US20040143197A1

Movatterモバイル変換

Info

Publication number: US20040143197A1
Application number: US10/752,466
Authority: US
Inventors: Thomas Soukup; John Wright; William Kuester; Patrick Haley
Original assignee: Synovis Interventional Solutions Inc
Current assignee: Heraeus Materials SA
Priority date: 2001-08-21
Filing date: 2004-01-06
Publication date: 2004-07-22
Also published as: US20030040684A1; US6776765B2

Abstract

A steerable stylet for use within a lumen of an intravascular device includes a stylet assembly and a handle. The stylet assembly has a distal end portion and a proximal end portion and includes a stylet wire having a lumen and a core wire positioned within the lumen with the distal end portion secured to the stylet wire proximate the distal end portion of the stylet wire. The handle includes a hand-held housing structure connected to one of the proximal end portion of the stylet wire or the core wire. In one embodiment, an adjustable tensioner is connected to the other of the proximal end portion of the stylet wire or the core wire to adjust a relative tension force applied between the stylet wire and the core wire. A tension limiter is arranged to limit the tension force to a limit force that is less than a breaking stress force of the stylet wire when the stylet wire is positioned within the lumen of the intravascular device. In another embodiment, a plurality of notches are defined in one or more regions of the distal portion of the tubular stylet wire to aid in the safe and effective creation of large and/or compound curves. Preferably, the core wire is secured within the tubular stylet wire without heating the either wire so as to prevent any annealing of the materials that would decrease the tensile strength of the distal end portion of the stylet.

Description

FIELD OF THE INVENTION

The present invention relates generally to the field of intravascular leads and catheters. More specifically, the present invention relates to steerable stylet for use in positioning such leads and catheters.[0001]

BACKGROUND OF THE INVENTION

Stylets and guidewires are used to control the manner in which intravascular leads and catheters are introduced into the veins or arteries of the body. Although both kinds of devices are often thought of as simply very small wires, the purpose and operation of stylets is significantly different as compared to guidewires.[0002]

Conventional intravascular procedures typically involve an initial step of introducing and routing a guidewire through a patient's vascular system to provide a rail or track along which additional intravascular devices may be introduced. Once a guidewire is in place, a sheath is routed over at least a portion of the guidewire to provide a larger opening into the vein or artery and sometimes to protect the inside walls of the vessels along the route of the guidewire. With the sheath in place, the guidewire may be removed or may remain in place as additional intravascular devices, such as intravascular leads and catheters, are introduced into the patient's vascular system.[0003]

To better accomplish the purpose of a guidewire providing a track along the patient's vascular system for other intravascular devices, it is desirable that the guidewire be extremely flexible and preferably have the ability to vary the flexibility of the distal tip and/or deflect the distal tip so as to aid in routing the guidewire through the patient's vascular system. U.S. Pat. Nos. 4,215,703, 4,456,017, 4,719,924, 4,757,827, 4,886,067 and 5,060,660 describe designs for guidewires that use an internal tensioning member or core wire to alter the characteristics of the non-expandable distal tip and/or to deflect the distal tip. U.S. Pat. Nos. 4,271,845 4,822,345, 5,605,162, 5,762,615, 5,851,203, 5,957,903 and 6,183,420 describe various designs for guidewires with adjustable stiffness by moving a core member axially within the guidewire. U.S. Pat. Nos. 5,938,623 and 6,039,743 describe a guidewire with adjustable stiffness that is controlled by running electricity through a memory metal wire tip. Flexibility of the guidewire has also been provided by gradually tapering some portion of the distal end as described in U.S. Pat. Nos. 5,851,203 and 5,916,178 or by changing materials at the end of the guidewire as described in U.S. Pat. Nos. 6,017,319 and 6,068,623. The flexibility of guidewires has also been enhanced by making cuts or slots in the distal region of the guidewire as shown in U.S. Pat. Nos. 3,802,440, 5,437,288, 5,605,543, 5,833,632, 6,004,279 and 6,017,319. Similar arrangements for increasing the flexibility of the catheter that is tracked over the guidewire are also described in U.S. Pat. Nos. 5,304,131, 5,315,996, 5,322,064, 5,441,483, 5,573,520, 5,743,876 and 6,048,339. Catheter arrangements capable of producing compound bends are described in U.S. Pat. Nos. 5,758,656 and 5,820,591.[0004]

In contrast to the guidewire that serves as a track over which other intravascular devices are routed, a stylet is used within an internal lumen of an intravascular device both to push that device through the vascular system and to steer the device as it is being pushed. Although some intravascular devices are designed to steer themselves using internal core wires, almost all leads, most catheters and some guidewires have an inner channel or lumen into which a stylet is inserted. In addition to pushing the intravascular device through the vascular system by engaging the distal end of the device, the stylet also serves to deflect the distal end of the intravascular device so as to steer the distal end through the vascular system. Unlike the lead, catheter or guidewire, which is highly flexible and floppy, the stylet must be stiffer and more rigid so as to enable the stylet to push the lead or catheter through the patient's vascular system. In addition, guidewires have diameters that are typically at least twice as large (0.030-0.040 inches) as the diameters of stylets (less than 0.016 inches) because guidewires are most often formed of a coiled wire, instead of a straight tubular wire.[0005]

Conventionally, stylets having different bends on the distal end are used at different points of advancing the lead or catheter to a desired location. For straight segments of a vessel a straight stylet is used, whereas a stylet with a curved distal tip is used to navigate the lead or catheter through a curved portion of a vessel. U.S. Pat. No. 2,118,631 shows an early stylet formed of coils of flat wire welded to plugs at both ends that could be bent by the physician into either a straight or curved configuration at its distal end prior to insertion into the lumen of a catheter or the like. U.S. Pat. Nos. 4,498,482 and 4,796,642 show early examples of solid wire stylets. While such conventional stylets can be used effectively in the hands of a skilled surgeon, the process can be complicated and time consuming. Implantation of a lead with a conventional stylet often involves multiple insertions and withdrawals of the stylet, with the surgeon adjusting the bend on the distal end so as to be able to continue to advance the stylet and lead into a desired position. One type of lead placement that is particularly complicated is the placement of a J-shaped lead in the atrial chamber. In this procedure, a straight stylet is used to advance the lead into the atrial chamber of the heart. Once there, a J-shaped stylet is used to force the lead to bend back on itself in order to be secured in a desired location in the atrium.[0006]

To overcome the problem of having to repeatedly insert and withdraw a stylet in order change the shape of the distal end, attempts have been made to develop a steerable stylet. In a steerable stylet an operator uses a handle at the proximal end of the stylet to control the direction of deflection of the distal tip of the stylet while it is in place in the lumen of the lead or catheter as it is moved along the veins or arteries. Typically, a steerable stylet is arranged as a stylet wire having a lumen within which a core wire is positioned with the distal ends of the two wires being attached. The handle is used to create a differential tension between the core wire and the stylet wire so as to deflect the distal end of the stylet as a result. Examples of such steerable stylets with deflectable tips are shown in U.S. Pat. Nos. 4,209,019, 5,396,902, 5,439,006, 5,662,119, 5,674,271, 5,824,031, 5,873,842, 6,027,462, 6,059,739, and 6,203,506. Other examples of steerable stylets can be found in PCT Publ. No. WO 00/22981 and publications describing the Placer™ steerable stylet and the Locator™ steerable stylet.[0007]

In U.S. Pat. No. 5,752,915, a steerable stylet uses an operating slide to retract a stylet sleeve that is not attached to the stylet wire so as to selectively expose a pre-bent distal portion of a stylet wire to deflect the distal end of an electrode lead. The handle of this stylet includes a spring for the purpose of enclosing the proximal end of the stylet wire in a tight brace to prevent buckling of the stylet wire due to friction between the stylet wire and the stylet sleeve as the stylet sleeve is retracted. In U.S. Pat. No. 5,327,906, a stress relief sleeve is provided at the junction of the stylet wire and a nose cone for the handle that allows the stylet to be removably mounted in the handle. A stop pin is also used to limit the rearward travel of a slide for the purpose of controlling the degree of curvature of the distal end of the stylet by using the stop pin to change the length of the slide. In U.S. Pat. No. 6,132,390, a conical tip is also provided to minimize stress on the stylet. A flexible plastic or polymeric jacket is disposed over the stylet wire to prevent kinking or catastrophic inelastic failure of the distal tip under a radial load.[0008]

While the advantages of a steerable stylet are apparent, none of the existing designs for steerable stylets has achieved widespread acceptance. One of the principle challenges in designing an effective steerable stylet is creating a robust design that enables a large curvature of the distal end, preferably more than 120° so as to accommodate placement of J-shaped leads or alternatively creating sigmoidal or compound bends, while at the same time providing the flexure strength to permit repeated bending of the stylet without fracture or breaking. Unlike guidewires or catheters, these design considerations must be developed to operate under conditions where the stylet is within and constrained by the lumen of the lead or catheter that is being implanted. It would be desirable to provide a steerable stylet that could overcome these challenges and provide a robust design capable of large or compound curvatures that safely allows for repeated bending of the stylet without fracture or breaking.[0009]

SUMMARY OF THE INVENTION

The present invention provides a steerable stylet for use within a lumen of an intravascular device. The stylet includes a stylet assembly and a handle. The stylet assembly has a distal end portion and a proximal end portion and includes a tubular stylet wire having a lumen and a core wire positioned within the lumen with the distal end portion secured to the stylet wire proximate the distal end portion of the stylet wire. Unlike a conventional guidewire, the stylet wire has diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf as measured by the ASTM E855-90 3-point bend test. The core wire has a distal end portion and a proximal end portion and is positioned within the lumen of the stylet wire with the distal end portion secured to the stylet wire proximate the distal end portion of the stylet wire. The handle includes a hand-held housing structure connected to one of the proximal end portion of the stylet wire or the core wire. In one embodiment, an adjustable tensioner is connected to the other of the proximal end portion of the stylet wire or the core wire to adjust a relative tension force applied between the stylet wire and the core wire. A tension limiter is arranged to limit the tension force to a limit force that is less than a breaking stress force of the stylet wire when the stylet wire is positioned within the lumen of the intravascular device. In another embodiment, a plurality of notches are defined in one or more regions of the distal portion of the tubular stylet wire to aid in the safe and effective creation of large and/or compound curves. Preferably, the core wire is secured within the tubular stylet wire without heating either wire so as to prevent any annealing of the materials that would decrease the tensile strength of the distal end portion of the stylet.[0010]

By limiting the tension force that can be applied between the core wire and the stylet wire to a force that is less than the breaking stress force of the stylet wire, the present invention prevents the stylet wire from failing as a result of an excessive stress force. This prevents an operator from overexerting the stylet wire by attempting to deflect the stylet in a situation where the intravascular device cannot be deflected, such as for example within a blood vessel. Unlike a design that provides for a fixed dimensional travel of the adjustable tensioner, the present invention provides for a floating or variable amount of travel up to a maximum deflection force. As a result, the stylet may be repeatedly deflected numerous times without causing either a stress or fatigue failure of the stylet wire. In one embodiment, the steerable stylet of the present invention is designed for implantation of cardiac J-leads and can be deflected up to a maximum deflection of at least 180° from an original position of the stylet wire and the deflections can be repeated at least fifty times without inducing stress or fatigue failure in the stylet wire. In another embodiment, the steerable stylet of the present invention is designed for use in neurological applications and can be deflected up to a maximum of 90° and can also be configured to create compound curves.[0011]

In a preferred embodiment, a series of at least ten notches are defined along a distal region of the stylet wire to prevent the stresses induced in the distal region of the stylet wire from kinking or bending the stylet when the distal end portion of the stylet is deflected by an operator. Preferably, the series of notches in the distal region includes at least a portion of the notches that have a progressively decreasing depth distally to proximally along the series. More preferably, the portion of the notches having a progressively decreasing depth has a constant decrease in depth between adjacent notches. In this embodiment, the distal region is preferably defined beginning between 0.050 inches and 1.000 inches proximal to the distal end of the stylet wire. Preferably, there are at least twenty-five notches of between 0.005 inches and 0.015 inches longitudinal width with a spacing between adjacent notches of between 0.010 inches and 0.050 inches and a depth of at least ten of the most distal notches of said series being approximately equal to a radius of the stylet wire minus a wall thickness of the stylet wire. In an alternate embodiment, more than one series of notches are defined in the distal region of the stylet wire to create compound curves, including curves oriented in two different planes. Preferably, the spacing and dimensions of the notches are different between the different series so as to stage the sequence in which each region associated with a given series of notches will induce a curve in response to tension on the core wire.[0012]

In a preferred embodiment, the proximal end portion of the core wire is fixedly connected to the adjustable tensioner and the tension limiter has a first end portion fixedly connected to the housing structure of the handle and a second end portion operably connected to the adjustable tensioner. Preferably, the breaking stress force of the stylet wire is at least six pounds and the limit force of the tension limiter is less than four pounds. In one embodiment, the tension limiter is a constant force spring. In another embodiment, the tension limiter is an elastomer member with a maximum compressive retention force less than the breaking stress force of the stylet wire.[0013]

Preferably, the core wire is secured within the tubular stylet wire without heating either wire so as to prevent any annealing of the materials that would decrease the tensile strength of the distal end portion of the stylet. In one embodiment, the core wire is taper ground to provide a smaller diameter core shaft while leaving a bulbous distal end having a diameter substantially equal to an outer diameter of the tubular stylet wire. The core wire is slide into the lumen of the tubular stylet wire and the bulbous distal end of the core wire is secured in place using adhesives together with a chamfered fit. By avoiding the use of heat for welding or thermal expansive fits, the core wire and stylet wire are not annealed and the corresponding decrease in tensile strength of the wires (to about 60% of their original tensile strength) is not encountered.[0014]

In one embodiment, the handle includes a mechanism for providing tactile psuedo-feedback to an operator that is generally indicative of the relative tension force without directly engaging the tension limiter. In another embodiment, the beam strength of the stylet wire is preferably about 0.010 lbf so as to be sufficient to cause the stylet wire to return to at least an original position as the relative tension force is removed from the stylet wire and preferably to an angle beyond its original position.[0015]

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating the steerable stylet and manipulative handle assembly of the present invention.[0016]

FIG. 2 is a perspective view of the first embodiment of the manipulative handle of the present invention in which the manipulation is controlled by sliding a thumb plate along the top of the handle.[0017]

FIG. 3 is a top view of the embodiment shown in FIG. 2.[0018]

FIG. 4 is a side view of the embodiment shown in FIG. 2.[0019]

FIG. 5 is a longitudinal cross-section of the embodiment shown in FIG. 2.[0020]

FIG. 6 is a side view of an additional embodiment of the manipulative handle of the present invention in which the manipulation is affected through turning a portion of the handle.[0021]

FIG. 7 is a top view of the embodiment shown in FIG. 6.[0022]

FIG. 8 is a perspective view of an additional embodiment of the manipulative handle of the present invention in which the manipulation is controlled by pulling or pushing the thumb hold of a three-finger handle.[0023]

FIG. 9 is a top view of the embodiment shown in FIG. 8.[0024]

FIG. 10 is a side view of the embodiment shown in FIG. 8.[0025]

FIG. 11 is a perspective view of an embodiment the distal portion of the stylet wire of the present invention illustrating an arrangement of notches in the stylet wire.[0026]

FIG. 12 is a detail of the notches in the distal portion of the stylet wire.[0027]

FIG. 13 is an illustration of the curvature imparted upon the stylet wire by manipulation of the handle in accordance with the teachings of the present invention.[0028]

FIG. 14 provides cross-sections of a vein containing a steerable stylet within a medical lead.[0029]

FIG. 15 is a cross-sectional view of the right atrium of a patient's heart containing a steerable stylet within a medical lead.[0030]

FIGS. 16 and 17 are isometric views of alternate embodiments of the tension limiting member.[0031]

FIGS. 18 and 19 are exploded views of alternate embodiments of the front portion of the handle.[0032]

FIG. 20 is a cross-section view of an alternate embodiment of the handle having an adjustable front portion.[0033]

FIG. 21 is a cross-section view of an embodiment of the handle incorporating a tactile psuedo-feedback mechanism.[0034]

FIGS. 22 and 23 are detailed cross-sectional views of an alternate embodiment of the stylet assembly for creating compound and sigmoidal curves.[0035]

FIGS. 24 and 25 are side and end views of the notches in a distal portion of the stylet assembly.[0036]

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The present invention is directed to a[0037]

steerable stylet

20 for use in various intravascular medical procedures, such as cardiac catheter procedures and neurological procedures. Although the present invention will be described with respect to embodiments designed specifically for cardiac and neurological procedures, it will be understood that asteerable stylet20 in accordance with the present invention may be used to advance and steer any kind ofintravascular device50 through the vascular system of a patient to a desired treatment location.

Referring to FIG. 1, a[0038]

steerable stylet

20 in accordance with the present invention broadly comprises astylet assembly22 that includes astylet wire24, acore wire26, and amanipulative handle28. For purposes of describing the present invention, thestylet assembly22 includes adistal end portion30 that can be selectively deflected by an operator through operation of themanipulative handle28 operably connected to aproximal end portion32 of thestylet assembly22. It will be understood that the terms distal end portion and proximal end portion are used in the present invention to mean the longitudinal end as well as a portion proximate the longitudinal end and extending longitudinally back from the longitudinal end.

The[0039]

stylet assembly

22 is preferably a multiple component arrangement that includes at least thestylet wire24 having at least onelumen34 defined therein with thecore wire26, sometimes referred to as a pull wire, positioned in thelumen34. Thedistal end portion36 of the stylet wire is fixedly attached to thedistal end portion40 of the core wire.Stylet wire24 is preferably 300 series stainless steel tubing that may be either high tensile or low tensile.Core wire26 is preferably 300 series stainless steel solid core wire that is preferably high tensile. Alternatively,stylet wire24 andcore wire26 can be made of other metal alloys, such as nickel-titanium, or have a portion of each wire created from different material combinations (e.g.,distal end portion36 made from nickel-titanium andproximal end portion32 made from stainless steel). Alternatively,core wire26 could be made of other metal alloys or of a filament material sufficient strong enough to transmit the relative tension force (as will be described) without breaking. It should be noted that if thestylet wire24 is welded to thecore wire26 at the

distal end portions

36,40, one or both of the wires may be annealed in the welding process.

[0040]

Stylet wire

24 has an outer diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf and preferably about 0.010 lbf as measured by the ASTM E855-90 3-point bend test, the specification of which is hereby incorporated by reference. In contrast, conventional floppy tip guidewires of the same relative size have beam strengths of less than 0.0025 lbf as measured by the ASTM E855-90 3-point bend test and more typically have beam strengths of only about 0.001 lbf. In one embodiment,stylet wire24 has an inner diameter of 0.008 inches andcore wire26 has an outer diameter of 0.007 inches providing approximately 0.0005 inches clearance within thelumen34. The outer diameter of less than 0.016 inches and beam strength of at least 0.005 lbf effectively permitstylet assembly22 to be used as a stylet for insertion into a lumen52 of anintravascular device50, as shown for example in FIGS. 14 and 15. Preferably,stylet wire24 has asingle lumen34 to permit the outer diameter to be as small as possible while still providing sufficient strength so as to meet the beam strength requirements. Alternatively,stylet wire24 could have multiple lumens although for current wire technology the number and size of the lumens will certainly impact on the beam strength and outer diameter limitations required by the present invention. In another embodiment, thelumen34 in whichcore wire26 is located could be defined partially or completely external to asolid stylet wire24 by use of collars or rings attached to the exterior of the solid wire, for example, or by providing slots or openings in thelumen34 of a tubular wire to allowcore wire26 to extend beyond the outer diameter ofstylet wire24 when a relative tension force is applied betweenstylet wire24 andcore wire26.

The[0041]

distal end portions

36 and40 of thestylet wire24 and thecore wire26 are preferably fixedly secured to one another without heating either wire so as to prevent any annealing of the materials that would decrease the tensile strength of the distal end portion of the stylet, such as by making a mechanical and/or adhesive connection or by crimping. Alternatively, the

distal end portions

36 and40 may be operably attached to one another by welding or soldering, or any combination of these techniques as long as the bond between thestylet wire24 and thecore wire26 is at least as strong, and preferably stronger, than the materials of the wires themselves. In one embodiment, the longitudinal ends or tips of

distal end portions

36 and40 are secured together. Alternatively, the longitudinal tip ofdistal end portion40 could be secured in thedistal end portion36 at a location other than the longitudinal end or tip that is proximate to the longitudinal tip.

In one embodiment as shown in FIG. 12,[0042]

stylet assembly

22 also includes apolymeric sheath44 surrounding at least thedistal end portion30 ofstylet assembly22. The polymeric sheath,44 is preferably a polyimide material. Alternatively, a Teflon® or Kapton® tubing material may be used. Thepolymeric sheath44 is particularly suited for an embodiment of thesteerable stylet20 intended for cardiac-related uses where the vessels are somewhat larger and theintravascular devices50 tend to have larger inner diameters. Thepolymeric sheath44 serves to protect thestylet assembly22 from body fluids and also can reduce sliding friction between thedistal end portion30 ofstylet assembly22 and the lumen52 ofintravascular device50. In a preferred embodiment for cardiac-related uses, thestylet assembly22, including thepolymeric sheath44, has an outer diameter of 0.015 inches. In an alternative embodiment intended for neurological uses where smaller vessels are typically involved and theintravascular devices50 tend to have lumens smaller inner diameters, thepolymeric sheath44 is not included and thestylet assembly22 has an outer diameter of 0.013 inches. It will be understood thatpolymeric sheath44 preferably extends at least over a distal region46 in which a number of notches48 are defined as will be described in connection with the description of FIG. 12. Alternatively,polymeric sheath44 can extend over substantially the entire length ofstylet wire24.

It will be realized that a variety of treatments for constructing the[0043]

distal end portion

30 ofstylet assembly22 can be utilized, depending upon the particular configuration and desired operation of thestylet assembly22 within the intravascular device. For example, a ball, tube, or coiled spring could be added to thedistal end portion30 of thestylet assembly22. Alternatively,distal end portion30 could include a structure designed to engage a distal portion54 of theintravascular device50, such as a flat driver structure or the like for extending and retracting a helical anchor coil located on the distal end portion54 of theintravascular device50.

FIG. 2 shows one embodiment of the[0044]

manipulative handle

28. FIG. 5 presents a cross-section of themanipulative handle28. Themanipulative handle28 comprises a housing60, atension limiting assembly62, and anadjustable tensioner mechanism64. In the embodiment shown in FIGS. 2 and 5, theadjustable tensioner mechanism64 is a sliding mechanism and thetension limiting assembly62 is a spring. Theproximal end portion42 of thecore wire26 is fixedly connected to the housing structure60. Theproximal end portion38 of thestylet wire24 is fixedly connected to the slidingmechanism64. Thetension limiting spring62 has afirst end portion66 fixedly connected to the housing structure60 and asecond end portion68 that is operably connected to the slidingmechanism64. When the stylet handle28 is activated by moving the slidingmechanism64 in a distal direction, thestylet wire24 moves distally, but thecore wire26 is restricted from moving, thus creating a relative tension force separating thecore wire26 from thestylet wire24. In the event that that activatedhandle28 is operated to exert a relative tension force of more than about four lbs. of force, the safety feature of thetension limiting spring62 starts to open and restricts any further load build-up of force on theproximal end portion30 of thestylet assembly22, other than the constant force of thetension limiting spring62 being extended.

It will be appreciated that numerous combinations of operable connections among the[0045]

proximal end portion

38 and42 with the housing60, adjustingmechanism64 andtension limiting member64 can be arranged to provide for a relative tension force that separates thecore wire26 from thestylet wire24. For example, thecore wire26 could be coupled to the slidingmechanism64 instead of thestylet wire24, with thestylet wire24 secured to the housing60. Alternatively, one or the other of thestylet wire24 orcore wire26 could be secured to the tension limiting member with the other operably coupled to theadjusting mechanism64. It will also be seen that theadjusting mechanism64 can be made to operate in any number of arrangements, with the relative tension force created by a distal movement of theadjusting mechanism64 or, alternatively, by a proximal movement of theadjusting mechanism64. Thetension limiting spring62 can be arranged to operate in either compression or tension modes, depending upon the configuration of the other connections of the

proximal end portions

38 and42 of thestylet wire24 andcore wire26 and the arrangements of theadjusting mechanism64.Multiple adjusting mechanisms64 can be arranged so as to provide, for example, for a course adjustment with a first mechanism and a fine adjustment with a second mechanism. FIGS. 16 and 17 show two different embodiments oftension limiting member62. A first embodiment as shown in FIG. 16 in whichtension limiting member62 is a coil spring that is attached at each end to an

engagement structure

92,94 for engaging thetension limiting member62 within place in the handle60. FIG. 17 shows a second embodiment in whichtension limiting member62 is a tubular elastomeric material surrounding acompressible piston arrangement96. It will be apparent that numerous other arrangements and configurations of the tension limiting member and the engagement structures could be used to accomplish the purpose of limiting the force applied to thestylet wire24.

FIG. 18 presents one embodiment of a[0046]

lead locking mechanism

124 that allows themanipulative handle28 to be placed at multiple locations along the length of the proximal end of thelead128. Thelead locking mechanism124 utilizes alead clip126 that secures the proximal end of thelead128 to the housing60 by grippinggrooves130 in the proximal end of thelead128. The proximal end of thelead128 feeds through a spacer132 at the distal end of themanipulative handle28 that keeps the proximal end of thelead128 centered within themanipulative handle28.

FIG. 19 presents another embodiment of the lead[0047]

lock locking mechanism

124 where the proximal end of thelead128 is threaded through agland134 that is in turn secured within aslot136 at the proximal end of themanipulative handle28. Twisting therear portion72 of themanipulative handle28 provides compressive force to thegland134, which secures the proximal end of thelead128 within themanipulative handle28.

FIG. 20 shows an embodiment of the[0048]

manipulative handle

28 that accommodates variations instylet wire24 andcore wire26 lengths. In this embodiment, thelead clip126 is at thedistal end38 of themanipulative handle28 and secures the proximal end of thelead128 within themanipulative handle28. Thedistal end38 of themanipulative handle28 may be moved toward or away from the housing60 to accommodate different lengths ofstylet wire24 orcore wire26.

With reference to FIG. 21, one embodiment of the[0049]

handle assembly

28 is provided with a tactile psuedo-feedback mechanism97. Although a feedback mechanism could be provided which directly engaged the tension limiting member of the preferred embodiment, this would tend to complicate the design and introduce additional forces that would need to be accounted for in the design of the tension limiting member arrangement. Instead, this embodiment utilizes acompression spring98 together with anengaging end99 of slidingmechanism64 positioned in thefront portion74 ofhandle assembly70. As the slidingmechanism64 is operated to increase actual relative tension between thestylet wire24 and thecore wire26, theengaging end99 of the slidingmechanism64 compresses thecompression spring98, thereby creating an increasing load on the slidingmechanism64 that can be sensed by an operator during operation of the device as an increasing resistance to the ability to move slidingmechanism64 forward. Preferably, thecompression spring98 is selected to provide a tactile feedback of increasing force that is similar in character to the actual force curve characteristics that occur for theparticular stylet assembly22. Preferably, thefeedback spring98 operates in a range that provides a feedback force of 0-2 lb. It will be understood that the force offeedback spring98 can be scaled to operate in varying ranges based on the mechanical properties of thestylet20 and the desired feedback for the operator. As with the actualtension limiting member64, it will be recognized that numerous combinations and arrangements can be utilized to accomplish the desired effect of psuedo-feedback mechanism97.

In an embodiment directed to cardiac applications, increasing the relative tension force between the[0050]

stylet wire

24 and thecore wire26 causes thedistal portion30 of thestylet assembly22 to bend until it ultimately forms a J-shape as illustrated in FIG. 13. The amount of curvature of thestylet wire24 can be increased and decreased as necessary to traverse a body lumen or position theintravascular device50 in a desired location. The curve of the J-shape that thedistal portion40 ofstylet assembly22 can assume when the slidingmechanism64 is activated is preferably at least 180° and up to a 190° bend in a radius of less than 0.8″ in response to a relative tension of about 3.5 lbs. FIG. 15 illustrates how thesteerable stylet20 of the present invention can be bent to allow for precise placement of a medical device such as acardiac lead50 in a patient's right atrium. FIG. 14 illustrates thestylet assembly22 of the present invention within amedical lead50 inside of a patient'svascular system56.

Modeling of the stress levels at the distal end of the stylet wire have indicated that high stress levels are reached early on when bending of the distal region first occurs, remain relatively constant through the bending function, and then rise again when the maximum design radius is achieved. The actual stress is a combination of load stress when the core wire applies force to the stylet wire and beam stress while the stylet assembly is passing through the bend radius.[0051]

To insure that the[0052]

stylet

20 andintravascular device50 effectively return to an original or home position, thesteerable stylet20 of a preferred embodiment arcs up to 15° in an opposite direction from the J-shape when the relative tension force is removed between thestylet wire24 and thecore wire26. Preferably, this counter-arcing is created due to the beam strength of thestylet wire24. The counter-arcing overshoots the neutral home position after which the home position is obtained as the stylet wire relaxes. As a result, thesteerable stylet20 is more likely to ultimately return to a neutral home position after being repeatedly flexed.

FIGS. 6 and 7 present a perspective and side view, respectively, of another embodiment of the[0053]

manipulative handle

28 of the present invention in which relative tension force is applied to thestylet assembly22 by twisting arear portion72 of thehandle housing70 in relation to thefront portion74 of thehandle70. Alternatively, a rotatable collar or similar arrangement could be mounted on thehandle70 to accomplish the same function. The rotational force is translated by a screw or other mechanism into a longitudinal force to create the relative tension force that will separate thecore wire26 from thestylet wire24.

FIGS. 8, 9, and[0054]10 show a perspective, top, and side view, respectively, of yet another embodiment of themanipulative handle28 of the present invention. The relative tension force is applied to thecore wire26 by pulling or pushing a pair of finger holds82 and84 in relation to themanipulative handle housing80. The finger holds82 and84 are positioned on opposite sides of amiddle portion86 of thehousing80 which preferably includes an additional thumb hold88 that is not moveable so as to allow for single handed operation of thesteerable stylet20.

Turning to FIGS. 11 and 12, they illustrate the[0055]

notches

38 in thedistal region36 of thestylet wire24. Thenotches38 alter the strength of the wall of thestylet wire24 in thedistal region36 that allows thestylet wire24 to more easily bend when the relative tension force is applied between thestylet wire24 and thecore wire26. Preferably, notches orslots38 are created by an electrical discharge machine (EDM) process. Alternatively, thenotches38 may be created by cutting, laser, or water processes to remove the desired material of the stylet wire from thenotches38. The shape of thenotches38 is preferably a rounded bottom channel, although other shapes such as a V-shape or a rectangular shape are also contemplated. In another embodiment, the effect ofnotches38 could be achieved by selectively removing portions of material from the wall ofstylet wire24 at the location similar to the locations ofnotches38 and replacing the removed material with a softer material. In still another embodiment, additional material could be added to the wall ofstylet wire24 at locations generally radially opposite of the region where a curve is desired to create a radially differential strength in the wall structure ofstylet wire24 that would encourage bending of thestylet wire24 at that region.

Spacing of the[0056]

notches

38 will aid in determining the diameter of the J-shape that can be created by thedistal region36 of thestylet wire24.Notches38 that are spaced farther apart will create a larger diameter J-shape.Notches38 that are spaced closer together will create a smaller diameter J-shape. The width of eachnotch38 is critical to be able to position the slots closely without over-scoring the back of thetubular stylet wire24.

In a preferred embodiment, the[0057]

stylet wire

24 includes a series of at least tennotches38 defined along thedistal region36 of thestylet wire24. In one embodiment, at least a portion of thenotches38 have a progressively decreasing depth distally to proximally along the series as shown best in FIG. 12. Preferably, the portion of thenotches38 that have a progressively decreasing depth is between 5% and 50% of said series and will depend upon the desired application for thesteerable stylet20 and the particular J-shape configuration to be obtained by operation of thesteerable stylet20. Preferably, at least three of the most proximal notches of the series have a progressively decreasing depth with a constant decrease in depth between adjacent notches. In one embodiment, the portion of thenotches38 having a progressively decreasing depth has a constant decrease in depth between adjacent notches. In a preferred embodiment, this constant decrease is 20% between adjacent notches. In an alternative embodiment, the progressively decreasing depths are not constant and may be selected along with alternate spacings between thenotches38 to achieve alternate shapes of the distal end other than a simple J-shape.

Preferably, the[0058]

distal region

36 is defined beginning between 0.050 inches and 1.000 inches proximal to the distal end of thestylet wire24 and includes at least twentynotches38 of between 0.005 inches and 0.015 inches longitudinal width. A spacing between adjacent notches is between 0.010 inches and 0.050 inches. A depth of at least ten of the mostdistal notches38 of the series is preferably approximately equal to a radius of thestylet wire24 minus a wall thickness of the stylet wire. It has been found that this depth provides for maximum bending stiffness in this application.

In another embodiment as shown in FIGS. 22 and 23, a stylet assembly particularly adapted for neurological uses is presented. In another embodiment, a longitudinal tip of[0059]

distal end portion

40 ofcore wire26 includes abulbous tip portion110 having an outer diameter similar to the outer diameter ofstylet wire24 that extends beyonddistal end portion36 ofstylet wire24. In this embodiment, chamfers112 are created at the opening of thedistal end portion36 ofstylet wire24 to seat thetip portion110 of thecore wire26 in the opening and preferably an adhesive, such as an ultraviolet cured adhesive or an acrylate adhesive or the like, is used to secure the two wires together. In a preferred embodiment, the stylet wire is a tubular wire having an outer diameter of 0.013 inches and an inner diameter of 0.008 inches. Thecore wire26 is created by starting with a solid core wire of 0.013 inches and center grinding the wire to an outer diameter of 0.007 inches except for thetip portion110, which remains at an outer diameter of 0.013 inches and is preferably rounded on the exterior. In this embodiment, a polymer sheath is not utilized to keep the outer diameter as small as possible. It will be understood that the selection on inner and outer diameters of thestylet wire24 are critical in being able to maintain the desired beam strength and that these selections will depend upon numerous factors, including the materials used for both the stylet wire and the core wire, and the nature and character of anynotches38 to be defined in the stylet wire. This embodiment includes 28total notches38 spaced at 0.030″ with the first notch located 0.035″ from thedistal end portion36 of thestylet wire24. Preferably, thestylet assembly22 of this embodiment is capable of deflecting at least 45 degrees and preferably up to 90 degrees in response to a relative tension force of about 8 lbs when deflected in a urethane lead.

In this embodiment, the[0060]

stylet wire

24 can include two or more series ofnotches38 that are created in thedistal region36 as shown, for example at120 and122. The spacing and dimension of thenotches38 infirst series120 located more distally and thesecond series122 located more proximally are chosen in this example to cause thestylet assembly22 to first bend proximate thefirst series120 in response to relative tension between thecore wire26 and thestylet wire24 and then make a second bend proximate thesecond series120 in response to a further increase in the relative tension. In this way, sigmoidal and compound curves can be created. Additionally, by altering the radial orientation of thenotches38 as shown in FIG. 22, it is possible to create sigmoidal and compound curves in different planes. These features are very desirable for many neurological applications where the vascularture is more tortuous than in cardiac applications.

Referring to FIGS. 24 and 25, the calculations for creating the[0061]

notches

38 of a preferred embodiment will be described. Fornotches38 of maximum depth, the cuts should be made to a depth that is equal to the thickness of the wall ofstylet wire24 and preferably the wall thickness ranges between 0.003 and 0.006 inches and the corresponding inner diameter ranges between 0.004 and 0.010 inches.

Referring to FIGS. 24 and 25, the calculations for determining the depth and distribution of[0062]

notches

38 of a preferred embodiment will be described. For maximum curvature of thestylet wire24, the cuts should be made to a depth equal to the thickness of the wall of the stylet wire and preferably the wall thickness ranges between 0.003 and 0.006 inches and the corresponding inner diameter ranges between 0.004 and 0.010 inches. The number ofnotches38 determines the maximum angle of deflection of thestylet wire24. The width of thenotches38 determines the maximum amount of bending of thestylet wire24.

A critical property of solid bodies and areas is the moment of inertia. Moments of inertia are used in calculating the strength of beams, such as the[0063]

stylet wire

24 of the present invention. Formulas are derived by multiplying basic particles of mass or area by the squares of their respective distances from the reference axis. Therefore, moments of inertia are dependent upon the location of their axis. Moments of inertia of plane area, where I is in the plane of the area are derived from equations for calculating deflective stresses in beams. These formulas have been employed to design the stylet to deflect to the desired positions while maintaining, but not exceeding the maximum allowable stresses under this desired deflection.

The following equations are used to determine the moments of inertia that, in turn, are used to determine the beam strength of the stylet wire[0064]24: $\begin{matrix} A = \frac{{Ro}^{2}}{2} (2 α - \sin 2 α) & (eq . 1) \\ I_{x} = \frac{{ARo}^{2}}{4} [I + \frac{2 \sin^{3} α \cos α}{α - \sin α \cos α}] & (eq . 2) \\ I_{y} = \frac{{ARo}^{2}}{4} [I - \frac{2}{3} (\frac{\sin^{3} α \cos α}{α \sin α \cos α})] & (eq . 3) \end{matrix}$
Where I[0065]_xand I_yrepresent the moments of inertia in the x and y plnaes; A represents the cross sectional area of thestylet wire24 at the cut; Ro represents the outside diameter of the stylet wire; r represents the inside diameter of the stylet wire; α represents the angle formed between the two radii extending from the center of the stylet wire to the edge of the cut.
As many different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the following claims.[0066]

Claims

What is claimed:

1. A steerable stylet for use within a lumen of an intravascular device comprising:

a stylet assembly having a distal end portion and a proximal end portion, said stylet assembly including:

a stylet wire having a lumen defined therein, said stylet wire having an outer diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf as measured by the ASTM E855-90 3-point bend test; and

a core wire positioned within said lumen of said stylet wire and having a distal end portion of said core wire operably secured to said stylet wire proximate a distal end portion of said stylet wire; and

a handle proximate said proximal end portion of said stylet assembly, said handle including:

a hand-held housing structure operably connected to one of a proximal end portion of said stylet wire and a proximal end portion of said core wire;

an adjustable tensioner mechanism operably connected to the other of said proximal end portion of said stylet wire and said proximal end portion of said core wire to adjust a relative tension force applied between said stylet wire and said core wire; and

a tension limiter operably arranged to limit said tension force applied between said core wire and said stylet wire to a limit force that is less than a breaking stress force of said stylet wire when said stylet assembly is positioned within said lumen of said intravascular device.

2. The steerable stylet ofclaim 1 wherein said breaking stress force of said stylet wire is at least six pounds and said limit force of said tension limiter is less than four pounds.

3. The steerable stylet ofclaim 1 wherein said adjustable tensioner mechanism operably engages with a separate compressible member to increase a force opposing movement of said adjustable tensioner mechanism so as to provide tactile feedback to an operator that is generally indicative of said relative tension force.

4. The steerable stylet ofclaim 1 wherein said beam strength of said stylet wire is sufficient to cause said stylet wire to return to at least an original position of said stylet wire as said relative tension force is removed from said stylet wire.

5. The steerable stylet ofclaim 1 wherein said stylet wire includes a series of at least ten notches defined along a distal region of said stylet wire.

6. The steerable stylet ofclaim 5 wherein said series of a least ten notches includes at least a portion of said notches having a progressively decreasing depth distally to proximally along said series.

7. The steerable stylet ofclaim 6 wherein said portion of said notches having said progressively decreasing depth comprises between five percent and fifty percent of said series.

8. The steerable stylet ofclaim 6 wherein each of said notches in said portion of said notches having said progressively decreasing depth has a constant decrease in depth between adjacent notches.

9. The steerable stylet ofclaim 5 wherein said distal region is defined beginning between 0.050 inches and 1.000 inches proximal to said distal end of said stylet wire and includes at least twenty notches of between 0.005 inches and 0.015 inches longitudinal width with a spacing between adjacent notches of between 0.010 inches and 0.050 inches and a depth of at least ten of the most distal notches of said series being approximately equal to a radius of said stylet wire minus a wall thickness of said stylet wire.

10. The steerable stylet ofclaim 5 wherein at least three of the most proximal notches of said series have a progressively decreasing depth with a constant decrease in depth between adjacent notches.

11. The steerable stylet ofclaim 1 wherein said stylet wire includes a plurality of separate sets of notches defined along a distal region of said stylet wire.

12. The steerable stylet ofclaim 11 wherein each set of notches is spaced apart from one another by at least 0.1 inches and each set of notches includes at least a plurality of notches having a longitudinal width of between 0.005 inches and 0.015 inches with a spacing between adjacent notches of between 0.010 inches and 0.050 inches.

13. The steerable stylet ofclaim 11 wherein at least one of said sets of notches includes at least a portion of said notches having a progressively decreasing depth distally to proximally along said series.

14. The steerable stylet ofclaim 11 wherein at least two of said sets of notches have different radial orientations of said notches such that the stylet assembly creates curves in two separate planes in response to said relative tension force.

15. The steerable stylet ofclaim 11 wherein at least two of said sets of notches have different spacings and widths of said notches such that the stylet assembly creates curves at two different times in response to said relative tension force.

16. The steerable stylet ofclaim 1 wherein said proximal end portion of said core wire is fixedly connected to said housing structure, said proximal end portion of said stylet wire is fixedly connected to said adjustable tensioner mechanism and said tension limiter has a first end portion fixedly connected to said housing structure and a second end portion operably connected to said adjustable tensioner mechanism.

17. The steerable stylet ofclaim 16 wherein said tension limiter is comprised of a constant force spring with a maximum tensile retention force less than the breaking stress force of said stylet wire.

18. The steerable stylet ofclaim 1 wherein said tension limiter is comprised of a spring with a maximum compressive retention force less than the breaking stress force of said stylet wire.

19. The steerable stylet ofclaim 1 wherein said tension limiter is comprised of an elastomer with a maximum compressive retention force less than the breaking stress force of said stylet wire.

20. The steerable stylet ofclaim 1 wherein said distal end portion of said core wire is operably secured to said distal end portion of said stylet wire without annealing either of said distal end portions.

21. A steerable stylet for use within a lumen of an intravascular device comprising:

a stylet wire having a distal end portion, a proximal end portion and a lumen defined in said stylet wire, said stylet wire having an outer diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf as measured by the ASTM E855-90 3-point bend test;

a core wire having a distal end portion and a proximal end portion, said core wire positioned within said lumen of said stylet wire and having said distal end portion of said core wire operably secured to said stylet wire proximate said distal end portion of said stylet wire; and

a handle proximate said proximal end portion of said stylet wire, said handle including a hand-held housing structure having:

means for adjusting a relative tension force applied between said stylet wire and said core wire; and

means for limiting said relative tension force to a limit force that is less than a breaking stress force of said stylet wire when said stylet wire is positioned within said lumen of said intravascular device.

22. The steerable stylet ofclaim 21 wherein said breaking stress force of said stylet wire is at least six pounds and said limit force of said tension limiter is less than four pounds.

23. The steerable stylet ofclaim 21 wherein said handle further includes means for providing tactile psuedo-feedback to an operator that is generally indicative of said relative tension force.

24. The steerable stylet ofclaim 21 wherein said beam strength of said stylet wire is sufficient to cause said stylet wire to return to at least an original position of said stylet wire as said relative tension force is removed from said stylet wire.

25. The steerable stylet ofclaim 21 wherein said stylet wire includes at least one means for altering a wall strength of said stylet wire along a distal region of said stylet wire.

26. The steerable stylet ofclaim 25 wherein said means for altering the wall strength creates a radially differential wall strength between generally opposing walls of said stylet wire.

27. The steerable stylet ofclaim 25 wherein said means for altering the wall strength is selected from the set consisting of: means for removing material at a series of locations along said stylet wire, means for adding material at a series of locations along said stylet wire, or any combination thereof.

28. The steerable stylet ofclaim 25 wherein said means for altering the wall strength comprises a series of means for altering a material characteristic of a wall of said stylet wire located along a portion of said stylet wire.

29. The steerable stylet ofclaim 28 wherein each of said means for altering a material characteristic of said wall in said portion have differing characteristics between adjacent means.

30. The steerable stylet ofclaim 28 comprising a plurality of said means for altering the wall strength, each said means for altering the wall strength being spaced apart from one another by at least 0.1 inches.

31. The steerable stylet ofclaim 30 wherein at least two of said means for altering the wall strength have different radial orientations of said series of means for altering the material characteristic such that the stylet assembly creates curves in two separate planes in response to said relative tension force.

32. The steerable stylet ofclaim 30 wherein at least two of said series of means for altering the material characteristic have different spacings and widths such that the stylet assembly creates curves at two different times in response to said relative tension force.

33. The steerable stylet ofclaim 21 wherein said distal end portion of said core wire is operably secured to said distal end portion of said stylet wire by means for adhering without annealing either of said distal end portions.

34. A method of steering a stylet within a lumen of an intravascular device comprising:

providing a steerable stylet including:

a stylet assembly having a distal end portion and a proximal end portion, said stylet assembly including a stylet wire having a lumen defined therein, said stylet wire having an outer diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf as measured by the ASTM E855-90 3-point bend test, and a core wire positioned within said lumen of said stylet wire and having a distal end portion of said core wire operably secured to said stylet wire proximate a distal end portion of said stylet wire; and

a handle operably connected to said stylet wire proximate said proximal end portion of said stylet assembly, said handle including a hand-held housing structure, a tension adjuster and a tension limiter;

inserting at least a portion of said stylet assembly into said lumen of said intravascular device; and

selectively deflecting a distal end portion of said intravascular device by using said tension adjuster to adjust a relative tension force applied between said stylet wire and said core wire in such a manner that said tension limiter limits said relative tension force to a limit force that is less than a breaking stress force of said stylet wire.

35. The method ofclaim 34 wherein the step of selectively deflecting deflects said distal end portion of said intravascular device to a maximum deflection of at least 180 degrees from an original position of said distal end portion of said intravascular device at a bend radius of less than an inch.

36. The method ofclaim 34 wherein the step of selectively deflecting deflects said distal end portion of said intravascular device to a maximum deflection of at least 45 degrees from an original position of said distal end portion of said intravascular device at a bend radius of less than an inch.

37. The method ofclaim 34 further comprising:

returning said distal end portion of said intravascular device to at least an original position of said distal end portion of said intravascular device by releasing said relative tension force applied between said stylet wire and said core wire and using said beam strength of said stylet wire to cause said stylet wire to return to a position beyond an original position of said stylet wire.

38. The method ofclaim 34 wherein said step of selectively deflecting is repeated at least fifty times without inducing stress or fatigue failure in said stylet wire.

39. The method ofclaim 34 wherein said stylet assembly includes a plurality of regions along said distal end portion having differing wall strengths such that the step of selectively deflecting creates a compound curve of said distal end portion.

40. The method ofclaim 39 wherein at least two of said plurality of regions are radially offset with respect to each other and the step of selectively deflecting creates curves in at least two different planes.

41. The method ofclaim 39 where at least two of said plurality of regions having differing characteristics and the step of selectively deflecting creates curves at two different times.

42. A steerable stylet for use within a lumen of an intravascular device comprising:

a stylet wire having a lumen defined therein, said stylet wire having an outer diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf as measured by the ASTM E855-90 3-point bend test, said stylet wire includes a series of at least ten notches defined along at least one distal region of said stylet wire; and

a handle proximate said proximal end portion of said stylet assembly, said handle including a hand-held housing structure having means for adjusting a relative tension force applied between said stylet wire and said core wire.

43. The steerable stylet ofclaim 42 wherein said series of a least ten notches includes at least a portion of said notches having a progressively decreasing depth distally to proximally along said series.

44. The steerable stylet ofclaim 43 wherein said portion of said notches having said progressively decreasing depth comprises between five percent and fifty percent of said series.

45. The steerable stylet ofclaim 43 wherein each of said notches in said portion of said notches having said progressively decreasing depth has a constant decrease in depth between adjacent notches.

46. The steerable stylet ofclaim 42 wherein said distal region is defined beginning between 0.050 inches and 1.000 inches proximal to said distal end of said stylet wire and includes at least twenty-five notches of between 0.005 inches and 0.015 inches longitudinal width with a spacing between adjacent notches of between 0.010 inches and 0.050 inches and a depth of at least ten of the most distal notches of said series being approximately equal to a radius of said stylet wire minus a wall thickness of said stylet wire.

47. The steerable stylet ofclaim 42 wherein at least three of the most proximal notches of said series have a progressively decreasing depth with a constant decrease in depth between adjacent notches.

48. The steerable stylet ofclaim 42 wherein said stylet wire includes a plurality of separate sets of notches defined along a distal region of said stylet wire.

49. The steerable stylet ofclaim 48 wherein each set of notches is spaced apart from one another by at least 0.1 inches and each set of notches includes at least a plurality of notches having a longitudinal width of between 0.005 inches and 0.015 inches with a spacing between adjacent notches of between 0.010 inches and 0.050 inches.

50. The steerable stylet ofclaim 48 wherein at least one of said sets of notches includes at least a portion of said notches having a progressively decreasing depth distally to proximally along said series.

51. The steerable stylet ofclaim 48 wherein at least two of said sets of notches have different radial orientations of said notches such that the stylet assembly creates curves in two separate planes in response to said relative tension force.

52. The steerable stylet ofclaim 48 wherein at least two of said sets of notches have different spacings and widths of said notches such that the stylet assembly creates curves at two different times in response to said relative tension force.

53. The steerable stylet ofclaim 42 wherein said distal end portion of said core wire is operably secured to said distal end portion of said stylet wire without annealing either of said distal end portions.

54. A steerable stylet for use within a lumen of an intravascular device comprising:

a stylet wire having a lumen defined therein, said stylet wire having an outer diameter of less than 0.016 inches and a beam strength of at least 0.005 lbf as measured by the ASTM E855-90 3-point bend test, said stylet wire includes a series of means for altering a material characteristic of a wall of said stylet wire located along a portion of said stylet wire; and

55. The steerable stylet ofclaim 54 wherein each of said means for altering a material characteristic of said wall in said portion have differing characteristics between adjacent means.

56. The steerable stylet ofclaim 54 comprising a plurality of said series of means, each of said series of means being spaced apart from one another by at least 0.1 inches.

57. The steerable stylet ofclaim 56 wherein at least two of said series of means have different radial orientations such that the stylet assembly creates curves in two separate planes in response to said relative tension force.

58. The steerable stylet ofclaim 56 wherein at least two of said series of means have different characteristics such that the stylet assembly creates curves at two different times in response to said relative tension force.

59. The steerable stylet ofclaim 54 wherein said distal end portion of said core wire is operably secured to said distal end portion of said stylet wire by means for adhering without annealing either of said distal end portions.