04, 604/264, 604523-529, 607/126
• US Class Current: 604/528
• 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 deflectable catheter includes a flexible element includes a flexible element, and at least one skirt extending at least part way around the flexible element. An encapsulant is coupled between the skirt and a deflectable distal end portion of the deflectable catheter. The encapsulant is adapted to transmit pushing and pulling forces from the skirt to the deflectable distal end portion.

Claims

1. A deflectable catheter comprising:

a catheter body including a deflectable distal end portion;

a flexible element including a flexible element distal portion extending along at least a portion of the deflectable distal end portion;

at least one skirt extending at least part way around the flexible element distal portion and secured to the flexible element distal portion at a deformed portion of the skirt, the at least one skirt including a flared projection at one or both of a skirt proximal end or a skirt distal end; and

the flexible distal end portion is at least partially received within the flared projection;

an encapsulant coupled between the at least one skirt and the deflectable distal end portion, wherein the encapsulant is adapted to transmit pushing and pulling forces from the at least one skirt to the deflectable distal end portion, the encapsulant is received within the flared projection, and the encapsulant forms at least a portion of an outer surface of the deflectable distal end portion; and

wherein the tension strength and compression strength of the flexible element and the at least one skirt are at least as strong as the encapsulant tension strength and compression strength.

2. The deflectable catheter of claim 1, wherein the at least one skirt includes at least one recess dimensioned and configured to receive the encapsulant.

3. The deflectable catheter of claim 1, wherein the at least one skirt is integral to the flexible element distal portion.

4. The deflectable catheter of claim 1, wherein the flared projection extends less than about half way around the deflectable distal end portion.

5. The deflectable catheter of claim 1, wherein the at least one skirt includes a clamp substantially surrounding the flexible element distal portion.

6. The deflectable catheter of claim 5, wherein the clamp is deformed and grasps the flexible element distal portion.

7. The deflectable catheter of claim 6, wherein the clamp is crimped at a plurality of points along the clamp.

8. The deflectable catheter of claim 1, wherein at least one of the skirt and the flexible element distal portion include at least one projection.

9. The deflectable catheter of claim 8, wherein at least one of the skirt and the flexible element distal portion include at least one recess sized and shaped to receive the at least one projection.

10. The deflectable catheter of claim 8, wherein the at least one projection extends from the at least one skirt and engages against the flexible element distal portion substantially immobilizing the at least one skirt relative to the flexible element.

11. The deflectable catheter of claim 1, wherein the at least one skirt and at least the flexible element proximal to the at least one skirt are free of welding.

12. A deflectable catheter assembly comprising:

a catheter body extending from a proximal end to a deflectable distal end portion, wherein the catheter body includes a sidewall surrounding a catheter lumen, and an actuator lumen within the side wall extends from the proximal end to an intermediate portion proximal to the deflectable distal end portion;

a flexible element extending through the actuator lumen, wherein a flexible element distal portion extends from the intermediate portion along at least a portion of the deflectable distal end portion;

at least one skirt secured to the flexible element distal portion and within the sidewall, wherein the at least one skirt extends at least part way around the flexible element distal portion, the skirt includes a proximal projection with a proximal tapered portion tapering toward a skirt distal end, and the skirt includes a distal projection with a distal tapered portion tapering toward a skirt proximal end;

an encapsulant coupled between the at least one skirt and the deflectable distal end portion, wherein the encapsulant is adapted to transmit tension and compression from the at least one skirt to the deflectable distal end portion, and the encapsulant forms at least a portion of the side wall of the deflectable distal end portion; and

wherein the catheter body is adapted to fail before failure of the flexible element and the skirt.

13. The deflectable catheter assembly of claim 12, wherein at least one weld couples the flexible element distal portion to the deflectable distal end portion and the at least one weld is distal to the at least one skirt.

14. The deflectable catheter assembly of claim 13, wherein the deflectable distal end portion includes a marker band and the weld couples the flexible element distal portion to the marker band.

15. The deflectable catheter assembly of claim 13, wherein the deflectable distal end portion includes a marker band and the flexible element distal portion and the at least one skirt are proximal to the marker band.

16. The deflectable catheter assembly of claim 15, wherein at least one flush opening is provided between the marker band and the flexible element distal portion and the at least one skirt.

17. The deflectable catheter assembly of claim 12, wherein at least one of the proximal projection and the distal projection includes a flared projection extending annularly away from the flexible element, and the flared projection includes a conical geometry.

18. The deflectable catheter assembly of claim 17, wherein the encapsulant fills at least a portion of the conical geometry.

19. The deflectable catheter assembly of claim 12, wherein the flexible element has substantially the same strength in tension and compression along an entire flexible element length, and the at least one skirt has substantially the same strength in tension and compression along an entire anchor length.

20. A deflectable catheter assembly comprising:

a catheter body extending from a catheter proximal end to a catheter deflectable distal end portion, the catheter body including;

a catheter side wall, the catheter sidewall including an encapsulant forming a smooth catheter outer surface around the catheter deflectable distal end portion,

a catheter delivery lumen surrounded by the encapsulant, and

a flexible element duct disposed within the catheter sidewall, the flexible element duct extends from near the catheter proximal end toward the catheter deflectable distal end portion;

a flexible element extending through the flexible element duct toward the catheter deflectable distal end portion, the flexible element is slidably disposed within the flexible element duct; and

at least one anchor fixedly engaged along the flexible element near the catheter deflectable distal end portion, the at least one anchor includes a deformed inner surface engaged against the flexible element, the at least one anchor including an exposed portion distinct from the deformed inner surface, the exposed portion including;

a deformed outer surface at an intermediate portion of the at least one anchor, and the deformed outer surface is secured on the flexible element,

a flared projection extending radially away from the flexible element, the flared projection is at one of an anchor proximal end or an anchor distal end, and a tapered portion of the flared projection of the anchor tapers toward the intermediate portion of the anchor,

wherein the at least one anchor is fully surrounded by the encapsulant around the deformed outer surface and the flared projection, and the encapsulant fills a space between the flared projection and the flexible element, and pushing and pulling forces are transmitted entirely through the encapsulant to the catheter deflectable distal end portion.

21. The deflectable catheter assembly of claim 20, wherein the flared projection extends annularly away from the flexible element, and the flared projection includes a conical geometry.

22. The deflectable catheter assembly of claim 21, wherein the encapsulant fills at least a portion of the conical geometry.

23. The deflectable catheter assembly of claim 20, wherein the at least one anchor includes a first flared projection at an anchor proximal end and a second flared projection at an anchor distal end.

24. The deflectable catheter assembly of claim 23, wherein the first flared projection extends proximally toward the catheter proximal end, and the second flared projection extends distally toward a catheter distal end.

25. The deflectable catheter assembly of claim 20, wherein the flexible element has substantially the same strength in tension and compression along an entire flexible element length.

26. The deflectable catheter assembly of claim 20, wherein the at least one anchor has substantially the same strength in tension and compression along an entire anchor length.

27. The deflectable catheter assembly of claim 20, wherein the at least one anchor and the flexible element are free of welding.

28. The deflectable catheter assembly of claim 20, wherein the deformed inner surface includes a clamp substantially surrounding the flexible element, and the clamp grasps the flexible element and immobilizes the at least one anchor relative to the flexible element.