US20010001890A1 - Method for contracting, loading or crimping self-expanding and balloon expandable stent devices - Google Patents

Abstract

An apparatus for manipulating a medical device is formed of at least three coupled movable blades which are disposed about a reference circle to form an aperture whose size may be varied. The aperture capable of being sized to contain a medical device. Each blade is in communication with an actuation device which is capable of moving the blade to alter the size of the aperture. Each blade includes a single radial point which a) lies on the circumference of the reference circle prior to movement of the blade, and b) may be moved only along a radius of the reference circle on movement of the blade.

Description

BACKGROUND OF THE INVENTION
• This invention relates to an apparatus and a method for reducing in size a medical device such as a stent, stent-graft, graft, or vena cava filter. The apparatus may be used in particular for fastening a medical device onto a catheter.[0001]
• Medical devices such as stents, stent-grafts, grafts, or vena cava filters and catheters for their delivery are utilized in a number of medical procedures and situations, and as such their structure and function are well known.[0002]
• A stent, for example, is a generally cylindrical prosthesis introduced via a catheter into a lumen of a body vessel in a configuration having a generally reduced diameter and then expanded to the diameter of the vessel. In its expanded configuration, the stent supports and reinforces the vessel walls while maintaining the vessel in an open, unobstructed condition.[0003]
• Stents are typically inflation expandable or self-expanding. Self expanding stents which are constrained by a sheath or other restraining means, must be provided in a reduced diameter.[0004]
• An example of a stent described in PCT Application No. 960 3092 A1, published Feb. 8, 1996.[0005]
• In advancing a stent through a body vessel to the deployment site, the stent must be able to securely maintain its axial position on the delivery catheter, without translocating proximally or distally, and especially without becoming separated from the catheter. Stents that are not properly secured or retained to the catheter may slip and either be lost or be deployed in the wrong location. The stent must be crimped in such a way as to minimize or prevent altogether distortion of the stent and to thereby prevent abrasion and/or reduce trauma of the vessel walls.[0006]
• In the past, this crimping or size reduction has been done by hand often resulting in the application of undesired uneven forces to the stent. Such a stent must either be discarded or re-crimped. Stents which have been crimped or otherwise reduced in size multiple times can suffer from fatigue and may be scored or otherwise marked which can cause thrombosis. A poorly crimped stent can also damage the underlying balloon.[0007]
• Recently, stent crimping devices halve been disclosed in U.S. Pat. No. 5,546,646 to Williams et al, U.S. Pat. No. 5,183,085 to Timmermans et al., U.S. Pat. No. 5,626,604 to Cottone, Jr., U.S. Pat. No. 5,725,519, U.S. Pat. No. 5,810,873 to Morales, WO 97/20593 and WO 98/19633.[0008]
• A cam actuated stent crimper, shown in FIG. 1, employs a plurality of arc-shaped or curved slots with semi-circular ends, disposed such that each slot or cam engages a cam follower bearing[0009]22. The arc-shaped or curved surfaces of the slots are inclined to be non-concentric relative to the axis ofrotation26, and therefore rotation of the cam plate28 transmits equal radial displacements to thecam follower bearings22, to simultaneously actuate a like number of linear bearings24, which have their corresponding linear tracks or rails mounted on a fixed plate. As shown in FIG. 1 the cam plate rotary drive29 comprises a pneumatic cylinder mounted on a pivot or trunnion, arranged with the cylinder rod connected rotatably to a short arm fixed rigidly to the cam plate. Accordingly, linear motion produced by the pneumatic cylinder translates into controllable arcs of motion of the circular cam plate, which has a projecting V-shaped profile on its outer edge in rolling engagement with three equally spaced rollers with mating inverse V-shaped profiles to provide precise rotatable support to the cam plate. Depending on the direction of rotation, the linear slides which each carry a radially disposed crimping blade, are either moved inwards to apply a crimping force to the stent, or outwards to release the stent. Also when crimping, depending on the degree of rotation of the cam plate, a specific radial crimping displacement may be obtained to match the diametral reduction required for any particular stent.
• All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety.[0010]
BRIEF SUMMARY OF THE INVENTION
• It would be desirable to produce at device capable of crimping a stent uniformly while minimizing the distortion of and scoring and marking of the stent due to the crimping. The present invention is directed to that end.[0011]
• The present invention is particularly concerned with the crimping and otherwise reducing in size of inflation expandable stents, self-expanding stents and other expandable medical devices. For the purpose of this disclosure, it is understood that the term ‘stent’ includes stents, stent-grafts, grafts and vena cava filters. It is also understood that the term ‘crimping’ refers to a reduction in size or profile of a stent.[0012]
• In the description that follows it is understood that the invention contemplates crimping a medical device either directly to a catheter tube or to a catheter balloon which is disposed about a catheter tube. When reference is made to crimping a medical device to a catheter, a balloon may be situated between the medical device and the catheter tube or the medical device may be crimped to a region of a catheter tube directly. The invention also contemplates crimping a stent in the absence of a catheter to reduce the stent in size.[0013]
• The present invention is directed, in one embodiment, to an apparatus for reducing a medical device in size. Desirably, the medical device is a stent, a stent-graft, a graft or a vena cava filter, whether self-expandable, balloon expandable or otherwise expandable, although the inventive apparatus may also be employed with any other suitable, generally tubular medical device which must be reduced in size.[0014]
• The inventive apparatus comprises at least three coupled movable blades disposed about a reference circle to form an aperture whose size may be varied. Each blade is in communication with an actuation device which is capable of moving the blade to alter the size of the aperture. Each blade includes a single radial point on the surface of the blade which a) lies on the circumference of the reference circle prior to movement of the blade, and b) may be moved only along a radius of the reference circle on movement of the blade.[0015]
• The apparatus further includes an actuation device which comprises a cam and a plurality of linear slide devices. Each linear slide device is in communication with a blade. Each of the linear slide devices is also in mechanical communication with the cam. Rotation of the cam results in linear translation of the slide device and blade, such that the slide device moves along an axis parallel to the radius on which the radial point of the blade lies or along the radius itself.[0016]
• The invention is also directed to an apparatus similar to that described above, with blades disposed about a reference tube to form a tubular aperture whose size may be varied. Each blade is in communication with an actuation device which is capable of moving the blade to alter the size of the tubular aperture. Each blade includes a single line which a) lies on the surface of the reference tube prior to movement of the blade, and b) may be moved only along a radial plane of the reference tube on movement of the blade.[0017]
• The inventive apparatus finds particular utility in crimping a medical device such as those mentioned above to a catheter or to a balloon disposed about a catheter.[0018]
• The inventive apparatus also finds utility in reducing the diameter of a medical device such as those mentioned above prior to crimping.[0019]
• The invention is also directed to a method of manipulating a medical device which comprises the steps of providing the medical device and providing at least three blades capable of applying a radial inward force. The blades are disposed about a reference circle to form a shrinkable aperture. A medical device such as a stent is placed into the shrinkable aperture and the blades simultaneously moved inward to apply a radial inward force to the medical device. The blades are constructed and arranged such that each blade has a single point which a) lies on the circumference of the reference circle prior to movement of the blade, and b) is moved along a radius of the reference circle on movement of the blade.[0020]
• The inventive apparatus may also be used as a variable size balloon mold. To that end, the invention is further directed to a method of molding a medical balloon. In the practice of the method, a balloon preform prepared through any suitable technique known in the art is provided. The preform is placed in an apparatus which has a shrinkable tubular aperture formed by at least three movable blades disposed about a reference tube. The blades are constructed and arranged such that each blade has a single line which a) lies on the surface of the reference tube prior to movement of the blade, and b) is moved along a radial plane of the reference tube on movement of the blade. The aperture may be set to a predetermined size prior to placement of the preform therein or after placement of the preform therein. An inflation fluid is supplied to the balloon preform to expand the balloon preform until it contacts the blades. The preform may optionally be heated prior to, during or after the blowing step. The thus formed balloon is then pressure relieved and removed from the apparatus.[0021]
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
• FIG. 1 shows a perspective view of a stent crimper;[0022]
• FIG. 2[0023]ais a schematic front view of an embodiment of the inventive apparatus;
• FIG. 2[0024]bis a schematic front view of the embodiment of FIG. 2aafter the stent has been reduced in size;
• FIGS. 3[0025]aand3bare schematics of blades;
• FIG. 3[0026]cis a partial schematic front view of an embodiment of the inventive apparatus employing the curved blades of FIG. 3b;
• FIG. 4[0027]ais a partial front view of an embodiment of the inventive apparatus;
• FIG. 4[0028]bis a partial front view of an embodiment of the inventive apparatus;
• FIG. 4[0029]cshows a side view of the embodiment of FIG. 4btaken along lines4c-4c;
• FIG. 5[0030]ashows a partial front view of another embodiment of the inventive apparatus;
• FIG. 5[0031]bshows a link connected to a blade;
• FIG. 6 is a schematic, perspective view of an embodiment of the inventive apparatus;[0032]
• FIG. 7 shows a partial view of the embodiment of FIG. 6;[0033]
• FIGS. 8[0034]aand8bare partial side elevational views of an embodiment of the inventive apparatus taken along a radial plane during the size reduction process;
• FIG. 8[0035]cis a partial side elevational view of an embodiment of the inventive apparatus taken along a radial plane following crimping of a stent to a catheter;
• FIG. 9 is a diagrammatic side elevational view of an embodiment of the inventive apparatus;[0036]
• FIG. 10 is a partial side elevational view of an embodiment of the inventive apparatus taken along a radial plane of an embodiment of the invention consisting of three individual apparatuses arranged sequentially;[0037]
• FIG. 11 is a schematic showing a stent being reduced in size and loaded into a sheath;[0038]
• FIG. 12 is a partial side elevational view of an embodiment of the inventive apparatus taken along a radial plane showing a balloon that has been molded with the inventive device; and[0039]
• FIG. 13 is a partial side elevational view taken along a radial plane showing a stepped balloon that has been molded with the inventive device.[0040]
DETAILED DESCRIPTION OF THE INVENTION
• While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.[0041]
• As shown generally at[0042]100 in FIGS. 2aand2b, the inventive apparatus comprises eight coupledblades106 disposed about areference circle114 to form anaperture118 whose size may be varied. The apparatus may comprise as few as three blades and as many as sixteen or more blades. Desirably, the apparatus will have four or more blades and more desirably, eight or more blades. The maximum number of blades is limited only by how many blades can physically be coupled together under the relevant size constraints. As the number of blades is increased, the profile of the aperture and hence of the medical device following reduction in size, becomes smoother. FIG. 2bshows the apparatus of FIG. 2aafter the stent has been reduced in size.
• [0043]Blades106 as shown in FIG. 3ahave aninner end108 which is desirably beveled111 so as to mesh with adjacent blades and anouter end110 which is displaced fromaperture118.Aperture118 is polygonal.Blades106 may also be shaped with acurved end112, as shown in FIGS. 3band3cso as to form a substantially circular shaped aperture, when the aperture is fully closed.
• Each[0044]blade106 includes a singleradial point122 which lies on aradial line126 ofreference circle114 prior to movement ofblade106 and which may be moved only along theradius126 ofreference circle114 on movement ofblade106. Desirably, the singleradial point122 will be disposed at the tip of the blade adjacent tobeveled end111.
• In the embodiment shown in FIG. 4[0045]a,radial point122 lies at the tip ofblade106. Eachblade106 has a connectinglink130 extending fromsecond end110.Connecting link130 ends in mounting means134, typically a mounting flange adapted for attachment to a linear bearing block, for interfacing with an actuation device, shown generally at138.Actuation device138 is capable of simultaneously movingblades106 to alter the size ofaperture118.
• [0046]Actuation device138 includesactuation plate142 which is coaxial withreference circle114.Actuation plate142 has eight equi-spacedradial slots146. More generally, for every blade there will be a corresponding radial slot onactuation plate142. Eachradial slot146 overlaps a mounting means134 for a linear bearing block at the end of a connectinglink130. Eachblade106 is engaged toactuation plate142 via a cam follower bearing150 disposed inradial slot146 and attached to mounting means in slottedend134.
• Each[0047]bearing150 extends from alinear slide154.Linear slide154 is mounted on a non-rotating plate156 (shown in FIG. 8).Linear slide154 is constructed and arranged to slide along aline158 which is parallel to theradius126 on whichradial point122 ofblade106 lies.
• For the purposes of this disclosure, the term ‘cam follower bearing’ includes cam follower bearings, low friction rollers, roller bearings, needle roller bearings and a slipper block pivot mounted on a bearing and stub shaft. FIG. 4[0048]bis a partial front view of an embodiment in which a slipper block is used. A side view of the embodiment of FIG. 4btaken along lines4c-4cis shown in FIG. 4c.Slipper block150 resides inslot146 ofactuation plate142.Slipper block150 is mounted onstub shaft151 which extends from connectinglink130. Desirably,bearings153 will be present betweenshaft151 andslipper block150.Connecting link130, in turn, is fastened tolinear bearing block212 via fasteners214.Bearing block212 is linearly mounted on linear slide which is mounted on fixedplate156. Linear motion is facilitated by the presence ofbearings216.
• Cam follower bearing[0049]150 may be replaced by any other suitable connecting member which can connect the slide and the link.
• In use, as[0050]actuation plate142 is rotated in a clockwise direction, the clockwise motion of the actuation plate is translated into linear motion of each oflinear slide154 andblade106 viabearing150. Eachblade106 moves outward in a direction parallel to theradius126 on which theradial point122 of theblade106 lies, resulting in the opening ofaperture118. Asactuation plate142 is rotated in a counterclockwise direction, eachblade106 moves inward in a direction parallel to theradius126 on which theradial point122 of theblade106 lies, resulting in the closing ofaperture118. Asaperture118 closes, a radially inward force is applied to a medical device disposed in the aperture. The actuation plate is rotated until the desired size reduction of the aperture and medical device has been achieved. Following the reduction, the actuation plate is rotated in the opposite direction to allow for removal of the medical device from the aperture.
• The apparatus may be used to reduce the diameter of a suitable medical device such as those disclosed above or may be used to crimp a medical device to a catheter.[0051]
• Another embodiment of the invention is shown in FIG. 5[0052]a.Eachblade106, as shown in FIG. 5a,has a connectinglink130 extending therefrom.Connecting link130 is rigidly attached toblade106.Connecting link130 ends in anangled end134 for interfacing with an actuation device, shown generally at138.Actuation device138 is capable of simultaneously movingblades106 to alter the size ofaperture118.
• [0053]Actuation device138 includes arotatable actuation plate142 which is co-axial withreference circle114. Rotatable actuation plate includescam slots146 which are not concentric with the axis of rotation, arcing inward. Each connectinglink130 is engaged toactuation plate146 via a cam follower bearing150 disposed inslot146 and attached to bothangled end134 of connectinglink130 and to alinear slide154.Linear slide154 is mounted on a non-rotating plate similar to that shown in FIG. 8.Linear slide154 is constructed and arranged to slide along aradial line158 on whichradial point122 ofblade106 lies.
• Connecting[0054]link130 may be bonded adhesively, welded, joined with a fastener or otherwise joined toblade106. As shown in FIG. 5a,asingle screw131 is used to connect link130 toblade106. FIG. 5bshows a connectinglink130 including a right angle portion which is fastened to ablade106 using twoscrews131.Connecting link130 andblade106 may optionally be formed of a single piece of material. Regardless of how the connecting member is joined to the blade, no movement of the blade relative to the connecting link is permitted.
• In use, as[0055]actuation plate142 is rotated in a clockwise direction, the clockwise motion of the actuation plate is translated into a linear outward motion of each oflinear slides154 andblades106 viabearings150 resulting in the opening ofaperture118. The outward motion results from the radially outward arcing ofcam slot146. Asactuation plate142 is rotated in a counterclockwise direction, eachblade106, because of the radially inward arc ofcam slots146, moves inward in a direction parallel to theradius126 on which theradial point122 of theblade106 lies, resulting in the closing ofaperture118. As discussed above, as the aperture is decreased in size, a radial inward force is brought to bear against a medical device disposed in the aperture, thereby reducing the size of the medical device.
• The embodiment of FIG. 5[0056]adiffers from the embodiment of FIG. 4ain that in the embodiment of FIG. 5a, the slide moves along the radial line on which the radial point of the attached blade lies whereas in FIG. 4athe slide moves parallel to the radial line. In both of the embodiments, each of the blades is constrained with two degrees of freedom to satisfy the condition that the movement of the tip be radial in accordance with the invention.
• In the embodiments of FIGS. 4[0057]aand5a,the slots in the actuation plate are constructed and arranged to allow for a sufficient reduction in size of the aperture so that a medical device can be reduced in size to a desired diameter. Those of ordinary skill in the art will recognize other suitable actuation devices that may be used in the practice of this invention.
• Desirably, in the above embodiments, the blades will be as long as or longer than the medical device disposed within so that the medical device is uniformly reduced in size along its entire length.[0058]
• This is illustrated in the embodiment of FIGS. 6 and 7 and further in FIGS. 3[0059]aand3bin whichblades106 are disposed about areference tube160 to form atubular aperture162 whose size may be varied.Reference circle114 is seen to lie alongreference tube160. Eachblade106 is in communication with an actuation device such as that shown in FIGS.4 or5. The actuation device is capable of movingblades106 to alter the size oftubular aperture162. Eachblade106 includes asingle line166 which a) lies on aradial plane170 of thereference tube160 prior to movement ofblade106, and b) may be moved only along aradial plane170 ofreference tube160 on movement ofblade106. Desirably,reference tube160 is cylindrical and exceeds the length of the medical device to be reduced in size.
• Another embodiment of the invention is illustrated in FIGS. 8[0060]aand8b. In the embodiment of FIGS. 8aand8b, twonon-rotating plates156 are present, one at each end of the apparatus. Eachblade106 is connected at first end174 to a linear slide154avia a connecting link130aand at second end178 to a linear slide154ba via a connecting link130b. Linear slide154ais mounted on non-rotating plate156aand linear slide154bis mounted on non-rotating plate156b. The presence of the second non-rotating plate156b, linear slide154band connecting link130bis optional but contributes to providing a rigid frame upon which the connecting links and associated blades may slide without misalignment relative to the reference circle.
• FIGS. 8[0061]aand8billustrate the use of the inventive apparatus in various stages of the size reduction process. In FIG. 8a,stent180 has been placed intubular aperture162 which is characterized by a diameter d₁. In FIG. 8b, the device has been actuated by rotatingactuation plate142 so as to moveblades106 inward.Aperture162, as shown in FIG. 8bis characterized by a diameter d₂which is reduced relative to diameter d₁.Stent180 is seen to be of reduced diameter relative to its previous diameter as shown in FIG. 8a.
• FIG. 8[0062]cdiffers from FIG. 8b, only in thatstent180 has been crimped ontocatheter184 in FIG. 8c.
• [0063]Blades106 may be made of any suitable, hard material including hardened steel. Desirably, the blades will be made of a material such as zirconia ceramic. Blades made of zirconia ceramic may be used without lubrication. Furthermore, because of their low thermal conductivity, they may be used to create a highly insulated chamber suitable for cryogenic processing of martensite in nitinol stents.
• Such an embodiment is shown in FIG. 9.[0064]Stent180 is disposed betweenblades106 which can move inward in the direction of the arrows.Blades106 are cooled by a first source of cooling fluid184 located at first end174 ofblades106. Although not shown, a second source of cooling fluid may be provided at second end178 ofblades106 as well. The cooling fluid may be a liquid cryogenic. Exemplary cryogenics include liquid nitrogen, argon or carbon dioxide although other cryogens may also be used. The cooling fluid may also be a chilled gas such as air. The cooling fluid may also be a cooled inert gas such as nitrogen, argon or other inert gasses.
• The aperture formed by the blades is a highly insulated chamber which is suitable for cryogenic processing of martensite in nitinol stents. The chamber is maintained at −80° C. and a nitinol stent inserted therein. Upon equilibration of the temperature of the stent, the blades are moved inward to reduce the diameter of the stent. The stent is thus reduced in diameter while being maintained in the martensitic state.[0065]
• The embodiment of FIG. 9 further has a[0066]loading plunger188 for loading a stent or other suitable medical device into the aperture. Asheath housing192 which housessheath196 is provided at second end178 ofblades106.Plunger188 may be further used to transfer the stent after it has been reduced in diameter or size tosheath196. Desirably,sheath196 will have a slightly larger diameter thanstent180 following reduction in size of the stent. More desirably, the fit of the stent within the sheath will be within about {fraction (1/32)}″ and even more desirably, within about {fraction (1/64)}″.
• Where lengthy stents or other medical devices are to be reduced in size, the invention contemplates using one of the above described apparatuses with long blades to accommodate the stent. As an alternative, the invention also contemplates disposing two or more of such apparatuses sequentially to form one long aperture. The two or more apertures may then be reduced in size simultaneously or consecutively. The arrangement of FIG. 10 shows an embodiment with three[0067]devices100a-carranged sequentially. A stepped reduction in size may be achieved by placing astent180 or similar medical device in the apparatus and independently reducing eachaperture118a-cto a desired size. To that end, the invention may provide particular utility in manipulating bifurcated stents or other stents whose diameter varies along its length. The embodiment of FIG. 10 shows the end portions of the stent being reduced in size prior to the middle portion of the stent. The device may also be operated so as to reduce the middle portion in size prior to the end portions or in any other sequence.
• The invention contemplates yet another approach to reducing the diameter of lengthy stents or similar medical devices, namely walking the stent through the apparatus. This may be accomplished by either moving the stent relative to the apparatus or moving the apparatus relative to the stent as shown schematically in FIG. 11. To that end,[0068]stent180 is inserted indevice100. Aperture118ais reduced in size with blades106ain turn reducing portion180aofstent180 in size. Aperture118ais then opened and aperture118breduced in size thereby reducing portion180bofstent180. Simultaneously, or shortly thereafter,sheath196 is pushed byplunger188 over the portion of the stent that has been reduced in size. Aperture118bis opened and the stent advanced in the apparatus. The process is repeated until the entire length, or the desired portion of the stent or medical device is reduced in size.
• The reduction in size of the stent or other medical device may occur as part of a precrimping step or it may occur as part of crimping a stent onto a catheter and desirably, onto a balloon disposed about a catheter. In a general sense, it may be used for manipulating a medical device and specifically, for applying a radial inward force to a medical device.[0069]
• In another embodiment, the invention is directed to a method of manipulating a medical device. As part of the method, a medical device such as those disclosed above is provided. The device has at least three blades capable of applying a radial inward force. The blades are disposed about a reference circle to form a shrinkable aperture. The blades are constructed and arranged such that each blade has only a single point which a) lies on the circumference of the reference circle prior to movement of the blade, and b) is moved along a radius of the reference circle on movement of the blade. The medical device is placed into the shrinkable aperture and the blades simultaneously moved inward to apply a radial inward force to the medical device and thereby reduce the medical device in size, and desirably, in diameter. Following reduction in size of the medical device, the blades are simultaneously moved outward and the medical device removed from the aperture.[0070]
• The inventive apparatus may also be incorporated into a blow molding tool to provide a variable size balloon mold as shown generally at[0071]100 in FIG. 12. The various parts of the apparatus of FIG. 12 have been discussed in conjunction with FIGS. 8a-cand, with exception of balloon181 and mold cavity ends193, the reference numerals used in FIG. 12 correspond to those used for FIGS. 8a-c.Mold cavity ends193 may be provided in a variety of sizes and lengths to contain the balloon at each end. Desirably, the end molds will be adjustably mounted to a portion of the apparatus such as fixedplates156 to provide for an adjustable length balloon mold.
• The invention is also directed to a method for molding a medical balloon using the inventive apparatus described above. A balloon preform prepared through any standard method is provided. The inventive mold, shown generally at[0072]100 is also provided. Balloon181 is inserted intoaperture162.Aperture162 is optionally reduced to a predetermined size and the preform expanded using standard techniques. An inflation fluid, for example, may be supplied to the preform and the preform expanded and heated. The balloon in its expanded state is shown in FIG. 12.
• More generally, the invention may be practiced by providing at least three movable blades disposed about a reference tube to form a shrinkable tubular aperture. The blades are constructed and arranged such that each blade has a single line which a) lies on the surface of the reference tube prior to movement of the blade, and b) is moved along a radial plane of the reference tube on movement of the blade. A balloon preform is placed into the shrinkable aperture. The aperture may be set at a predetermined size prior to or following insertion of the balloon therein. An inflation fluid is provided and the balloon preform inflated so that the preform expands to the size of the aperture. The preform may be heated during this inflation blowing step. The inflation fluid is then removed from the thus formed balloon and the balloon removed from the apparatus.[0073]
• The balloon may be also be molded in accordance with the method described in U.S. Pat. No. 5,163,989, or in accordance with other methods as are known to those of ordinary skill in the art, substituting the instant apparatus for the standard balloon mold. Other patents which discuss balloon molding include U.S. Pat. No. 5,807,520. Other references illustrating the materials and methods of making catheter balloons include: U.S. Pat. No. 4,413,989 and U.S. Pat. No. 4,456,000 to Schjeldahl et al, U.S. Pat. No. 4,490,421, U.S. Pat. No. Re 32,983 and U.S. Pat. No. Re 33,561 to Levy, and U.S. Pat. No. 4,906,244, U.S. Pat. No. 5,108,415 and U.S. Pat. No. 5,156,612 to Pinchuck et al.[0074]
• The use of the inventive apparatus as a mold allows for the blowing of a balloon to a predetermined size using a single adjustable size balloon mold thereby eliminating the need to have multiple molds of different sizes.[0075]
• The invention further contemplates molding a balloon to a desired shape using a plurality of the inventive devices arranged sequentially. As an example of this, shown in FIG. 13, a stepped balloon[0076]181 may be prepared by arranging several devices100a,100band100csequentially. A balloon preform is inserted in the aperture formed by the device. The aperture of each device may be preset at a desired size or may be reduced in size to a predetermined size after the balloon preform is inserted therein. The balloon may then be blow molded in accordance with any suitable blow molding technique known in the art.
• The invention is also understood to be directed to embodiments employing various combinations of the features disclosed herein.[0077]
• The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the attached claims. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims attached hereto.[0078]

Claims (26)

What is claimed is:

1. An apparatus for reducing in size a medical device comprising:

at least three coupled movable blades disposed about a reference circle to form an aperture whose size may be varied, the aperture capable of being sized to contain the medical device,

each blade in communication with an actuation device which is capable of moving the blade to alter the size of the aperture,

wherein each blade includes a single radial point which

a) lies on a radial line of the reference circle prior to movement of the blade, and

b) may be moved only along the radial line of the reference circle on movement of the blade.

2. The apparatus of

claim 1

wherein the blades are constructed and arranged to form a shrinkable polygonal aperture.

3. The apparatus of

claim 1

wherein the blades are constructed and arranged to form a substantially circular aperture.

4. The apparatus of

claim 1

wherein the actuation device comprises

a cam, and

a plurality of linear slide devices,

each of the linear slide devices in mechanical communication with the cam,

and each blade is mounted to a linear slide device,

each linear slide device movable along an axis parallel to the radius on which the radial point of the blade lies.

5. The apparatus of

claim 1

comprising from 4 to 16 blades.

6. The apparatus of

claim 5

comprising 8 blades.

7. The apparatus of

claim 1

wherein the blades are disposed about a reference tube to form a tubular aperture whose size may be varied, the reference circle lying along the reference tube,

each blade in communication with an actuation device which is capable of moving the blade to alter the size of the tubular aperture,

each blade includes a single line which

a) lies on the circumference of the reference tube prior to movement of the blade, and

b) may be moved only along a radial plane of the reference tube on movement of the blade.

8. The apparatus of

claim 7

wherein the reference tube is a cylinder.

9. The apparatus of

claim 1

in combination with a medical device which may be reduced in size, the medical device selected from the group consisting of stents, grafts stent-grafts and vena cava filters.

10. The apparatus of

claim 1

wherein each blade has an inner end and an outer end, the inner end being beveled to form a tip.

11. The apparatus of

claim 13

wherein the single radial point on each blade is at the tip of the blade

12. An apparatus for applying a radial inward force to a medical device comprising:

at least three coupled movable blades disposed about a reference circle to form an aperture whose size may be varied, the aperture capable of being sized to contain the medical device,

each blade in communication with an actuation device which is capable of moving the blade to alter the size of the aperture,

wherein each blade includes a single radial point which

a) lies on the circumference of the reference circle prior to movement of the blade, and

b) may be moved only along a radius of the reference circle on movement of the blade.

13. The apparatus of

claim 12

with a medical device selected from the group consisting of stents, grafts, stent-grafts and vena cava filters disposed in the aperture.

14. The apparatus of

claim 13

wherein the medical device is disposed about a catheter.

15. An apparatus for crimping a medical device comprising:

at least three coupled movable blades disposed about a reference circle to form an aperture whose size may be varied, the aperture capable of being sized to contain the medical device,

each blade in communication with an actuation device which is capable of moving the blade to alter the size of the aperture,

wherein each blade includes a single radial point which

a) lies on the circumference of the reference circle prior to movement of the blade, and

b) may be moved only along a radius of the reference circle on movement of the blade.

16. A method of manipulating a medical device comprising the steps of:

providing a medical device;

providing at least three blades capable of applying a radial inward force, the blades disposed about a reference circle to form a shrinkable aperture;

placing the medical device into the shrinkable aperture;

simultaneously moving the blades inward to apply a radial inward force to the medical device;

wherein the blades are constructed and arranged such that each blade has a single point which

a) lies on the circumference of the reference circle prior to movement of the blade, and

b) is moved along a radius of the reference circle on movement of the blade.

17. The method of

claim 16

wherein the medical device is selected from the group consisting of stents, stent-grafts, grafts and vena cava filters.

18. The method of

claim 17

wherein the medical device is reduced in size.

19. The method of

claim 17

wherein the medical device is characterized by a diameter and the diameter is reduced in size.

20. The method of

claim 17

wherein the medical device is disposed about a catheter.

21. The method of

claim 17

wherein the medical device is disposed about a balloon which is disposed about a catheter.

22. The method of

claim 20

wherein a sufficient radial inward force is applied to crimp the medical device to the catheter.

23. The method of

claim 21

further comprising the steps of:

simultaneously moving the blades outward; and

removing the medical device from the aperture.

24. A method of molding a balloon comprising the steps of:

providing a balloon preform;

providing at least three movable blades disposed about a reference tube to form a shrinkable tubular aperture, wherein the blades are constructed and arranged such that each blade has a single line which

a) lies on the surface of the reference tube prior to movement of the blade, and

b) is moved along a radial plane of the reference tube on movement of the blade;

placing the balloon preform into the shrinkable aperture;

providing an inflation fluid; and

inflating the balloon preform so that the preform contacts the blades.

25. The method of

claim 24

wherein the balloon is heated during the inflating step to form a balloon.

26. The method of

claim 25

wherein the inflation fluid is removed from the formed balloon and the balloon is removed from the aperture.

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