Methods of manufacturing variable porosity flow diverting devices

• US 8,813,625 B1
• Filed: 01/29/2014
• Issued: 08/26/2014
• Est. Priority Date: 07/29/2013
• 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:
  US14/167,204
• Time in Patent Office: 209 Days
• Field of Search: 87/9, 87/11, 87/34, 623 11- 153
• US Class Current: 87/11
• 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 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 device for treating a vascular cavity, the method comprising:

arranging a plurality of spools on a yarn wheel, each of the spools comprising wire;

braiding the wire from each of the plurality of spools to form a textile structure, wherein braiding the wire comprises;

braiding the wire for a first duration to form a first segment of the textile structure,

wherein the first duration comprises;

a third duration, and

a fourth duration after the third duration,

wherein braiding the wire during the first duration comprises;

rotating the yarn wheel 180°

at a first speed during the third duration,

rotating the yarn wheel 180°

at a second speed different than the first speed during the fourth duration, and

pulling a puller at a third speed, at least one of the first speed and the second speed being greater than the third speed, and

braiding the wire for a second duration to form a second segment of the textile structure,

wherein the second duration comprises;

a fifth duration, and

a sixth duration after the fifth duration,

wherein braiding the wire during the second duration comprises;

rotating the yarn wheel 180°

at a fourth speed during the fifth duration,

rotating the yarn wheel 180°

at a fifth speed different than the fourth speed during the sixth duration, and

pulling the puller at a sixth speed, at least one of the fourth speed and the fifth speed less than the sixth speed; and

heat treating the textile structure, wherein after the heat treatment the textile structure is expandable from a compressed state to an expanded state, the textile structure comprising a bulb in the expanded state.

2. The method of claim 1, wherein the first duration is before the second duration.

3. The method of claim 1, wherein the first duration is after the second duration.

4. The method of claim 1, wherein the first segment comprises the bulb.

5. The method of claim 1, wherein the second segment comprises the bulb.

6. The method of claim 1, further comprising a second bulb, wherein the first segment comprises the bulb and the second segment comprises the second bulb.

7. The method of claim 1, wherein braiding the textile structure is around a first mandrel, the method further comprising a first preliminary heat treatment before the heat treatment, wherein the heat treatment is on a second mandrel different than the first mandrel, wherein the second mandrel comprises a shape of the bulb.

8. The method of claim 1, wherein braiding the textile structure is around a mandrel comprising a shape of the bulb, and wherein the heat treatment is on the mandrel.

9. The method of claim 1, further comprising coating a portion of the bulb with a polymer.

10. A method of manufacturing a device for treating a vascular cavity, the method comprising:

braiding a plurality of wires to form a textile structure, each of the plurality of wires extending from one of a plurality of spools on a yarn wheel,

wherein braiding the wires comprises;

braiding the wires for a first duration to form a first segment of the textile structure,

wherein the first duration comprises;

a second duration, and

a third duration after the second duration,

wherein braiding the wires during the first duration comprises;

rotating the yarn wheel 180°

at a first speed during the second duration,

rotating the yarn wheel 180°

at a second speed different than the first speed during the third duration, and

pulling a puller at a third speed, and

heat treating the textile structure to impart an expanded shape comprising a bulb.

11. The method of claim 10, wherein at least one of the first speed and the second speed is greater than the third speed.

12. The method of claim 10, wherein braiding the wires further comprises:

braiding the wires for a fourth duration to form a second segment of the textile structure.

13. The method of claim 12, wherein the first duration is before the fourth duration.

14. The method of claim 12, wherein the first duration is after the fourth duration.

15. The method of claim 12, wherein a plurality of bulbs comprises the bulb, and wherein the first segment comprises a first bulb of the plurality of bulbs and the second segment comprises a second bulb of the plurality of bulbs.

16. A method of manufacturing a device for treating a vascular cavity, the method comprising:

braiding a plurality of wires to form a textile structure comprising a bulb,

each of the wires on a spool,

the spools arranged on a yarn wheel,

wherein after braiding the plurality of wires the textile structure has a longitudinal axis and comprises;

a first longitudinal segment having a length along the longitudinal axis and a circumference around the longitudinal axis, the first longitudinal segment comprising;

a first circumferential portion extending along the entire length and around a first part of the circumference on a first side of the longitudinal axis, the first circumferential portion having a braid angle between 91° and

180°

, and

a second circumferential portion extending along the same entire length and around a second part of the circumference along a second side of the longitudinal axis different than the first side, the second circumferential portion having a braid angle between 0° and

90°

.

17. The method of claim 16, wherein braiding the plurality of wires comprises:

rotating the yarn wheel 180°

at a first speed during a first duration, and

rotating the yarn wheel 180°

at a second speed different than the first speed during a second duration different than the first duration.

18. The method of claim 16, wherein after braiding the plurality of wires the textile structure further comprises a second longitudinal segment along the longitudinal axis adjacent to the first longitudinal segment, the second longitudinal segment having a braid angle between 0°

and 90°

.

19. The method of claim 18, wherein after braiding the plurality of wires the textile structure further comprises a third longitudinal segment along the longitudinal axis adjacent to the first longitudinal segment, the third longitudinal segment having a braid angle between 0°

and 90°

, wherein the first longitudinal segment comprises the bulb, wherein the bulb is elongate, wherein the second longitudinal segment comprises a second bulb, wherein the second bulb is spherical, wherein the third longitudinal segment comprises a third bulb, and wherein the third bulb is spherical.

20. The method of claim 16, wherein the first circumferential portion has a porosity between 60% and 78%.