BOND BETWEEN COMPONENTS OF A MEDICAL DEVICE

• US 20130123795A1
• Filed: 11/14/2012
• Published: 05/16/2013
• Est. Priority Date: 11/15/2011
• Status: Active Grant

• Current Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Scimed (Boston Scientific Corporation)
• Inventors: Sutton, Benjamin, Ino, Takashi, Wallin, Joshua, Brandt, Brian D., Gamarra, Randy S., Tung, David S.
• Granted Patent: US 8,940,014 B2
• Time in Patent Office: Days
• US Class Current: 606/108
• CPC Class Codes: A61B 17/00234 for minimally invasive surgery A61B17/0218, A61B17/0469, A61B17/12013, A61B17/1285, A61B17/29, A61B17/320016 take precedence
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61F 2/2427 Devices for manipulating or deploying heart valves during implantation
• CPC Class Codes: A61F 2/2436 Deployment by retracting a sheath
• CPC Class Codes: A61F 2/2439 Expansion controlled by filaments
• CPC Class Codes: A61F 2/9517 handle assemblies therefor
• CPC Class Codes: A61M 25/0009 Making of catheters or other medical or surgical tubes
• CPC Class Codes: A61M 25/0026 Multi-lumen catheters with stationary elements catheter assemblies comprising a catheter in combination with a guide tube, sheath or sleeve A61M2025/0681; catheters comprising telescoping coaxial elements A61M2025/0175
• CPC Class Codes: A61M 25/09016 with mandrils
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

An elongated member and a method of manufacturing an elongated member may include first, second, and third elongated rod mandrels. The first, second, and third elongated rod mandrels may be fixed together at predetermined proximal and distal locations and at a ball tip. The first, second, and third rod mandrels may be disposed within a tubular coupling element and fixed to the tubular coupling element at the ball tip. The tubular coupling element may be placed into abutment with and fixed to the distal end of an elongated shaft.

Claims

1. A method of manufacturing an elongated member, comprising:

obtaining first, second, and third elongated rod mandrels, a tubular coupling element, and an elongated shaft, wherein each of the first, second, and third elongated mandrels, the tubular coupling element, and the elongated shaft have a proximal end and a distal end;

cutting the first, second, and third elongated rod mandrels to a predetermined length;

welding the first, second, and third elongated rod mandrels together at a predetermined distal location;

welding the first, second, and third elongated rod mandrels together at a predetermined proximal location;

disposing the first, second, and third elongated rod mandrels within a lumen of the tubular coupling element;

welding the proximal ends of the first, second, and third elongated rod mandrels together to form a ball tip;

sliding the tubular coupling element proximally into abutment with the ball tip to form a joint having a circumference;

welding the tubular coupling element to the ball tip about the entire circumference of the joint;

disposing the tubular coupling element in abutment with the distal end of the elongated shaft to form a second joint having a circumference; and

welding the tubular coupling element to the distal end of the elongated shaft about the entire circumference of the second joint.

2. The method of claim 1, further comprising:

prior to welding the first, second, and third elongated rod mandrels together at a predetermined proximal location, removing slack and twist from the first, second, and third elongated rod mandrels.

3. The method of claim 1, further comprising:

modifying the proximal end of the elongated shaft to include a fastening means.

4. The method of claim 3, wherein modifying the proximal end of the elongated shaft to include a fastening means consists of drilling a hole transversely through the elongated shaft.

5. The method of claim 3, wherein modifying the proximal end of the elongated shaft to include a fastening means consists of cutting external threads into the elongated shaft.

6. The method of claim 1, wherein at least one of the tubular coupling element and the elongated shaft is made of Elgiloy®

.

7. The method of claim 1, wherein the elongated shaft is a hypotube having a lumen extending therethrough.

8. The method of claim 1, wherein the elongated shaft is a solid rod having a counterbore disposed within the distal end.

9. The method of claim 1, wherein the tubular coupling element includes a stepped outer surface having a first outer diameter portion adjacent the proximal end and a greater, second outer diameter portion adjacent the distal end.

10. The method of claim 9, wherein disposing the tubular coupling element in abutment with the distal end of the elongated shaft to form a second joint having a circumference includes disposing the second outer diameter portion in abutment with the distal end of the elongated shaft to form the second joint.

11. The method of claim 1, wherein the first, second, and third elongated rod mandrels each include a flattened portion at the distal end thereof.

12. The method of claim 11, further comprising arranging the flattened portion of the first, second, and third elongated rod mandrels at radially equal intervals about a central axis.

13. An elongated member having a central longitudinal axis, comprising:

a first elongated rod mandrel including a first flattened distal portion;

a second elongated rod mandrel including a second flattened distal portion;

a third elongated rod mandrel including a third flattened distal portion;

wherein the first, second, and third elongated rod mandrels are fixed together such that the first, second, and third flattened distal portions are arranged perpendicular to radii extending out from the central longitudinal axis at 120-degree radial intervals;

a coupling element having a lumen therethrough; and

an elongate shaft;

wherein the coupling member fixes the first, second, and third elongated rod mandrels to the elongate shaft.

14. The elongated member of claim 13, wherein the coupling element and the elongate shaft are coaxial with the central longitudinal axis.

15. The elongated member of claim 13, wherein the coupling element includes a proximal portion having a first outer diameter and distal portion having a second outer diameter greater than the first outer diameter.

16. The elongated member of claim 15, wherein the proximal portion of the coupling element is inserted into a distal end of the elongate shaft such that the distal portion of the coupling element abuts the distal end of the elongate shaft to form a joint.

17. The elongated member of claim 16, wherein the joint is laser welded about its entire circumference.

18. The elongated member of claim 15, wherein the second outer diameter is substantially equivalent to an outer diameter of the distal end of the elongate shaft.

19. The elongated member of claim 13, wherein the first, second, and third elongated rod mandrels are welded together at a proximal end to form a ball tip.

20. The elongated member of claim 19, wherein the first, second, and third elongated rod mandrels are disposed within the lumen of the coupling element such that a proximal end of the coupling element abuts the ball tip to form a seam, and the seam is laser welded about its entire circumference.