Stent Delivery System Having Dynamic Deployment and Methods of Manufacturing Same

• US 20160022455A1
• Filed: 07/24/2014
• Published: 01/28/2016
• Est. Priority Date: 07/24/2014
• Status: Active Grant

• Current Assignee: Medtronic Vascular, Inc. (Medtronic Plc)
• Original Assignee: Medtronic Vascular, Inc. (Medtronic Plc)
• Inventors: Wong, Mark
• Granted Patent: US 9,668,898 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61F 2/88 the wire-like elements formed as helical or spiral coils forming a net-like or mesh-like structure A61F2/90
• CPC Class Codes: A61F 2/915 with bands having a meander structure, adjacent bands being connected to each other
• CPC Class Codes: A61F 2/958 Inflatable balloons for placing stents or stent-grafts
• CPC Class Codes: A61F 2002/91516 the meander having a change in frequency along the band
• CPC Class Codes: A61F 2002/91525 within the whole structure different bands showing different meander characteristics, e.g. frequency or amplitude
• CPC Class Codes: A61F 2002/91575 connected peak to trough
• CPC Class Codes: A61F 2002/9583 Means for holding the stent on the balloon, e.g. using protrusions, adhesives or an outer sleeve
• CPC Class Codes: A61F 2240/002 Designing or making customized prostheses
• CPC Class Codes: A61F 2250/0018 differing in elasticity, stiffness or compressibility
• CPC Class Codes: A61F 2250/0029 differing in bending or flexure capacity
• CPC Class Codes: A61F 2250/0037 differing in height or in length
• CPC Class Codes: A61F 2250/0048 differing in mechanical expandability, e.g. in mechanical, self- or balloon expandability
• CPC Class Codes: A61M 2025/0183 Rapid exchange or monorail catheters
• CPC Class Codes: A61M 2025/1004 Balloons with folds, e.g. folded or multifolded
• 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 25/1002 characterised by balloon shape A61M25/1006, A61M25/1009 take precedence
• CPC Class Codes: A61M 25/1029 Production methods of the balloon members, e.g. blow-moulding, extruding, deposition or by wrapping a plurality of layers of balloon material around a mandril
• CPC Class Codes: A61M 25/1038 Wrapping or folding devices for use with balloon catheters
• CPC Class Codes: B23P 11/005 by expanding or crimping
• CPC Class Codes: Y10T 29/49913 by constricting outer annulus

Abstract

A stent delivery system for dynamic deployment of a stent loaded thereon and a method of manufacturing the system. The stent delivery system includes a balloon catheter with a balloon in a spirally twisted delivery configuration on which a stent is crimped or otherwise loaded. The stent is made from a single, continuous strand of wire formed into a sinusoidal waveform that is wrapped into a helical pattern and joined at selected crowns. Upon inflation of the spirally twisted balloon of the stent delivery system, the stent undergoes dynamic deployment such that the stent in a deployed or expanded configuration has crowns with obtuse deployment angles and crowns with acute deployment angles.

Claims

1. A method of manufacturing a stent delivery system for dynamic deployment of a stent comprising:

twisting an uninflated balloon of a stent delivery catheter into a spirally twisted delivery configuration; and

loading a stent onto the spirally twisted balloon, the stent being made from a single, continuous strand of wire formed into a sinusoidal waveform that is wrapped into a helical pattern and joined at selected crowns, wherein upon inflation of the spirally twisted balloon the stent undergoes dynamic deployment such that the stent in a deployed configuration has crowns with obtuse deployment angles and crowns with acute deployment angles.

2. The method of claim 1, wherein the obtuse deployment angles are in the range of greater than 90 ninety degrees to less than or equal to 180 degrees and the acute deployment angles are in the range of greater than or equal to 70 degrees to less than 90 degrees.

3. The method of claim 1, wherein in the deployed configuration one or more segments of the stent having crowns with obtuse deployment angles possess a higher hoop strength than one or more segments of the stent having crowns with acute deployment angles.

4. The method of claim 1, wherein the spirally twisted balloon is configured to untwist upon inflation and thereby apply a twisting force to the stent.

5. The method of claim 1, wherein the step of loading includes crimping the stent into a delivery configuration on the spirally twisted balloon.

6. The method of claim 5, wherein in the delivery configuration crowns of the stent are uniform in shape.

7. The method of claim 1, wherein the step of twisting the balloon includes incrementally twisting the balloon in a clockwise direction from a proximal end to a distal end thereof such that the spirally twisted balloon has a right-handed spiral and wherein the helical pattern of the stent forms a right-handed helix.

8. The method of claim 1, wherein the step of twisting the balloon includes incrementally twisting the balloon in a counterclockwise direction from a proximal end to a distal end thereof such that the spirally twisted balloon has a left-handed spiral and wherein the helical pattern of the stent forms a left-handed helix.

9. The method of claim 1, wherein the step of twisting the balloon provides the spirally twisted balloon with a right-handed spiral and wherein the helical pattern of the stent forms a right-handed helix.

10. The method of claim 1, wherein the step of twisting the balloon provides the spirally twisted balloon with a left-handed spiral and wherein the helical pattern of the stent forms a left-handed helix.

11. A stent delivery system having dynamic deployment comprising:

a balloon catheter having an uninflated balloon in a spirally twisted delivery configuration; and

a stent loaded onto the spirally twisted balloon, the stent being made from a single, continuous strand of wire formed into a sinusoidal waveform that is wrapped into a helical pattern and joined at selected crowns, wherein upon inflation of the spirally twisted balloon the stent undergoes dynamic deployment such that the stent in a deployed configuration has crowns with obtuse deployment angles and crowns with acute deployment angles.

12. The stent delivery system of claim 11, wherein the obtuse deployment angles are in the range of greater than 90 ninety degrees to less than or equal to 180 degrees and the acute deployment angles are in the range of greater than or equal to 70 degrees to less than 90 degrees.

13. The stent delivery system of claim 11, wherein in the deployed configuration one or more segments of the stent having crowns with obtuse deployment angles possess a higher hoop strength than one or more segments of the stent having crowns with acute deployment angles.

14. The stent delivery system of claim 11, wherein the spirally twisted balloon is configured to untwist upon inflation and thereby apply a twisting force to the stent.

15. The stent delivery system of claim 11, wherein the stent loaded on the spirally twisted balloon in a delivery configuration has crowns that are uniform in shape.

16. The stent delivery system of claim 11, wherein the spirally twisted balloon has a right-handed spiral.

17. The stent delivery system of claim 16, wherein the helical pattern of the stent forms a right-handed helix.

18. The stent delivery system of claim 11, wherein the spirally twisted balloon has a left-handed spiral.

19. The stent delivery system of claim 18, wherein the helical pattern of the stent forms a left-handed helix.