Method of manufacturing a catheter sheath

• US 10,279,144 B2
• Filed: 07/10/2017
• Issued: 05/07/2019
• Est. Priority Date: 08/13/2010
• Status: Active Grant

• Current Assignee: Cathrx Ltd
• Original Assignee: Cathrx Ltd
• Inventors: Ogle, David, Partlett, Matthew J., Ryan, Garrett
• Primary Examiner(s): Hayman, Imani N
• Application Number:
  US15/645,224
• Publication Number:
  US 20170354798A1
• Time in Patent Office: 666 Days
• CPC Class Codes: A61B 18/1492 having a flexible, catheter-like structure, e.g. for heart ablation A61B18/1477 takes precedence
• 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 25/0015 Making lateral openings in a catheter tube, e.g. holes, slits, ports, piercings of guidewire ports; Methods for processing the holes, e.g. smoothing the edges
• CPC Class Codes: A61M 25/0043 characterised by structural features
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A catheter sheath comprises a tubular member connected to a catheter handle, the tubular sheath including one or more electrical conductors and one or more electrode rings attached to the tip of the tubular member. The tubular member further includes at least one opening that allows the one or more electrical conductor to be electrically connected to the one or more electrode rings. The electrode ring is slid over the tubular member so as to cover the opening. The tubular member and the electrode ring are subjected to heat treatment by induction heating so that the material of the tubular member melts locally around the electrode ring to form a seal between the tubular member and the electrode ring.

Claims

1. A method of manufacturing a catheter sheath, comprising:

providing a tubular member of non-conductive material having a proximal end and a distal end;

forming at least one opening in an outer wall of the tubular member;

attaching at least one conductive element on the outer wall of the tubular member;

placing a mold about the at least one conductive element and longitudinally adjacent the outer wall of the tubular member;

heating by induction the at least one conductive element in which the induction heat is directly conducted by only the at least one conductive element, such that indirect heat from the induction heated at least one conductive element causes local melting of the tubular member; and

constraining the local melting of the tubular member to fill a transition zone adjacent the at least one conductive element with the mold.

2. The method of claim 1, wherein attaching the at least one conductive element on the tubular member comprises applying a radial force.

3. The method of claim 2, wherein applying the radial force compresses the at least one conductive element so that an outer surface of the at least one conductive element lies substantially flush with the outer wall of the tubular member.

4. The method of claim 3, further comprising swaging the at least one conductive element.

5. The method of claim 2, further comprising swaging the at least one conductive element.

6. The method of claim 1, further comprising applying a sacrificial heat-shrink member over the at least one conductive element.

7. The method of claim 1, wherein one or more electrical conductors are arranged within a lumen defined by the tubular member.

8. The method of claim 1, wherein one or more electrical conductors are arranged between an inner wall and an outer wall of the tubular member.

9. The method of claim 1, wherein the at least one conductive element includes a ring electrode snug fit about the tubular member.

10. The method of claim 1, wherein the at least one conductive element comprises a conductive ring, and further comprising, prior to the induction heating, reducing a diameter of the conductive ring after the placing on the outer wall of the tubular member to be flush with a diameter of the tubular member.

11. A method of manufacturing a catheter sheath, comprising:

providing a tubular member of non-conductive material having a proximal end and a distal end;

forming at least one opening in an outer wall of the tubular member;

attaching at least one conductive element comprising a conductive ring on the outer wall of the tubular member;

reducing a diameter of the conductive ring after the attaching on the outer wall of the tubular member to be flush with a diameter of the tubular member;

placing a sacrificial heat-shrink sleeve about the conductive ring and longitudinally adjacent outer wall of the tubular member;

heating by induction the at least one conductive element in which the induction heat is directly conducted by only the at least one conductive element, such that indirect heat from the induction heated at least one conductive element causes local melting of the tubular member; and

shrinking the heat-shrink sleeve responsive to the induction heating of the at least one conductive element and constraining the local melting of the tubular member to fill a transition zone adjacent the at least one conductive element.

12. A catheter sheath, comprising:

a tubular member of non-conductive material having a proximal end and a distal end;

at least one electrical conductor extending from the proximal end to the distal end within the tubular member;

at least one opening in an outer wall of the tubular member for accessing the at least one electrical conductor within the tubular member;

at least one conductive element on the outer wall of the tubular member, the at least one conductive element being adjacent to and surrounding the at least one opening and arranged in conductive connection with the at least one electrical conductor; and

a seal, formed by induction heating, in a transition zone along each edge of the at least one conductive element between the at least one conductive element and the tubular member, the seal comprising locally melted and re-solidified material of the tubular member, the inductively heated, locally melted material of the tubular member constrained to fill the transition zones and form the seal by a mold placed about the at least one conductive element prior to the induction heating, longitudinally adjacent the outer wall of the tubular member.

13. The catheter sheath of claim 12, wherein an outer surface of the at least one conductive element lies substantially flush with the outer wall of the tubular member.