Methods of manufacturing woven vascular treatment devices

• US 8,789,452 B1
• Filed: 08/28/2013
• Issued: 07/29/2014
• 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:
  US14/012,904
• Time in Patent Office: 335 Days
• Field of Search: None
• 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 17/12122 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 17/22 Implements for squeezing-off ulcers or the like on the inside of inner organs of the body; Implements for scraping-out cavities of body organs, e.g. bones; Calculus removers; Calculus smashing apparatus; Apparatus for removing obstructions in blood vessels, not otherwise provided for dilators A61M29/00
• CPC Class Codes: A61B 17/22031 Gripping instruments, e.g. forceps, for removing or smashing calculi A61B17/221 takes precedence
• CPC Class Codes: A61B 17/22032 having inflatable gripping elements balloon catheters A61M25/10
• 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 17/32056 Surgical snare instruments for removing or smashing calculi A61B2017/2212; tonsillotomes A61B17/26
• CPC Class Codes: A61B 17/3207 Atherectomy devices working by cutting or abrading; Similar devices specially adapted for non-vascular obstructions A61B17/32037 takes precedence; endoscopic cutting instruments A61B17/320016
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00575 for closure at remote site, e.g. closing atrial septum defects
• CPC Class Codes: A61B 2017/00592 Elastic or resilient implements
• CPC Class Codes: A61B 2017/00606 Implements H-shaped in cross-section, i.e. with occluders on both sides of the opening
• CPC Class Codes: A61B 2017/00641 for closing fistulae, e.g. anorectal fistulae
• CPC Class Codes: A61B 2017/00778 Operations on blood vessels A61B2017/22097, A61B2017/320741 take precedence
• CPC Class Codes: A61B 2017/22001 Angioplasty, e.g. PCTA
• CPC Class Codes: A61B 2017/22002 preventing restenosis
• CPC Class Codes: A61B 2017/22034 for gripping the obstruction or the tissue part from inside
• CPC Class Codes: A61B 2017/22035 for retrieving or repositioning foreign objects
• CPC Class Codes: A61B 2017/22067 : Blocking; Occlusion A61B2017/22054 takes precedence
• CPC Class Codes: A61B 2090/3966 : Radiopaque markers visible in an X-ray image
• CPC Class Codes: A61B 90/39 : Markers, e.g. radio-opaque or breast lesions markers
• CPC Class Codes: A61F 2/011 : Instruments for their placement or removal
• CPC Class Codes: A61F 2002/018 : made from tubes or sheets of material, e.g. by etching or laser-cutting
• CPC Class Codes: A61M 1/74 : Suction control underwater drainage A61M1/61
• CPC Class Codes: A61M 1/84 : Drainage tubes; Aspiration tips for negative pressure wound therapy A61M1/90; for surgical cutting instruments A61B17/32
• CPC Class Codes: A61M 2025/0042 : Microcatheters, cannula or the like having outside diameters around 1 mm or less
• CPC Class Codes: A61M 2202/06 : Solids
• CPC Class Codes: A61M 2207/10 : Device therefor
• CPC Class Codes: A61M 2210/12 : Blood circulatory system
• CPC Class Codes: A61M 25/0023 : by the form of the lumen, e.g. cross-section, variable diameter
• CPC Class Codes: A61M 25/10 : Balloon catheters A61M25/0125 takes precedence; embolectomy A61B17/22032; retractors A61B17/02; inflatable balloons for placing stents or stent-grafts A61F2/958 ; stomach balloons for treatment of obesity A61F5/0003; oesophagal tubes A61J15/00
• CPC Class Codes: A61M 29/00 : Dilators with or without means for introducing media, e.g. remedies instruments for performing visual medical inspections of cavities or tubes of the body A61B1/00
• CPC Class Codes: B23K 26/083 : Devices involving movement of the workpiece in at least one axial direction
• CPC Class Codes: B23K 26/14 : using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor B23K26/12 takes precedence
• CPC Class Codes: B23K 26/142 : for the removal of by-products
• CPC Class Codes: B23K 26/1435 : involving specially adapted flow control means
• CPC Class Codes: B23K 26/146 : the fluid stream containing a liquid
• CPC Class Codes: B23K 26/20 : Bonding soldering by means of radiant energy B23K1/005; joining of preformed plastics parts by heating using laser beam B29C65/16
• CPC Class Codes: B23K 26/38 : by boring or cutting
• CPC Class Codes: B26F 3/004 : by means of a fluid jet methods for use of abrasive blasting for cutting B24C1/045; guns for abrasive fluid jets B24C5/02; perforating by non-mechanical means, e.g. by fluid jet B26F1/26
• CPC Class Codes: D04C 1/06 : Braid or lace serving particular purposes
• CPC Class Codes: D04C 1/12 : Cords, lines, or tows
• CPC Class Codes: D04C 3/48 : Auxiliary devices
• CPC Class Codes: D10B 2403/0333 : with tubular portions of variable diameter or distinct axial orientation
• CPC Class Codes: D10B 2509/06 : Vascular grafts; stents
• CPC Class Codes: Y10T 137/8376 : Combined
• CPC Class Codes: Y10T 137/85954 : Closed circulating system
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/49913 : by constricting outer annulus
• CPC Class Codes: Y10T 29/49995 : Shaping one-piece blank by removing material
• CPC Class Codes: Y10T 82/2521 : Bar feeder

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

attaching an end of each of the wires to a ring over a first mandrel, the first mandrel comprising a substantially cylindrical shape;

braiding the radiopaque wires and the shape memory wires in a one-over-one-under-one pattern around the first mandrel to form a textile structure, wherein braiding comprises rotating the yarn wheel, rotating the spindles, and longitudinally pulling the ring along the first mandrel away from the yarn wheel;

shape setting the textile structure into a substantially cylindrical shape;

securing the shape-set textile structure on a second mandrel comprising bulbs and necks, wherein the second mandrel comprises bulbs threaded along a strand;

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 a wire around the necks of the second mandrel.

3. The method of claim 1, further comprising forming the second mandrel.

4. The method of claim 3, wherein forming the second mandrel comprises stringing the bulbs along the strand.

5. The method of claim 4, wherein stringing the bulbs along the strand comprises selecting shapes of the bulbs, sizes of the bulbs, and spacing between the bulbs.

6. The method of claim 1, wherein arranging the plurality of spools comprises positioning at least two of the spools comprising radiopaque wires adjacent to each other.

7. The method of claim 1, further comprising bonding the shape-set textile structure to a hypotube.

14. The method of claim 1, wherein the textile structure comprises two sine waves each comprising a radiopaque wire, the two sine waves phase shifted from each other by about 180°

.

15. The method of claim 1, wherein the textile structure comprises three sine waves each comprising a radiopaque wire, the three sine waves phase shifted from each other by about 120°

.

16. The method of claim 1, wherein the textile structure comprises a first sine wave comprising a radiopaque wire, a second sine wave comprising a radiopaque wire, the second sine wave phase shifted from the first sine wave by about 180°

, a third sine wave comprising a radiopaque wire, the third sine wave phase shifted from the first sine wave by about 7.5°

, and a fourth sine wave comprising a radiopaque wire, the fourth sine wave phase shifted from the third sine wave by about 7.5°

.

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

18. The method of claim 1, wherein securing the shape-set textile structure on the second mandrel comprises wrapping c-shaped clamps around the necks of the second mandrel.

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

arranging a plurality of spools of wire on spindles on a yarn wheel;

braiding the wires around a mandrel comprising bulbs and necks to form a textile structure, wherein the mandrel comprises bulbs threaded along a strand, and wherein braiding comprises pulling a ring attached to an end of each of the wires away from the yarn wheel;

shape setting the textile structure on the mandrel; and

removing the shape-set textile structure from the mandrel.

9. The method of claim 8, further comprising securing the textile structure on the mandrel before shape setting.

10. The method of claim 8, further comprising forming the mandrel.

11. The method of claim 10, wherein forming the mandrel comprises stringing the bulbs along the strand.

12. The method of claim 11, wherein stringing the bulbs along the strand comprises selecting shapes of the bulbs, sizes of the bulbs, and spacing between the bulbs.

13. The method of claim 8, further comprising bonding the shape-set textile structure to a hypotube.

19. The method of claim 8, wherein securing the shape-set textile structure on the second mandrel comprises wrapping a wire around the necks of the second mandrel.

20. The method of claim 8, wherein securing the shape-set textile structure on the second mandrel comprises wrapping bangles around the necks of the second mandrel.

21. The method of claim 8, wherein securing the shape-set textile structure on the second mandrel comprises wrapping c-shaped clamps around the necks of the second mandrel.