Methods of manufacturing flow diverting devices

• US 8,863,631 B1
• Filed: 01/29/2014
• Issued: 10/21/2014
• 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:
  US14/167,138
• Time in Patent Office: 265 Days
• Field of Search: 87/9, 87/11, 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 17/12122 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 device for treating a vessel, the method comprising:

arranging a first mandrel extension on a bulbous mandrel, wherein arranging the first mandrel extension comprises coupling the first mandrel extension to a first sprocket in a first retainer in the bulbous mandrel;

arranging a second mandrel extension on the bulbous mandrel, wherein arranging the second mandrel extension comprises coupling the second mandrel extension to a second sprocket in a second retainer in the bulbous mandrel;

arranging a third mandrel extension on the bulbous mandrel, wherein arranging the third mandrel extension comprises coupling the third mandrel extension to a third sprocket in a third retainer in the bulbous mandrel;

after arranging the first mandrel extension, the second mandrel extension, and the third mandrel extension, removing sprockets that are not coupled to the first mandrel extension, the second mandrel extension, or the third mandrel extension from other retainers in the bulbous mandrel; and

braiding a plurality of wires over the bulbous mandrel, the first mandrel extension, the second mandrel extension, and the third mandrel extension to form a textile structure comprising;

a first bulb,

a first neck,

a second bulb between the first bulb and the first neck,

a second neck between the first bulb and the second bulb, the first neck, the second bulb, and the second neck extending from the first bulb along a longitudinal axis,

a lateral neck extending from the first bulb at a first angle to the longitudinal axis, and

a medial neck extending from the first bulb at a second angle to the longitudinal axis.

2. The method of claim 1, wherein the first bulb has a first diameter, the first neck has a second diameter less than the first diameter, the second bulb has a third diameter greater than the second diameter, and the second neck has a fourth diameter less than the first diameter and less than the third diameter.

3. The method of claim 1, wherein the first bulb has a first diameter and a first braid angle, the first neck has a second diameter less than the first diameter and having a second braid angle less than the first braid angle, the second bulb has a third diameter greater than the second diameter, the second neck has a fourth diameter less than the first diameter and less than the third diameter, the lateral neck has a first length, and the medial neck has a second length less than the first length.

4. The method of claim 1, wherein at least one of the first mandrel extension, the second mandrel extension, and the third mandrel extension comprises a bulb.

5. The method of claim 1, wherein at least one of the first mandrel extension, the second mandrel extension and the second mandrel extension comprises a cylindrical shape.

6. The method of claim 1, wherein the lateral neck and the medial neck are each in a different plane.

7. The method of claim 1, further comprising attaching the textile structure to a proximal portion through a detachable joint.

8. The method of claim 1, wherein the first bulb has a first braid angle and the first neck has a second braid angle less than the first braid angle.

9. The method of claim 1, wherein the lateral neck has a first length and the medial neck has a second length less than the first length.

10. The method of claim 1, wherein the first bulb has a first braid angle and at least one of the first neck, the lateral neck, and the medial neck has a second braid angle less than the first braid angle.

11. The method of claim 1, wherein the first bulb has a first braid angle, the second bulb has a second braid angle less than the first braid angle, the first neck has a third braid angle less than the first braid angle, and the second neck has a fourth braid angle less than the first braid angle.

12. The method of claim 1, wherein the first bulb has a first braid angle, the second bulb has a second braid angle, the second neck has a third braid angle, and the first neck has a fourth braid angle less than the first braid angle, the second braid angle, and the third braid angle.

13. The method of claim 1, wherein the first bulb has a first braid angle and the second bulb has a second braid angle less than the first braid angle.

14. The method of claim 1, wherein the sprockets are able to rotate between about 0°

and about 180°

.

15. The method of claim 1, wherein, before arranging the first mandrel extension, the second mandrel extension, and the third mandrel extension, the sprockets are interspersed on substantially an entire outer surface of the bulbous mandrel.

16. The method of claim 1, wherein arranging the first mandrel extension, the second mandrel extension, and the third mandrel extension comprises customizing the textile structure for at least one of:

a pathology, and vasculature of a patient.

17. The method of claim 1, wherein the first bulb has a first braid angle between about 91°

and about 180°

.

18. The method of claim 17, wherein at least one of the second bulb, the first neck, the second neck, the lateral neck, and the medial neck has a second braid angle between about 0°

and about 90°

.

19. The method of claim 1, wherein the first bulb has a first diameter between about 5 mm and about 6 mm, the first neck has a second diameter between about 3.25 mm and about 4 mm, the lateral neck has a third diameter between about 2.75 mm and about 3.25 mm, and the medial neck has a fourth diameter between about 2.25 mm and about 2.75 mm.

20. The method of claim 1, wherein the first bulb has a first diameter between about 10 mm and about 40 mm, the first neck has a second diameter between about 10 mm and about 40 mm, the lateral neck has a third diameter between about 8 mm and about 12 mm, and the medial neck has a fourth diameter between about 8 mm and about 12 mm.