Push/pull wire anchor

• US 8,056,207 B2
• Filed: 06/05/2009
• Issued: 11/15/2011
• Est. Priority Date: 06/09/2005
• Status: Active Grant

• Current Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Original Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Inventors: Honebrink, Brian, Fischer, Brian
• Primary Examiner(s): Bryant; David
• Assistant Examiner(s): Salone; Bayan
• Application Number:
  US12/479,193
• Publication Number:
  US 20090235511A1
• Time in Patent Office: 893 Days
• Field of Search: 604/95.04, 604/528, 604/85.05, 604/95.05, 604/527, 604/525, 604/529, 294/695, 264/279
• US Class Current: 29/469.5
• 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 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 the steps of:

a) positioning a flexible element along a catheter liner with a distal portion thereof extending along at least a deflectable distal end portion of the catheter liner;

b) engaging at least one anchor to the flexible element distal portion, the anchor having a conical geometry flaring annularly away from the flexible element as it extends along the flexible element; and

c) providing an encapsulant contacting at least the deflectable distal end portion of the catheter liner and the flexible element distal portion including the anchor such that a portion of the encapsulant resides between the flexible element, and an annular inner surface of the conical anchor,

d) wherein the encapsulant forms at least a portion of a sidewall of the deflectable distal end portion of the catheter liner and at least the anchor is within the sidewall, and

e) wherein the encapsulant is adapted to transmit pushing and pulling forces from the at least one anchor to the deflectable distal end portion of the catheter liner, the tension strength and compression strengths of the flexible element and the at least one anchor being at least as strong as the encapsulant tension strength and compression strength.

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

3. The method of claim 2 including squeezing the encapsulant through the braided sheath and around the catheter liner to form the sidewall.

4. The method of claim 1 including deforming an engaging portion of the anchor to the flexible element distal portion.

5. The method of claim 4 including providing the engaging portion of the anchor as a clamp that grasps the flexible element distal portion.

6. The method of claim 5 including crimping the clamp at a plurality of points along the flexible element distal portion.

7. The method of claim 1 including forming the anchor comprising at least one flared projection tapering toward an engaged portion of the anchor contacting the flexible element, and filling the flared projection with the encapsulant.

8. The method of claim 7 including flaring at least one of the flexible element distal portion. and the at least one anchor.

9. The method of claim 1 including flaring at least one of the flexible element distal portion and the at least one anchor.

10. The method of claim 1 including providing the anchor extending proximally along the flexible element.

11. A method for making a catheter, comprising securing at least one anchor to a distal portion of a flexible element, wherein securing the anchor to the flexible element includes the steps of:

a) forming the anchor having a conical geometry;

b) deforming an engaging portion of the anchor to the flexible element distal portion such that the conically-shaped anchor flares annularly away from the flexible element as it extends along the flexible element; and

c) contacting the flexible element distal portion and the anchor with an encapsulant thereby forming a sidewall of a catheter body with the anchor and the flexible element distal portion being disposed within the sidewall of the catheter body forming the deflectable distal end portion such that a portion of the encapsulant resides between the flexible element and an annular inner surface of the conical anchor, the flexible element extending from the deflectable distal end portion toward a proximal end portion of the catheter.

12. The method of claim 11 including squeezing the encapsulant around the anchor and the flexible element distal portion.

13. The method of claim 12 including positioning the flexible element and the anchor along a catheter liner including a delivery lumen.

14. The method of claim 13 including squeezing the encapsulant over the catheter liner to form the sidewall.

15. The method of claim 12 including squeezing the encapsulant through a braided sheath positioned around at least the anchor connected to the flexible element distal portion.

16. The method of claim 11 including forming the flared projection of the anchor tapering toward the anchor engaging portion.

17. The method of claim 11 including forming a flared projection extending annularly away from the flexible element, the annularly extending flared projection including a conical geometry.

18. The method of claim 11 including clamping the engaging portion of the anchor around the flexible element distal portion.

19. The method of claim 11 including providing a tension strength and a compression strength of the flexible element and the anchor being greater than an encapsulant tension strength and an encapsulant compression strength.

20. The method of claim 11 including providing the anchor extending proximally along the flexible element.

21. A method for making a catheter, comprising the steps of:

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

b) clamping an engaging portion of the anchor onto the flexible element distal portion such that the conically-shaped anchor flares annularly away from the flexible element as it extends along the flexible element;

c) providing an encapsulant contacting the anchor and the flexible element, thereby forming a sidewall of a catheter body comprising a deflectable distal end portion of the catheter body with the anchor and the flexible element residing within the sidewall and being surrounded by the encapsulant at the deflectable distal end portion; and

d) wherein the conically-shaped anchor is filled with the encapsulant such that a portion of the encapsulant resides between the flexible element and an annular inner surface of the conical anchor so that the encapsulant aids in transmitting tension and compression from the anchor to the deflectable distal end portion.

22. The method of claim 21 wherein forming the one or more projections extending from the engaging portion of the anchor includes:

a) forming the anchor with a proximal projection tapering toward the engaging portion, and

b) forming the anchor with a distal projection tapering toward the engaging portion.

23. The method of claim 22 including filling the proximal and distal projections of the anchor with the encapsulant.

24. The method of claim 21 including forming a projection extending radially away from the engaging portion of the anchor.

25. The method of claim 21 including flaring at least one projection of the anchor annularly away from the flexible element.

26. The method of claim 21 including crimping the engaging portion of the anchor at a plurality of points along the flexible element distal portion.

27. The method of claim 21 including positioning a tube around the flexible element distal portion.

28. The method of claim 21 including squeezing the encapsulant through a braided sheath positioned around at least the anchor and the flexible element distal portion.

29. The method of claim 21 including providing the anchor extending proximally along the flexible element.