Embolic filter frame having looped support strut elements

• US 9,023,077 B2
• Filed: 03/14/2013
• Issued: 05/05/2015
• Est. Priority Date: 10/17/2002
• Status: Expired due to Term

• Current Assignee: WL Gore and Associates Incorporated (W.L. Gore and Associates)
• Original Assignee: WL Gore and Associates Incorporated (W.L. Gore and Associates)
• Inventors: Cully, Edward H., Vonesh, Michael J.
• Primary Examiner(s): Nguyen, Victor
• Application Number:
  US13/804,153
• Publication Number:
  US 20130197566A1
• Time in Patent Office: 782 Days
• Field of Search: 606/159, 606/194, 606/198, 606/200, 604/22, 604/96, 604/103.01
• US Class Current: 606/200
• CPC Class Codes: A61F 2/0105 Open ended, i.e. legs gathered only at one side
• CPC Class Codes: A61F 2002/018 made from tubes or sheets of material, e.g. by etching or laser-cutting
• CPC Class Codes: A61F 2230/0006 circular
• CPC Class Codes: A61F 2230/0067 conical
• CPC Class Codes: B23P 11/00 Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for connecting sheet metal or metal tubes, rods or profiles B21D39/00; riveting B21J; soldering, unsoldering, welding B23K; hand tools for connecting wire or strip B25B25/00; connecting metal parts by adhesives F16B11/00
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

An improved embolic filter frame is provided. The filter frame provides enhanced longitudinal compliance, improved sealing, low profile delivery, and short deployed length. The looped support struts have high “radial” stiffness with low “longitudinal” stiffness. When deployed, the frame exerts a relatively high stress onto a vessel wall to maintain an effective seal, yet remains longitudinally compliant. Minor displacements of the support wire or catheter are therefore not translated to the filter. The looped support struts elongate when tensioned and assume a compressed and essentially linear form. When the delivery catheter constraint is removed, the struts “snap open” and assume a looped configuration, exerting a high degree of force onto the vessel wall, creating an enhanced filter to vessel wall seal.

Claims

1. A method of making an embolic filter device, comprising:

providing a cylindrical tube;

providing a filter element;

cutting the cylindrical tube to form a filter frame that includes;

a collar that is adapted to be coupled to a support wire;

a filter support portion; and

multiple support struts, each of which extends from the filter support portion to the collar; and

attaching the filter element to the filter support portion,

wherein at least one support strut of the multiple support struts has at least one portion with a bend equal to or greater than 90 degrees in a deployed state, and wherein the at least one portion with the bend equal to or greater than 90 degrees is unattached to the filter element.

2. The method of claim 1, wherein the cylindrical tube is cut by a laser.

3. The method of claim 1, wherein the cylindrical tube is cut by stamping.

4. The method of claim 1, wherein the cylindrical tube is cut by etching.

5. The method of claim 1, wherein the cylindrical tube is cut by mill cutting.

6. The method of claim 1, wherein the cylindrical tube is cut by a water jet.

7. The method of claim 1, wherein the cylindrical tube is cut by electrical discharge machining.

8. The method of claim 1, wherein the at least one support strut of the multiple support struts is positioned essentially within a plane of an opening of the filter when in the deployed state.

9. The method of claim 1, wherein each support strut of the multiple support struts has at least one portion with a bend equal to or greater than 90 degrees in a deployed state, and wherein each portion with the bend equal to or greater than 90 degrees is unattached to the filter element.

10. The method of claim 1, wherein the at least one bend portion with the bend equal to or greater than 90 degrees provides a filter frame configuration that enhances a radial force imparted against a vessel wall for improved sealing of the filter support portion against the vessel wall.

11. The method of claim 1, wherein the collar is positioned within a cavity defined by the filter element in the deployed state.

12. The method of claim 11, wherein the cavity defined by the filter element comprises a volume bounded by a surface of the filter element and an opening of the filter element.

13. The method of claim 1, wherein the collar is positioned distal of an opening of the filter element in the deployed state.

14. The method of claim 1, wherein at least one support strut of the multiple support struts has an “

s”

shape.

15. The method of claim 1, wherein the multiple support struts includes three support struts.

16. The method of claim 1, wherein the multiple support struts includes four support struts.

17. The method of claim 1, wherein the multiple support struts includes five support struts.

18. The method of claim 1, wherein the multiple support struts includes six support struts.

19. The method of claim 1, wherein at least one support strut of the multiple support struts projects a looped configuration in two orthogonal views.

20. An embolic filter device, comprising:

a filter element; and

a filter frame that includes;

a collar that is adapted to be coupled to a support wire;

a filter support portion, wherein at least a portion of the filter support portion is attached to the filter element; and

multiple support struts, each of which extends from the filter support portion to the collar, wherein the collar, the filter support portion, and the multiple support struts are formed by cutting a cylindrical tube,

wherein at least one support strut of the multiple support struts has at least one portion with a bend equal to or greater than 90 degrees in a deployed state, and wherein the at least one portion with the bend equal to or greater than 90 degrees is unattached to the filter element.

21. The embolic filter device of claim 20, wherein the cylindrical tube is cut by a laser.

22. The embolic filter device of claim 20, wherein the cylindrical tube is cut by stamping.

23. The embolic filter device of claim 20, wherein the cylindrical tube is cut by etching.

24. The embolic filter device of claim 20, wherein the cylindrical tube is cut by mill cutting.

25. The embolic filter device of claim 20, wherein the cylindrical tube is cut by a water jet.

26. The embolic filter device of claim 20, wherein the cylindrical tube is cut by electrical discharge machining.

27. The embolic filter device of claim 20, wherein the at least one support strut of the multiple support struts is positioned essentially within a plane of an opening of the filter when in the deployed state.

28. The embolic filter device of claim 20, wherein each support strut of the multiple support struts has at least one portion with a bend equal to or greater than 90 degrees in a deployed state, and wherein each portion with the bend equal to or greater than 90 degrees is unattached to the filter element.

29. The embolic filter device of claim 20, wherein the at least one bend portion with the bend equal to or greater than 90 degrees provides a filter frame configuration that enhances a radial force imparted against a vessel wall for improved sealing of the filter support portion against the vessel wall.

30. The embolic filter device of claim 20, wherein the collar is positioned within a cavity defined by the filter element in the deployed state.

31. The embolic filter device of claim 30, wherein the cavity defined by the filter element comprises a volume bounded by a surface of the filter element and an opening of the filter element.

32. The embolic filter device of claim 20, wherein the collar is positioned distal of an opening of the filter element in the deployed state.

33. The embolic filter device of claim 20, wherein at least one support strut of the multiple support struts has an “

s”

shape.

34. The embolic filter device of claim 20, wherein the multiple support struts includes three support struts.

35. The embolic filter device of claim 20, wherein the multiple support struts includes four support struts.

36. The embolic filter device of claim 20, wherein the multiple support struts includes five support struts.

37. The embolic filter device of claim 20, wherein the multiple support struts includes six support struts.

38. The embolic filter device of claim 20, wherein at least one support strut of the multiple support struts projects a looped configuration in two orthogonal views.