Method of making elongated medical devices
First Claim
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1. A method of manufacturing a medical device, comprising the steps of:
- providing a core wire having a proximal section and a distal section, the distal section of the core wire formed from a metal or metal alloy, the distal section including a widened diameter portion at a distal end of the core wire;
providing a tubular body member having a proximal portion and a distal portion, the tubular body defining a lumen therethrough having an inner diameter configured to fit over an outer diameter of the widened diameter portion;
attaching a tip to the distal portion of the tubular member to form a distal cap member comprising the tubular body member and the tip, the distal cap member formed from a metal or metal alloy that is welding-compatible with the metal or metal alloy of the distal section of the core wire;
after forming the distal cap member, inserting the widened diameter portion of the distal section of the core wire into the lumen of the tubular body; and
after inserting the widened diameter portion into the lumen, welding the distal cap member to the distal section of the core wire;
wherein the widened diameter portion of the distal section of the core wire is a heat sink during the welding.
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Abstract
Elongate medical devices such as guidewires can be formed from a core wire and a preformed distal cap that is configured to fit over a distal end of the core wire. The distal cap can be attached using a variety of techniques. In particular, the distal cap can be attached to the core wire using laser welding.
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Citations
18 Claims
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1. A method of manufacturing a medical device, comprising the steps of:
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providing a core wire having a proximal section and a distal section, the distal section of the core wire formed from a metal or metal alloy, the distal section including a widened diameter portion at a distal end of the core wire; providing a tubular body member having a proximal portion and a distal portion, the tubular body defining a lumen therethrough having an inner diameter configured to fit over an outer diameter of the widened diameter portion; attaching a tip to the distal portion of the tubular member to form a distal cap member comprising the tubular body member and the tip, the distal cap member formed from a metal or metal alloy that is welding-compatible with the metal or metal alloy of the distal section of the core wire; after forming the distal cap member, inserting the widened diameter portion of the distal section of the core wire into the lumen of the tubular body; and after inserting the widened diameter portion into the lumen, welding the distal cap member to the distal section of the core wire;
wherein the widened diameter portion of the distal section of the core wire is a heat sink during the welding. - View Dependent Claims (2, 3, 4)
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5. A method of producing a guidewire, comprising:
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providing a core wire having a distal end and a proximal end, the distal end including a widened diameter portion; providing a metallic tubular sleeve having a distal end and a proximal end; positioning the tubular sleeve over the widened diameter portion at the distal end of the core wire; positioning a metal ball proximate the distal end of the tubular sleeve; and melting at least a portion of the tubular sleeve and the metal ball via laser or plasma welding to form an atraumatic tip. - View Dependent Claims (6, 7)
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8. A method of producing a guidewire, comprising:
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providing a core wire having a distal end and a proximal end, the distal end of the core wire including a widened diameter portion; providing a distal cap having a distal end and a proximal end, the proximal end of the distal cap comprising an aperture configured to fit over the widened diameter portion at the distal end of the core wire; inserting the distal end of the core wire into the distal cap aperture; and welding the distal cap over the distal end of the core wire. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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Specification