Methods of manufacturing vascular treatment devices

• US 8,783,151 B1
• Filed: 08/28/2013
• Issued: 07/22/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Insera Therapeutics, Inc.
• Original Assignee: Insera Therapeutics, Inc.
• Inventors: Janardhan, Vallabh, Janardhan, Vikram
• Primary Examiner(s): Patel, Devang R
• Application Number:
  US14/012,348
• Time in Patent Office: 328 Days
• Field of Search: 87/8, 87/9, 87/33, 87/34, 623 11- 153
• US Class Current: 87/9
• CPC Class Codes: A61B 17/12109 in a blood vessel
• CPC Class Codes: A61B 17/12113 within an aneurysm
• CPC Class Codes: A61B 17/12118 for positioning in conjunction with a stent
• CPC Class Codes: A61B 17/12122 within the heart for closing a cardiac septal defect A61B17/0057
• CPC Class Codes: A61B 17/12172 having a pre-set deployed three-dimensional shape methods of manufacturing A61B2017/00526
• CPC Class Codes: A61B 17/22031 Gripping instruments, e.g. forceps, for removing or smashing calculi A61B17/221 takes precedence
• CPC Class Codes: A61B 17/221 Gripping devices in the form of loops or baskets for gripping calculi or similar types of obstructions surgical snare instruments A61B17/32056
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00867 shape memory effect
• CPC Class Codes: A61B 2017/00955 thermoplastic
• CPC Class Codes: A61B 2017/12077 Joint changing shape upon application of heat, e.g. bi-metal or reversible thermal memory
• CPC Class Codes: A61B 2017/22034 for gripping the obstruction or the tissue part from inside
• CPC Class Codes: A61B 2017/22038 with a guide wire
• CPC Class Codes: A61B 2017/2217 single wire changing shape to a gripping configuration
• CPC Class Codes: A61B 2090/3966 Radiopaque markers visible in an X-ray image
• CPC Class Codes: A61M 2025/0042 Microcatheters, cannula or the like having outside diameters around 1 mm or less
• 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 25/0021 characterised by the form of the tubing A61M25/0054 takes precedence
• CPC Class Codes: A61M 25/0043 characterised by structural features
• CPC Class Codes: D04C 1/06 Braid or lace serving particular purposes
• CPC Class Codes: D04C 3/48 : Auxiliary devices
• CPC Class Codes: D10B 2509/06 : Vascular grafts; stents
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 83/0596 : Cutting wall of hollow work

Abstract

Vascular treatment and methods include a plurality of self-expanding bulbs and a hypotube including interspersed patterns of longitudinally spaced rows of kerfs. Joints between woven structures and hypotubes include solder. Woven structures include patterns of radiopaque filaments measureable under x-ray. Structures are heat treated to include at least shapes at different temperatures. A catheter includes a hypotube including interspersed patterns of longitudinally spaced rows of kerfs. Heat treating systems include a detachable flange. Laser cutting systems include a fluid flow system.

Claims

1. A method of manufacturing a vascular treatment device, the method comprising:

arranging a plurality of spools on a yarn wheel, at least some of the spools comprising radiopaque wires and at least some of the spools comprising shape memory wires;

braiding the radiopaque wires and the shape memory wires in a one-over-one-under-one pattern around a first mandrel to form a textile structure;

shape setting the textile structure in a substantially cylindrical shape;

providing a second mandrel comprising bulbs and necks, wherein the second mandrel comprises the bulbs threaded along a strand;

securing the shape-set textile structure on the second mandrel, wherein securing the shape-set textile structure on the second mandrel comprises wrapping at least one of bangles and c-shaped clamps around the necks of the second mandrel;

shape setting the shape-set textile structure on the second mandrel; and

removing the shape-set textile structure from the second mandrel.

2. The method of claim 1, wherein securing the shape-set textile structure on the second mandrel comprises wrapping wire around the necks of the second mandrel.

3. The method of claim 1, wherein the radiopaque wires comprise platinum tungsten wires.

4. The method of claim 1, wherein the shape memory wires comprise nickel titanium wires.

5. The method of claim 1, further comprising bonding the shape-set textile structure to a delivery system.

6. The method of claim 5, wherein bonding the shape-set textile structure to the delivery system comprises inlay bonding.

7. The method of claim 6, further comprising, before bonding the shape-set textile structure to the delivery system, positioning the wires in a pinch ring or a pinch cylinder.

8. The method of claim 5, wherein bonding the shape-set textile structure to the delivery system comprises overlay bonding.

9. The method of claim 8, wherein bonding the shape-set textile structure to the delivery system comprises bonding a proximal end of the shape-set textile structure to a distal end of the delivery system.

10. The method of claim 8, wherein bonding the shape-set textile structure to the delivery system comprises bonding a distal end of the shape-set textile structure to a distal end of the delivery system.

11. The method of claim 8, wherein bonding the shape-set textile structure to the delivery system comprises placing a tubing around a bonding area.

12. The method of claim 5, wherein bonding the shape-set textile structure to the delivery system comprises soldering the shape-set textile structure to the cut hypotube delivery system.

13. The method of claim 5, wherein the delivery system comprises a cut hypotube.

14. The method of claim 5, wherein the delivery system comprises a hypotube comprising a first pattern and a second pattern.

15. The method of claim 14, further comprising:

cutting the first pattern of longitudinally-spaced rows each comprising two kerfs and two stems into the hypotube, the two stems in each of the rows of the first pattern circumferentially opposite, the stems of the first pattern offset in a first circumferential direction; and

cutting the second pattern of longitudinally-spaced rows each comprising two kerfs and two stems into the hypotube, the two stems in each of the rows of the second pattern circumferentially opposite, the stems of the second pattern offset in a second circumferential direction opposite the first circumferential direction, the second pattern singly alternatingly interspersed with the first pattern.

16. The method of claim 15, wherein cutting the first pattern and cutting the second pattern comprises cutting rounded edges of the kerfs in each of the rows of the first pattern and the second pattern.

17. The method of claim 15, wherein cutting the first pattern and cutting the second pattern comprises cutting each of the rows of the first pattern and the second pattern at an angle with respect to a longitudinal axis of the hypotube.

18. The method of claim 15, wherein the hypotube comprises stainless steel.

19. The method of claim 15, wherein the hypotube comprises nitinol.

20. The method of claim 15, wherein a pitch of the longitudinally-spaced rows of the first pattern and the second pattern varies longitudinally along the hypotube.