Methods for manufacturing non-prolapsing catheters with linerless tube

• US 9,272,119 B2
• Filed: 06/03/2013
• Issued: 03/01/2016
• Est. Priority Date: 06/03/2013
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Cohen, Adam, Wang, Hao
• Primary Examiner(s): Gross, Carson
• Application Number:
  US13/908,498
• Publication Number:
  US 20140352871A1
• Time in Patent Office: 1,002 Days
• Field of Search: 156/143, 156/144, 156/168, 156171-173, 156/184, 156/185, 156/187, 156/188, 156/190, 156/191, 156/194, 156/195, 604/526
• US Class Current: 1/1
• CPC Class Codes: A61M 25/0009 Making of catheters or other medical or surgical tubes
• CPC Class Codes: A61M 25/0012 with embedded structures, e.g. coils, braids, meshes, strands or radiopaque coils
• CPC Class Codes: A61M 25/0013 Weakening parts of a catheter tubing, e.g. by making cuts in the tube or reducing thickness of a layer at one point to adjust the flexibility
• CPC Class Codes: A61M 25/0051 made from fenestrated or weakened tubing layer
• CPC Class Codes: B29C 53/566 for making tubular articles followed by compression
• CPC Class Codes: B29C 53/822 Single use mandrels, e.g. destructible, becoming part of the wound articles B29C53/825 takes precedence
• CPC Class Codes: B29C 63/0069 of tubular articles
• CPC Class Codes: B29C 63/42 using tubular layers or sheathings
• CPC Class Codes: B29D 23/001 Pipes; Pipe joints pleated hoses B29D23/18
• CPC Class Codes: B29L 2031/7542 Catheters
• CPC Class Codes: F16L 11/081 comprising one or more layers of a helically wound cord or wire in combination with braided layers F16L11/088
• CPC Class Codes: F16L 11/121 specially profiled cross sections

Abstract

A method for manufacturing a catheter member having at least one lumen is disclosed herein. The method includes, winding a sacrificial coil over a mandrel in a first direction and winding a reinforcement coil over the sacrificial coil in a second direction. A polymer is then laminated over the sacrificial coil and the reinforcement coil. After the polymer is laminated, the mandrel is removed and the sacrificial coil is removed to thereby form the catheter member having the lumen.

Claims

1. A method for manufacturing a catheter member having a lumen, the method comprising:

winding a sacrificial coil over a mandrel in a first direction;

winding a reinforcement coil over the sacrificial coil in a second direction;

laminating a polymer over the sacrificial coil and the reinforcement coil;

removing the mandrel;

removing the sacrificial coil to thereby form the catheter member having the lumen; and

filling at least one groove in the polymer created by removing the sacrificial coil.

2. The method according to claim 1, wherein filling the at least one groove in the polymer comprises:

inserting a second mandrel into the lumen;

applying a heat shrink member over the catheter member; and

melting the polymer to fill the at least one groove created by removing the sacrificial coil.

3. The method according to claim 1, wherein the step of winding the sacrificial coil includes winding the sacrificial coil over the mandrel with a first pitch.

4. The method according to claim 3, wherein the step of winding the reinforcement coil includes winding the reinforcement coil over the sacrificial coil with a second pitch greater than the first pitch.

5. The method of claim 1, wherein at least one of the sacrificial coil or the reinforcement coil is fabricated from stainless steel.

6. The method of claim 1, wherein at least one of the sacrificial coil or the reinforcement coil is fabricated from nitinol.

7. The method of claim 1, wherein at least one of the sacrificial coil or the reinforcement coil is fabricated from cobalt chromium.

8. The method of claim 1, wherein the polymer is fabricated from a thermoplastic.

9. The method of claim 1, wherein laminating the polymer over the sacrificial coil and the reinforcement coil comprises laminating a polymer tube over the sacrificial coil and the reinforcement coil.

10. The method of claim 3, wherein the first pitch is in a range of 125 wraps per inch to 250 wraps per inch.

11. The method of claim 4, wherein the second pitch is in a range of 25 wraps per inch to 100 wraps per inch.