Methods of manufacturing variable porosity devices

• US 8,869,670 B1
• Filed: 01/29/2014
• Issued: 10/28/2014
• 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:
  US14/167,147
• Time in Patent Office: 272 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 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 vessel, 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 for a first duration to form a first segment of a textile structure, wherein braiding the wire during the first duration comprises pulling a ring away from the yarn wheel at a first speed;

after forming the first segment, rearranging at least some of the plurality of spools on the yarn wheel, wherein rearranging at least some of the plurality of spools forms empty spindle pairs; and

after rearranging at least some of the plurality of spools, braiding the wire from each of the plurality of spools for a second duration to form a second segment of the textile structure, wherein braiding the wire during the second duration comprises pulling the ring away from the yarn wheel at a second speed different than the first speed, wherein the second segment has a different porosity than the first segment,

wherein at least one of the first duration and the second duration comprises;

a third duration, and

a fourth duration after the third duration,

wherein braiding the wire during the third duration comprises rotating the yarn wheel for 180°

at a third speed, and

wherein braiding the wire during the fourth duration comprises rotating the yarn wheel for 180°

at a fourth speed different than the third speed.

2. The method of claim 1, wherein the first speed is greater than the second speed and wherein porosity of the first segment of the textile structure is greater than porosity of the second segment of the textile structure.

3. The method of claim 1, wherein the second speed is greater than the first speed and wherein porosity of the first segment of the textile structure is less than porosity of the second segment of the textile structure.

4. The method of claim 1, wherein one of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises symmetrically arranging the plurality of spools and the other of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises asymmetrically arranging the plurality of spools.

5. The method of claim 1, wherein one of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises asymmetrically arranging the plurality of spools and the other of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises symmetrically arranging the plurality of spools.

6. The method of claim 1, wherein pulling the ring away from the yarn wheel during at least one of the first duration and the second duration comprises pulling the ring away from the yarn wheel in a direction perpendicular to the yarn wheel.

7. The method of claim 1, wherein the ring comprises a circular ring.

13. The method of claim 1, wherein braiding the wire during the first duration comprises braiding over a mandrel, wherein braiding the wire during the second duration comprises braiding over the mandrel, and wherein, after the second duration, the first segment is longitudinally aligned with the second segment along the mandrel.

14. The method of claim 1, wherein one of the first segment and the second segment comprises a braid angle between 91°

and 180°

, and wherein the other of the first segment and the second segment comprises a braid angle between 0° and

90°

.

15. The method of claim 1, wherein at least one of the first segment and the second segment comprises a porosity between 60% and 78%.

16. The method of claim 1, further comprising forming a bulb in at least one of the first segment and the second segment.

8. A method of manufacturing a device for treating a vessel, 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 for a first duration to form a first segment of a textile structure;

after forming the first segment, rearranging at least some of the plurality of spools on the yarn wheel, wherein rearranging at least some of the plurality of spools forms empty spindle pairs; and

after rearranging at least some of the plurality of spools, braiding the wire from each of the plurality of spools for a second duration to form a second segment of the textile structure, wherein the second segment has a different porosity than the first segment,

wherein at least one of the first duration and the second duration comprises;

a third duration, and

a fourth duration after the third duration,

wherein braiding the wire during the third duration comprises rotating the yarn wheel for 180°

at a first speed, and

wherein braiding the wire during the fourth duration comprises rotating the yarn wheel for 180°

at a second speed different than the first speed.

9. The method of claim 8, wherein porosity of the first segment of the textile structure is greater than porosity of the second segment of the textile structure.

10. The method of claim 8, wherein porosity of the first segment of the textile structure is less than porosity of the second segment of the textile structure.

11. The method of claim 8, wherein one of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises symmetrically arranging the plurality of spools and the other of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises asymmetrically arranging the plurality of spools.

12. The method of claim 8, wherein one of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises asymmetrically arranging the plurality of spools and the other of arranging the plurality of spools and rearranging at least some of the plurality of spools comprises symmetrically arranging the plurality of spools.

17. The method of claim 8, wherein braiding the wire during the first duration comprises braiding over a mandrel, wherein braiding the wire during the second duration comprises braiding over the mandrel, and wherein, after the second duration, the first segment is longitudinally aligned with the second segment along the mandrel.

18. The method of claim 8, wherein one of the first segment and the second segment comprises a braid angle between 91°

and 180°

, and wherein the other of the first segment and the second segment comprises a braid angle between 0° and

90°

.

19. The method of claim 8, wherein at least one of the first segment and the second segment comprises a porosity between 60% and 78%.

20. The method of claim 8, further comprising forming a bulb in at least one of the first segment and the second segment.