US20070170623A1 - Catheter Having Selectively Varied Lamination - Google Patents

Abstract

A tubular medical catheter having at least one region of selectively varied lamination is provided herein.

Description

FIELD OF THE INVENTION
• The present invention relates to catheters comprising sections of selectively varied lamination. More specifically, the invention relates to catheters having increased flexibility towards the distal end due to at least one section of selectively varied lamination between the inner liner and outer shell, and methods for making the same.
BACKGROUND OF THE INVENTION
• A number of intravascular procedures are currently utilized to treat a stenosis within a body vessel of a human being. A common intravascular procedure is referred to as percutaneous transluminal coronary angioplasty (PTCA or hereinafter “angioplasty”). During a typical angioplasty procedure, a guidewire is initially positioned within the body vessel and a guiding catheter is positioned over the guidewire. Next, a balloon catheter having an inflatable balloon is advanced through the guiding catheter and vessel until the balloon is adjacent to the stenosis. Subsequently, inflation of the balloon compresses the stenosis and dilates the body vessel.
• During many diagnostic or interventional catheterization procedures, it is necessary to route the catheter from an entry point, such as either the femoral, brachial or radial artery, to a target location within the vasculature. When properly placing a catheter into position, the catheter should be able to be turned, pulled, and pushed so that the distal end of the catheter can navigate the twists and turns of the blood vessels on its path to the final location. This requires that the catheter be rigid enough to transfer the torque being applied by the operator of the catheter, but also flexible enough so that the catheter will not damage any of the blood vessels of the patient. The catheter can be too stiff, which can prevent the catheter from passing through tortuous blood vessels. Alternatively, the catheter can be too soft, which can result in the occurrence of kinks along the length of the catheter. In either of these situations, the usefulness of the catheter in the patient is limited.
• In order for intravascular catheters to be neither too stiff nor too soft, it is common to make such catheters with a relatively stiff shaft and a relatively soft distal region. Typically, this variable stiffness is achieved by varying the properties of the materials used to fabricate the catheters. For example, catheters intended for use as angiography catheters or as guiding catheters often comprise a tubular liner surrounded by an outer tubular shell, with a reinforcing layer interposed there between. Either the outer shell or the liner, or both tubular elements may include relatively softer polymeric materials in a distal region of the catheter. Optionally, the reinforcing layer, which is usually a tubular braid, may also have a more flexible, modified form in the distal region.
• A problem that has arisen in variable stiffness catheters relates to the challenge of reliable, low-cost manufacturing, especially since many of these devices are distracted after use in only one patient. One fabrication technique taught in the prior art is to make a laminated catheter assembly with uniform polymer materials. Selected regions of the catheter are then modified by radiation treatment to selectively increase stiffness. However, this technique has not become popular due to limitations in the choice of catheter materials and in the control of the final catheter properties. It is therefore more common for intravascular catheters to have a composite construction employing different polymeric materials.
• One known technique for manufacturing variable stiffness catheters requires sliding a series of tubular segments having different stiffness over an inner assembly comprising a liner surrounded by a reinforcing layer. The tubular segments are shrink-fitted and melt-bonded to the inner assembly using a removable length of heat-shrink tubing. Such a process is tedious and inefficient since catheters can only be fabricated one-at-a-time. In a known reel-to-reel process, outer jacket material is varied by switching between extrusion sources as a length of inner assembly passes through a wire-coating type extruder head. Alternatively, discrete sections of one material are extruded or over-molded onto a length of inner assembly. Then, a different material is extruded onto the length of inner assembly, filling in the spaces between the discrete sections. After forming the continuous, variable-stiffness outer shell, the long assembly is cut into catheter-length sections. Such reel-to-reel processes are more cost-efficient than assembling catheters one-at-a-time. However, the use of different materials to achieve variable catheter stiffness requires multiple assembly steps and/or complex tooling, and the junctions between the different material sections require careful control of design and manufacturing to avoid potentially weak joints that could fail during use.
• Accordingly, there is a need for a medical catheter that is simple to manufacture and has varied properties along its length, such as varying catheter stiffness, curve retention, and overall back-up support. The present invention addresses these needs, as well as other problems associated with existing medical catheters. The present invention also offers further advantages over the prior art and solves other problems associated therewith.
SUMMARY OF THE INVENTION
• The present invention is directed to medical catheters adapted for use within a body vessel and having variable physical properties along the length of the catheter. The medical catheter comprises a tubular catheter shaft having a distal end that fits within the body vessel. The tubular catheter shaft comprises an inner liner and an outer shell. The medical catheter comprises at least one region of selectively varied lamination between the inner liner and the outer shell.
• In some embodiments, at least one region of selectively varied lamination comprises a pattern of laminated sections and non-laminated sections. As examples, the non-laminated sections may be diamond-shaped or oval-shaped, the size of the non-laminated sections may increase towards the distal end, the laminated sections between non-laminated sections may decrease towards the distal end, and/or the non-laminated sections may form circumferentially arranged pairs that can be staggered at 90°. The non-laminated sections increase flexibility of the catheter by intentionally permitting localized movement between the inner liner and the outer shell.
• In some embodiments, the distal end of the catheter comprises at least one region of selectively varied lamination, or the proximal end of the catheter comprises at least one region of selectively varied lamination, or the region of selectively varied lamination is present throughout the length of the catheter.
• The present invention is also directed to methods for making a medical catheter comprising at least one region of selectively varied lamination. In some embodiments, where the inner liner and outer shell can form a thermal bond, a thermal bond inhibiting agent, such as an ink or wax, is applied in a pattern to selectively inhibit thermal bonding, thus creating at least one non-laminated section. Alternately, a thermoplastic tie layer may be used to thermally bond an inner liner and an outer shell having otherwise incompatible surfaces. A pattern of gaps can be introduced into such a tie layer to produce laminated sections and non-laminated sections. In other embodiments, the inner liner and outer shell are laminated with adhesive instead of a thermal bond. The adhesive may be selectively applied to create a pattern of laminated sections and non-laminated sections. In embodiments where the inner liner requires etching or other preparation to foster adhesive bonding, the etching of the inner liner may be selectively applied or prevented, as by masking in at least one region of the inner liner.
BRIEF DESCRIPTION OF THE DRAWINGS
• The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
• FIG. 1 is a perspective view, in partial cutaway, of a medical catheter having features of the present invention;
• FIG. 2 is an enlarged cutaway view of a portion of the medical catheter ofFIG. 1;
• FIG. 3 is a perspective illustration of the inventive medical catheter positioned within a patient;
• FIG. 4 is an enlarged side plan assembly view illustrating a grooved portion of a catheter shaft in accordance with the present invention; and
• FIGS. 5-7 illustrate catheters in accordance with the present invention, wherein sections of the outer shell have been removed to show a variety of regions of selectively varied lamination.
DETAILED DESCRIPTION OF THE INVENTION
• The present invention is directed to a catheter that has at least one region of selectively varied lamination. Any multi-layered medical catheter can be modified to have regions of selectively varied lamination. The catheters described herein are merely exemplary and the invention should not be construed to be limited to only the catheters described herein.
• Referring toFIGS. 1, 2 and4, a first embodiment ofmedical catheter10 having features of the present invention includestubular catheter shaft12,hub14, and tubularflexible tip16.Catheter shaft12 can optionally includegroove18, which is cut out ofcatheter shaft12 neardistal end20 ofcatheter shaft12.
• Medical catheter10 illustrated herein is utilized to guide an interventional catheter (not shown) and is commonly referred to as a grinding catheter.FIG. 3 illustrates a portion ofmedical catheter10 and guidewire22 positioned inbody vessel24 ofpatient26 during a procedure. The location of entry intopatient26 and the location ofdistal end20 inpatient26 are merely exemplary.
• Referring back toFIGS. 1 and 2,hub14 is secured toproximal end28 ofcatheter shaft12 whileflexible tip16 is secured todistal end20 ofcatheter shaft12. The physician manipulateshub14 andproximal end28 to positionmedical catheter10 inbody vessel24.Flexible tip16 assists in guidingmedical catheter10 inbody vessel24 and minimizes the trauma tovessel24 and coronary ostium (not shown).
• Flexible tip16 is made of a relatively soft material when compared to thecatheter shaft12. Suitable materials forflexible tip16 may include polymers such as a polyether block amide (“PEBA”) having a hardness of about 40 Shore D. Depending upon the materials utilized,hub14 andflexible tip16 can be thermally bonded or attached with an adhesive (not shown) tocatheter shaft12. Those skilled in the art will recognize alternate ways to attachhub14 andflexible tip16 and that alternate materials can be utilized forflexible tip16.
• In the embodiment illustrated inFIGS. 1 and 2,tubular catheter shaft12 includesinner liner30, optional reinforcingsection32, andouter shell34. Further, when the catheter comprisesgroove18, fillsection35 may be positioned ingroove18.Inner liner30 is tubular and defineslumen36, which is sized and shaped to receive, for example, guidewire22 and subsequently an interventional catheter (not shown). Typically,inner liner30 is manufactured by extruding a polymer such as PEBA, nylon, polytetrafluoroethylene (PTFE), high density polyethylene (HDPE), or fluorinated ethylene propylene (FEP), which provide good catheter flexibility and movement ofguidewire22 there within. The composition of the inner liner, however, is not limited to these polymers and any suitable polymer can be used so that the catheter has the desired properties. A suitableinner liner30 has an inner diameter of between about 0.06 and 0.09 inches and an inner liner thickness of about 1.0-1.5 mils. A lubricious coating (not shown) may be added tolumen36 ofinner liner30 to facilitate movement ofinner liner30 overguidewire22 and the interventional catheter withinlumen36.
• Reinforcingsection32 enhances the torsional strength and prevents or reduces kinking ofcatheter shaft12 during movement ofmedical catheter10 inbody vessel24. Reinforcingsection32 is embedded betweeninner liner30 andouter shell34 and is substantially coaxial withinner liner30 andouter shell34. Reinforcingsection32 may be formed by braiding wire mesh aroundinner liner30. Subsequently,outer shell34 is formed around reinforcingsection32 by applying materials making up the outer shell.
• In some embodiments,inner liner30 and/orouter shell34 comprise unfilled or low-loaded thermoplastic polymers. For example,inner liner30 andouter shell34 each, independently, may include a radiopaque material and/or filler and/or colorant, such that the total content of the radiopaque material and/or filler and/or colorant ininner liner30 and/orouter shell34 is between about 0.1% and about 10%, or between about 0.1% and about 5%, or between about 0.1% and about 2% of the total weight making upinner liner30 and/orouter shell34. In some embodiments,inner liner30 andouter shell34 each, independently, may exclude a radiopaque material and/or filler and/or colorant, thus having 0% by weight of the total weight making upinner liner30 and/orouter shell34. An unfilledinner liner30 and/orouter shell34 have the advantages of retaining mechanical integrity and modulus of elasticity.
• Outer shell34 provides support tocatheter shaft12 and covers reinforcingsection32 to protectbody vessel24 from reinforcingsection32. Further,outer shell34 prevents reinforcingsection32 from unwrapping.Outer shell34 is tubular and coaxial withinner liner30 and optional reinforcingsection32. A suitableouter shell34 has an inner diameter of about 0.1 inches and wall thickness40 of about 1.5-2.5 mils.
• Typically,outer shell34 is manufactured by extruding a polymer over the reinforcingsection32. A suitable shell material forouter shell34 is a nylon sold under the trademark “TROGAMID” by Creanova (Somerset, N.J.). The shell material may have a hardness of approximately 81 Shore D. Additionally, a lubricious coating (not shown) may be added toouter shell34 to facilitate movement ofcatheter shaft12 withinvessel24.
• Those skilled in the art will recognize alternate ways to manufactureinner liner30, reinforcingsection32, andouter shell34 and that alternate materials can be utilized forinner liner30, reinforcingsection32, andouter shell34. Those skilled in the art will also recognize alternate ways to apply reinforcingsection32 oninner liner30.
• The catheters of the invention comprise at least one region of selectively varied lamination. As used herein, the term “region” refers to a site or location oncatheter shaft12. Region(s) of selectively varied lamination can be located on the distal end of the catheter, the proximal end of the catheter, on any location there between, or any combination thereof. Additionally, the region(s) of selectively varied lamination can be located throughout the entire catheter. Each region(s) of selectively varied lamination can be laid down in a particular pattern comprising laminated sections and non-laminated sections. Non-laminated sections include those sections having no lamination as well as those sections having reduced lamination. For example, the pattern of lamination can be in longitudinal non-laminated strips along the length of the catheter without going around the circumference of the catheter. Alternately, regions of selectively varied lamination can form continuous or non-continuous non-laminated rings around the circumference of the catheter.
• FIGS. 5-7 illustrate a variety of patterns of regions of selectively varied lamination formed in accordance with the invention. InFIG. 5,non-laminated sections200,200′ inpattern160 are diamond-shaped, andpattern160 varies to change the physical properties along the length of the catheter. The portions ofpattern160 betweennon-laminated sections200,200′ represent sections that are laminated to bondinner liner30 toouter shell34. Largenon-laminated sections200′ inpattern160 provide decreased laminated areas and corresponding greater flexibility in comparison to smallernon-laminated sections200.Non-laminated sections200′ may be disposed distal tonon-laminated sections200 to create a more flexible distal region of the catheter. Alternatively,pattern160 can be reversed, such thatsections200,200′ would represent diamond-shaped laminated portions and the portions between the diamond shapes would not be laminated. In such an arrangement, the relative flexibility ofregions comprising sections200 and200′ would also be reversed.
• InFIG. 6,non-laminated sections300 inpattern260 are oval or elliptical in shape andpattern260 varies along the catheter. Inpattern260, allnon-laminated sections300 are of the same size and shape, but the spacing between non-laminated sections changes. In this case, the contracted spacing creates greater flexibility in selected, e.g. distal, portions of the catheter. As mentioned in the previous example,pattern260 can be reversed, such thatsections300 would represent laminated sections and the portions between the oval or elliptical shapes would not be laminated. In such an arrangement, the relative flexibility is also reversed, making the more distal portion less flexible instead of more flexible.
• InFIG. 7,pattern360 has circumferentially arranged pairs of largenon-laminated sections400. Adjacent pairs are staggered at 9020 to create a highly flexible catheter. Many other patterns are possible, including differently sized and shaped sections of selectively varied lamination, differently sized and shaped spacing between non-laminated sections, pattern variations along the length of the catheter, and long regions or selected regions having no sections of selectively varied lamination. Such regions could be either fully laminated or have no lamination.
• Typically,inner liner30 andouter shell34 are adhered to each other via thermoplastic bonding, with or without a tie layer, or via a bonding agent, such as glue, depending upon the materials used to makeinner liner30 andouter shell34. Regions of selectively varied lamination may be formed betweeninner liner30 andouter shell34 by selectively interfering with the bonding between the two layers. These regions of selectively varied lamination have non-laminated sections with reduced bonding or no bonding at all between theinner liner30 andouter shell34.
• In some embodiments,outer shell34 may be formed about inner liner by the process of thermoplastic extrusion, which includes forcing shell material around and into thermal bonding contact withinner liner30. Alternatively,outer shell34 may be compression molded aroundinner liner30 by the use of heat shrink tubing, which can be removed afterwards. Within regions of selectively varied lamination, non-laminated sections can be formed by selectively interfering with the bonding betweeninner liner30 andouter shell34. Interruption of thermal bonding in the non-laminated sections can be carried out, for example, by depositing an agent that interrupts bonding. Such agents include, but are not limited to, waxes and inks, which can be selectively applied to the outer surface ofinner liner30.
• The bond-interrupting agent can be applied toinner liner30 by known processes such as printing, spraying or dipping. The agent can be applied in a desired pattern, as by pad printing, roller pad printing, or spraying through a mask. The bond-interrupting agent can also be applied to completely cover the intended regions of selectively varied lamination. Then, the agent can be selectively removed or altered to create the desired pattern of bondable and non-bondable sections. Such selective removal or alteration of the bond-interrupting agent can be via photo or laser treatment, for example. Desirably, the agent is applied to a long piece ofinner liner30 by a continuous reel-to-reel process. If it is desired to vary the lamination along the length of eachcatheter10, then the pattern of bond-interrupting agent can be repeated or reversed along the long piece ofinner liner30.
• Next,outer shell34 is extruded or molded overinner layer30. In those sections where the bond-interrupting agent has been applied, there will be a reduced or non-existent thermal bond betweenouter shell34 andinner liner30. Next, the composite catheter tubing can be severed at desired cut points, forming multiple sub-assemblies of intended catheter length. Finally,catheters10 are finished by securing the remaining components.
• In some embodiments, thermal bonding betweenouter shell34 andinner liner30 is weak or non-existent because the materials are incompatible. Examples of this combination include nylon-based outer shells combined with polyolefin inner liners. In such cases, thermal bonding of the assembly can still be achieved by use of a tie layer interposed betweenouter shell34 andinner liner30. A tie layer is thermally bondable to bothouter shell34 andinner liner30, acting like a hot-melt adhesive. In catheter construction, a tie layer can be applied overinner liner30 by a continuous extrusion step or by use of heat shrink tubing, as described above. In one embodiment of the invention, a tie layer can be modified to include a pattern of open sections; each open section will not promote thermal bonding betweenouter shell34 andinner liner30. The openings can be formed in the tie layer by laser machining, for example, before or after the layer has been applied toinner liner30.
• As is well known in the field of medical catheters, there are material combinations wherein no thermal bonding can occur betweeninner liner30 andouter shell34, even with a tie layer. For example, ifinner liner30 comprises PTFE, then additional means must be used to permit bonding of the two layers. Typically, the outer surface ofinner liner30 is etched using either a laser or a strongly acidic etchant. After the liner surface has been prepared, an adhesive, such as an epoxy, can be used to bondinner liner30 toouter shell34. In one embodiment of the instant invention, the outer surface of a non-thermally bondableinner liner30 can be treated to create a selected pattern of sections that can be glued toouter shell34. These glue-able sections are interspersed with sections that cannot be glued to generate a catheter shaft having variable stiffness, as described in other embodiments above. Controlled etching can be used to form a pattern on the surface ofinner liner30. For example, a laser can be used to selectively etch desired sections. For example, a laser source can be switched off and on while the continuousinner liner30 passes thereby. Alternatively, prior to etching, portions ofinner liner30 can be masked to cover the areas where laser or chemical etching is not desired. Upon completion of the etching process, the mask material is removed.
• In some embodiments of the invention, theinner liner30 is an ultra high molecular weight high density polyethylene (UHMW-HD PE), which is melt-extrudable. UHMW-HD PE, in contrast to PTFE, can be processed in a continuous, reel-to-reel fashion. UHMW-HD PE, however, is highly chemically resistant and, thus, cannot be chemically etched so as to create a surface that can bond to a polymerouter shell34. A solution to this problem, however, is to utilize a laser, such as an excimer laser, to modify the surface of the UHMW-HD PE to enhance bonding between UHMW-HD PE and theouter shell34.
• In any of the above embodiments of the invention, an optional reinforcingsection32, such as a braid, can be created around etchedinner liner30 beforeouter shell34 is formed. Reinforcingsection32 is typically porous so that any of the above-mentioned lamination processes can occur there through.
• There are many benefits of having regions of selectively varied lamination in a catheter. For example, such a catheter processes variation in the properties along the length of the catheter. These properties include, but are not limited to, catheter stiffness, curve retention, overall back-up support, and the like.
• As illustrated inFIG. 4,catheter shaft12 can optionally includegroove18, which is cut out ofcatheter shaft12 neardistal end20 ofcatheter shaft12, as described in U.S. Pat. No. 6,059,769, which is incorporated herein by reference in its entirety.Groove18 provides flexibility atdistal end20 ofcatheter shaft12 without compromising the durability and torsional strength ofcatheter shaft12. Further, groove18 functions astransitional region21 between relativelystiff catheter shaft12 andflexible tip16. This prevents or reduces kinking and/or collapsing ofmedical catheter10. As a result thereof,medical catheter10 has improved tracking and movement in the vessel.Fill section35 may be positioned ingroove18. An embodiment of the invention may combine filledgroove18 with one or more regions of selectively varied lamination to achieve a desirable combination of mechanical properties.
• While the particularmedical catheter10 as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
• Various modifications of the invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. Each reference cited in the present application is incorporated herein by reference in its entirety.

Claims (8)

1-24. (canceled)

25. A method for making a medical catheter comprising at least one region of selectively varied lamination, the method comprising the steps of:

providing a medical catheter comprising an inner liner;

applying a material for forming an outer shell over the inner liner;

interfering with the bonding between the inner liner and the outer shell in at least one selective region; and

wherein said selectively varied lamination is achieved by one of the following:

a) the inner liner bonds to the outer shell by means of a thermoplastic bond and a thermal bond inhibiting agent is selectively applied to the outer surface of the inner liner; or

b) the inner liner bonds to the outer shell by means of a thermoplastic tie layer which is selectively applied to the outer surface of the inner layer; or

c) the inner liner bonds to the outer shell by means of an adhesive which is selectively applied to the outer surface of the inner layer.

26. The method ofclaim 25 wherein the interfering step comprises masking the at least one selective region of the inner liner prior to etching the inner liner.

27. The method ofclaim 25 wherein the method further comprises providing a tie layer between the inner liner and the outer shell and wherein the interfering step comprises introducing gaps in a tie layer between the inner liner and outer shell.

28. The method ofclaim 25 wherein the interfering step comprises applying a thermal bonding inhibitor to the at least one selective region of the inner liner.

29. The method ofclaim 25 further comprising applying a reinforcing section over the inner liner prior to applying material to form the outer shell.

30. The method ofclaim 25 wherein the inner liner is melt-extruded ultra high molecular weight high density polyethylene.

31. The method ofclaim 30 wherein the interfering step comprises masking the at least one selective region of the inner liner prior to laser etching the inner liner.

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