US20100179634A1 - Methods and Devices for Delivery of Prosthetic Heart Valves and Other Prosthetics - Google Patents

Abstract

Prosthetic valves and their component parts are described, as are prosthetic valve delivery devices and methods for their use. The prosthetic valves are particularly adapted for use in percutaneous aortic valve replacement procedures. The delivery devices are particularly adapted for use in minimally invasive surgical procedures. The preferred delivery device includes a catheter having a deployment mechanism attached to its distal end, and a handle mechanism attached to its proximal end. A plurality of tethers are provided to selectively restrain the valve during deployment. A number of mechanisms for active deployment of partially expanded prosthetic valves are also described.

Description

CROSS REFERENCES TO RELATED APPLICATIONS
• This application is a divisional of U.S. Ser. No. 11/364,724, filed Feb. 27, 2006, which is fully incorporated by reference herein.
FIELD OF THE INVENTION
• The present invention relates generally to medical devices and methods. More particularly, the present invention relates to methods and devices for delivering and deploying prosthetic heart valves and similar structures using minimally invasive surgical methods.
BACKGROUND OF THE INVENTION
• Diseases and other disorders of the heart valve affect the proper flow of blood from the heart. Two categories of heart valve disease are stenosis and incompetence. Stenosis refers to a failure of the valve to open fully, due to stiffened valve tissue. Incompetence refers to valves that cause inefficient blood circulation by permitting backflow of blood in the heart.
• Medication may be used to treat some heart valve disorders, but many cases require replacement of the native valve with a prosthetic heart valve. Prosthetic heart valves can be used to replace any of the native heart valves (aortic, mitral, tricuspid or pulmonary), although repair or replacement of the aortic or mitral valves is most common because they reside in the left side of the heart where pressures are the greatest. Two primary types of prosthetic heart valves are commonly used, mechanical heart valves and prosthetic tissue heart valves.
• The caged ball design is one of the early mechanical heart valves. The caged ball design uses a small ball that is held in place by a welded metal cage. In the mid-1960s, another prosthetic valve was designed that used a tilting disc to better mimic the natural patterns of blood flow. The tilting-disc valves had a polymer disc held in place by two welded struts. The bileaflet valve was introduced in the late 1970s. It included two semicircular leaflets that pivot on hinges. The leaflets swing open completely, parallel to the direction of the blood flow. They do not close completely, which allows some backflow.
• The main advantages of mechanical valves are their high durability. Mechanical heart valves are placed in young patients because they typically last for the lifetime of the patient. The main problem with all mechanical valves is the increased risk of blood clotting.
• Prosthetic tissue valves include human tissue valves and animal tissue valves. Both types are often referred to as bioprosthetic valves. The design of bioprosthetic valves are closer to the design of the natural valve. Bioprosthetic valves do not require long-term anticoagulants, have better hemodynamics, do not cause damage to blood cells, and do not suffer from many of the structural problems experienced by the mechanical heart valves.
• Human tissue valves include homografts, which are valves that are transplanted from another human being, and autografts, which are valves that are transplanted from one position to another within the same person.
• Animal tissue valves are most often heart tissues recovered from animals. The recovered tissues are typically stiffened by a tanning solution, most often glutaraldehyde. The most commonly used animal tissues are porcine, bovine, and equine pericardial tissue.
• The animal tissue valves are typically stented valves. Stentless valves are made by removing the entire aortic root and adjacent aorta as a block, usually from a pig. The coronary arteries are tied off, and the entire section is trimmed and then implanted into the patient.
• A conventional heart valve replacement surgery involves accessing the heart in the patent's thoracic cavity through a longitudinal incision in the chest. For example, a median sternotomy requires cutting through the sternum and forcing the two opposing halves of the rib cage to be spread apart, allowing access to the thoracic cavity and heart within. The patient is then placed on cardiopulmonary bypass which involves stopping the heart to permit access to the internal chambers. Such open heart surgery is particularly invasive and involves a lengthy and difficult recovery period.
• A less invasive approach to valve replacement is desired. The percutaneous implantation of a prosthetic valve is a preferred procedure because the operation is performed under local anesthesia, does not require cardiopulmonary bypass, and is less traumatic. Current attempts to provide such a device generally involve stent-like structures, which are very similar to those used in vascular stent procedures with the exception of being larger diameter as required for the aortic anatomy, as well as having leaflets attached to provide one way blood flow. These stent structures are radially contracted for delivery to the intended site, and then expanded/deployed to achieve a tubular structure in the annulus. The stent structure needs to provide two primary functions. First, the structure needs to provide adequate radial stiffness when in the expanded state. Radial stiffness is required to maintain the cylindrical shape of the structure, which assures the leaflets coapt properly. Proper leaflet coaption assures the edges of the leaflets mate properly, which is necessary for proper sealing without leaks. Radial stiffness also assures that there will be no paravalvular leakage, which is leaking between the valve and aorta interface, rather than through the leaflets. An additional need for radial stiffness is to provide sufficient interaction between the valve and native aortic wall that there will be no valve migration as the valve closes and holds full body blood pressure. This is a requirement that other vascular devices are not subjected to. The second primary function of the stent structure is the ability to be crimped to a reduced size for implantation.
• Prior devices have utilized traditional stenting designs which are produced from tubing or wire wound structures. Although this type of design can provide for crimpability, it provides little radial stiffness. These devices are subject to “radial recoil” in that when the device is deployed, typically with balloon expansion, the final deployed diameter is smaller than the diameter the balloon and stent structure were expanded to. The recoil is due in part because of the stiffness mismatches between the device and the anatomical environment in which it is placed. These devices also commonly cause crushing, tearing, or other deformation to the valve leaflets during the contraction and expansion procedures. Other stenting designs have included spirally wound metallic sheets. This type of design provides high radial stiffness, yet crimping results in large material strains that can cause stress fractures and extremely large amounts of stored energy in the constrained state. Replacement heart valves are expected to survive for many years when implanted. A heart valve sees approximately 500,000,000 cycles over the course of 15 years. High stress states during crimping can reduce the fatigue life of the device. Still other devices have included tubing, wire wound structures, or spirally wound sheets formed of nitinol or other superelastic or shape memory material. These devices suffer from some of the same deficiencies as those described above.
• A number of improved prosthetic heart valves and scaffolding structures are described in co-pending U.S. patent application Ser. No. 11/066,126, entitled “Prosthetic Heart Valves, Scaffolding Structures, and Methods for Implantation of Same,” filed Feb. 25, 2005, (“the '126 application”) which application is hereby incorporated by reference in its entirety. Several of the prosthetic heart valves described in the '126 application include a support member having a valvular body attached, the support member preferably comprising a structure having three panels separated by three foldable junctions. The '126 application also describes several delivery mechanisms adapted to deliver the described prosthetic heart valve. Although the prosthetic heart valves and delivery systems described in the '126 application represent a substantial advance in the art, additional delivery systems and methods are desired, particularly such systems and methods that are adapted to deliver and deploy the prosthetic heart valves described therein.
SUMMARY OF THE INVENTION
• The present invention provides methods and devices for deploying prosthetic heart valves and other prosthetic devices in body lumens. The methods and devices are particularly adapted for use in percutaneous aortic valve replacement. The methods and devices may also find use in the peripheral vasculature, the abdominal vasculature, and in other ducts such as the biliary duct, the fallopian tubes, and similar lumen structures within the body of a patient. Although particularly adapted for use in lumens found in the human body, the apparatus and methods may also find application in the treatment of animals.
• Without intending to limit the scope of the methods and devices described herein, the deployment devices and methods are particularly adapted for delivery of prosthetic heart valves and scaffolding structures identical or similar to those described in the '126 application described above. A particularly preferred prosthetic heart valve includes a generally cylindrical support structure formed of three segments, such as panels, interconnected by three foldable junctions, such as hinges, a representative embodiment of which is illustrated inFIG. 1A of the '126 application, which is reproduced herein asFIG. 1A. The exemplaryprosthetic valve30 includes a generallycylindrical support member32 made up of three generally identicalcurved panels36 and avalvular body34 attached to the internal surface of the support member. Each panel includes anaperture40 through which extends a plurality of interconnecting braces42 that define a number ofsub-apertures44,46,48,50. Ahinge52 is formed at the junction formed between each pair of adjacent panels. The hinge may be a membrane hinge comprising a thin sheet ofelastomeric material54 attached to theexternal edge56 of each of a pair ofadjacent panels36.
• Turning toFIG. 1B-C, a method for transforming a prosthetic valve from its expanded state to its contracted state is illustrated. These Figures show a three-panel support member without a valvular body attached. The method for contracting a full prosthetic valve, including the attached valvular body, is similar to that described herein in relation to the support member alone. As shown inFIG. 1B, each of thepanels36 is first inverted, by which is meant that alongitudinal centerline80 of each of thepanels36 is forced radially inward toward the centrallongitudinal axis82 of the support member. This action is facilitated by having panels formed of a thin, resilient sheet of material having generally elastic properties, and by the presence of thehinges52 located at the junction between each pair ofadjacent panels36. During the inversion step, theedges56 of each of the adjacent pairs of panels fold upon one another at thehinge52. The resulting structure, shown inFIG. 1B, is a three-vertex58 star shaped structure, referred to herein as a “tri-star” shape. Those skilled in the art will recognize that a similar procedure may be used to invert a four (or more) panel support member, in which case the resulting structure would be a four- (or more) vertex star shaped structure.
• Theprosthetic valve30 may be further contracted by curling each of thevertices58 of the star shaped structure to form a multi-lobe structure, as shown inFIG. 1C. As shown in that Figure, each of the threevertices58 is rotated toward the centerlongitudinal axis82 of the device, causing each of the three folded-upon edges of the adjacent pairs of panels to curl into alobe84. The resulting structure, illustrated inFIG. 1C, is a “tri-lobe” structure that represents the fully contracted state of the prosthetic valve. Those skilled in the art will recognize that a similar procedure may be used to fully contract a four (or more) panel support member, in which case the resulting structure would be a four- (or more) lobed structure.
• The foregoing processes are performed in reverse to transform the prosthetic valve from its contracted state to its expanded state. For example, beginning with the prosthetic valve in its “tri-lobe” position shown inFIG. 1C, the threevertices58 may be extended radially to achieve the “tri-star” shape shown inFIG. 1B. The “tri-star” shape shown inFIG. 1B is typically not stable, as thepanels36 tend to spontaneously expand from the inverted shape to the fully expanded shape shown inFIG. 1A unless the panels are otherwise constrained. Alternatively, if the panels do not spontaneously transition to the expanded state, it will typically only require a slight amount of force over a relatively short amount of distance in order to cause the panels to fully expand. For example, because of the geometry of the three panel structure, a structure having an expanded diameter of about 21 mm would be fully expanded by insertion of an expanding member having a diameter of only 16 mm into the interior of the structure. In such a circumstance, the 16 mm diameter member would contact the centerline of each panel and provide sufficient force to cause each panel to transform from the inverted shape shown inFIG. 1B to the fully expanded shape shown inFIG. 1A. This is in contrast to a typical “stent”-like support structure, which requires an expanding member to expand the stent to its full radial distance.
• Additional details of this and other embodiments of the prosthetic heart valve and scaffolding structures are provided in the '126 application, to which the present description refers. It is to be understood that those prosthetic heart valves and scaffolding structures are only examples of such valves and prosthetic devices that are suitable for use with the devices and methods described herein. For example, the present devices and methods are suitable for delivering valves and prosthetic devices having any cross-sectional or longitudinal profile, and is not limited to those valves and devices described in the '126 application or elsewhere.
• Turning to the deployment devices and methods, in one aspect of the present invention, a delivery catheter for prosthetic heart valves and other devices is provided. The delivery catheter is preferably adapted for use with a conventional guidewire, having an internal longitudinal lumen for passage of the guidewire. The delivery catheter includes a handle portion located at a proximal end of the catheter, a deployment mechanism located at the distal end of the catheter, and a catheter shaft interposed between and operatively interconnecting the handle portion and the deployment mechanism. The deployment mechanism includes several components that provide the delivery catheter with the ability to receive and retain a prosthetic valve or other device in a contracted, delivery state, to convert the prosthetic device to a partially expanded state, and then to release the prosthetic valve completely from the delivery device. In several preferred embodiments, the deployment mechanism includes an outer slotted tube, a plurality of wrapping pins attached to a hub and located on the interior of the slotted tube, and a plurality of restraining members that extend through the wrapping pins to the distal end of the catheter. Each of the deployment mechanism components is individually controlled by a corresponding mechanism carried on the handle portion of the catheter. The deployment mechanism preferably also includes a nosecone having an atraumatic distal end.
• In several particularly preferred embodiments, the restraining members comprise tethers in the form of a wire, a cable, or other long, thin member made up of one or more of a metal such as stainless steel, metallic alloys, polymeric materials, or other suitable materials. A particularly preferred form of the tethers is suture material. In several embodiments, the tethers are adapted to engage the guidewire that extends distally past the distal end of the delivery catheter. The tethers preferably engage the guidewire by having a loop, an eyelet, or other similar construction at the distal end of the tether. Optionally, the tether is simply looped around the guidewire and doubles back to the catheter handle. Thus, the tethers are released when the guidewire is retracted proximally into the delivery catheter. In still other embodiments, the tethers may be released from the guidewire by actuation of a member carried on the handle mechanism at the proximal end of the catheter. In still other embodiments, a post or tab is provided on the guidewire, and the tether engages the post or tab but is able to bend or break free from the post or tab when a proximally-oriented force is applied to the tethers.
• In a second aspect of the present invention, several optional active deployment mechanisms are described. The active deployment mechanisms are intended to convert a prosthetic valve, scaffolding structure, or similar device from an undeployed, partially deployed, or not-fully deployed state to its fully expanded state. Several of the active deployment mechanisms take advantage of the fact that the preferred prosthetic valves and scaffolding structures require only a small amount of force applied any any of a large number of points or locations on the valve or structure in order to cause the valve to fully expand. Exemplary embodiments of the active deployment mechanisms include embodiments utilizing expandable members that are placed into the interior of the prosthetic valve and then expanded; embodiments that operate by causing the hinges of the undeployed prosthetic valve to open, thereby transitioning to the fully expanded state; embodiments that include implements that engage one or more of the panels to cause the panel to expand to its deployed state; and other embodiments described herein.
• Other aspects, features, and functions of the inventions described herein will become apparent by reference to the drawings and the detailed description of the preferred embodiments set forth below.
DESCRIPTION OF THE DRAWINGS
• FIG. 1A is a perspective view of a prosthetic valve suitable for use by the delivery catheter of the present invention.
• FIG. 1B is a top view of a partially contracted support member illustrating inverted panels to form a “tri-star” shape.
• FIG. 1C is a top view of a fully contracted support member illustrating inverted and curled panels to form a “tri-lobe” shape.
• FIG. 2 is a perspective view of a delivery catheter in accordance with the present invention.
• FIG. 3 is a perspective view of a deployment mechanism of the delivery catheter ofFIG. 2.
• FIG. 3A is a cross-sectional view of the deployment mechanism shown inFIG. 3.
• FIG. 3B is a perspective view of several of the internal components included in the deployment mechanism shown inFIG. 3.
• FIG. 3C is a perspective view of a wrapping pin stabilizer.
• FIGS. 3D-F are cross-sectional views of wrapping pins and their associated tethers.
• FIG. 3G is another perspective view of a wrapping pin stabilizer.
• FIG. 4 is a perspective view of a handle mechanism of the delivery catheter shown inFIG. 2.
• FIG. 5 is a cross-sectional view of the handle mechanism shown inFIG. 4.
• FIG. 6 is a side view of the handle mechanism of the delivery catheter shown inFIG. 2, illustrating several positions corresponding with steps performed during use of the delivery catheter to deliver a prosthetic device.
• FIG. 7 is a perspective view of the deployment mechanism, shown with a prosthetic valve in a star shape and with the slotted tube fully advanced.
• FIG. 8 is a perspective view of the deployment mechanism, shown with a prosthetic valve in a star shape with the wrapping pins fully advanced and with the slotted tube retracted.
• FIG. 9 is a perspective view of the deployment mechanism, shown with a prosthetic valve in a star shape with the wrapping pins and the slotted tube retracted.
• FIG. 9A is a closeup view of the nosecone and guidewire shown inFIG. 9, showing detail of the manner in which a tether is looped over the guidewire.
• FIG. 10 is a perspective view of the deployment mechanism, shown with a prosthetic valve in expanded shape with tethers retaining the valve in place.
• FIG. 11 is a perspective view of the deployment mechanism, shown with a prosthetic valve in expanded shape, and showing the guidewire and tethers withdrawn to release the valve.
• FIGS. 12A-B are side cross-sectional and end views, respectively, of a portion of the distal end of a delivery catheter, illustrating an eyelet formed on the ends of each tether.
• FIGS. 12C-D are side cross-sectional views of a first wrapping pin having no recess, and a second wrapping pin having an eyelet recess formed therein.
• FIG. 12E is an end cross-sectional view of a prosthetic valve partially restrained by three dual tethers.
• FIGS. 12F-G are illustrations of two methods for selectively attaching dual tethers to a guidewire.
• FIG. 13 is a side view of a portion of a delivery catheter illustrating a valve stop formed on each tether.
• FIGS. 14A-B are side partial cross-sectional views of a portion of a delivery catheter illustrating tethers including linkage members.FIG. 14A shows a valve in its expanded state, andFIG. 14B shows the valve in its “tri-star” state.
• FIG. 15 is a side view in partial cross-section of a delivery catheter illustrating tethers having loops that are routed through throughholes in the nosecone.
• FIGS. 16A-B are a side view in partial cross-section and an end view showing a slotted nosecone.
• FIG. 17 is a side view in partial cross-section of a delivery catheter illustrating tethers having primary and secondary sections.
• FIGS. 18A-B are side views of a portion of a prosthetic valve having loops for engaging a tether to prevent migration.
• FIGS. 19A-D are side views of several embodiments of wrapping pins.
• FIGS. 20A-B are side views in partial cross-section showing a pair (out of three) of articulating wrapping pins, forming a gripper mechanism.
• FIGS. 21A-B are an end perspective view in partial cross-section and a top view in partial cross-section of a slotted tube.
• FIG. 21C is a side cross-sectional view of a slotted tube having runners and a valve panel in its contracted state.
• FIGS. 22A-B are a perspective view and an end view, respectively, of an alternative deployment mechanism for a delivery catheter.
• FIG. 23A is an illustration of a shape set nosecone shaft.
• FIG. 23B is a cross-sectional end view of the shape set nosecone shaft ofFIG. 23A.
• FIG. 23C is a side view of the shape set nosecone shaft ofFIG. 23A showing the tensioning member in tension.
• FIGS. 24A-C illustrate a side view in partial cross-section and two end views, respectively, of an active deployment mechanism for deploying a valve, in accordance with the present invention.
• FIGS. 25A-C illustrate side views in partial cross-section of another active deployment mechanism for deploying a valve, in accordance with the present invention.
• FIGS. 26A-E illustrate several embodiments of active deployment mechanism employing inflatable members, such as balloons.
• FIGS. 27A-B illustrates another embodiment of an active deployment mechanism employing inflatable members, such as balloons.
• FIG. 28 illustrates an active deployment mechanism utilizing a roller and pincher.
• FIGS. 29A-B illustrate an active deployment mechanism utilizing a wedge.
• FIG. 30 illustrates an active deployment mechanism utilizing a torsion spring.
• FIGS. 31A-B illustrate an active deployment mechanism utilizing a membrane balloon mounted on a slotted tube.
• FIG. 32 illustrates an active deployment mechanism utilizing a plurality of linkages able to be expanded by an inflatable member.
• FIGS. 33A-B illustrate an active deployment mechanism utilizing an expansion balloon mounted within the nosecone of a delivery catheter.
• FIGS. 34A-C illustrate an active deployment mechanism utilizing a yoke and linkage system adapted to extend radially outward upon actuation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
• Before the present invention is described, it is to be understood that this invention is not limited to particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
• Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these inventions belong. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.
• It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
• The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
• As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present inventions.
• This application relates to U.S. Ser. No. 11/066,126, filed Feb. 25, 2005, which is fully incorporated by reference herein. The '126 application claims the benefit of U.S. Provisional Ser. No. 60/548,731, filed Feb. 27, 2004, and U.S. Provisional Ser. No. 60/559,199, filed Apr. 1, 2004, both of which are fully incorporated by reference herein.
A. Delivery Devices and Methods of Use
• Devices for delivering prosthetic valves and other devices to a treatment location in a body lumen are described below, as are methods for their use. The delivery devices are particularly adapted for use in minimally invasive interventional procedures, such as percutaneous aortic valve replacements.FIG. 2 illustrates a preferred embodiment of the device, in the form of a delivery catheter. Thedelivery catheter100 includes ahandle mechanism102 located at the proximal end of the catheter, adeployment mechanism104 located at the distal end of the device, and ashaft106 extending between and interconnecting thehandle mechanism102 and thedeployment mechanism104. Thecatheter100 is preferably provided with a guidewire lumen extending through the entire length of the catheter, such that aguidewire108 is able to extend through the delivery catheter in an “over-the-wire” construction. In an optional embodiment (not shown in the drawings), thecatheter100 is provided with a “rapid-exchange” construction whereby the guidewire exits the catheter shaft through an exit port located near the distal end of the catheter. The cross-sectional profile of thedeployment mechanism104 and theshaft106 are of a sufficiently small size that they are able to be advanced within the vasculature of a patient to a target location, such as the valve root of one or more of the valves of the heart. A preferred route of entry is through the femoral artery in a manner known to those skilled in the art. Thus, thedeployment mechanism104 has a preferred maximum diameter of approximately 24 Fr. It is understood, however, that the maximum and minimum transverse dimensions of thedeployment mechanism104 may be varied in order to obtain necessary or desired results.
• Thedeployment mechanism104 is provided with components, structures, and/or features that provide the delivery catheter with the ability to retain a prosthetic valve (or other prosthetic device) in a contracted state, to deliver the valve to a treatment location, to convert the prosthetic valve to its deployed state (or to allow the valve to convert to its deployed state on its own), to retain control over the valve to make any necessary final position adjustments, and to convert the prosthetic valve to its contracted state and withdraw the valve (if needed). These components, structures, and/or features of the preferred deployment mechanism are described below.
• Turning toFIGS. 3 and 3A, thedeployment mechanism104 is shown in its fully contracted state for use when themechanism104 has not yet reached the target site within the body of a patient, such as prior to use and during the delivery process. Thedeployment mechanism104 includes a slottedtube110 that is connected to anouter sheath112 of thecatheter shaft106, such as by way of the attachment collar111 (shown inFIG. 3A). Thus, longitudinal movement or rotation of theouter sheath112 causes longitudinal movement or rotation of the slottedtube110. The slottedtube110 is a generally cylindrical body that includes a plurality oflongitudinal slots114 that extend from the distal end of the slottedtube110 to near its proximal end. In the preferred delivery catheter, the slottedtube110 includes threeslots114 spaced equidistantly about the circumference of the slottedtube110. Theslots114 have a length and width that are sufficient to accommodate the extension of portions of theprosthetic valve30 therethrough, as described more fully below in reference toFIG. 7, described elsewhere herein. The slottedtube110 is preferably formed of stainless steel or other generally rigid material suitable for use in medical devices or similar applications.
• Thedeployment mechanism104 may also include aretainer ring116 and anosecone118. Although theretainer ring116 andnosecone118 are not necessary parts of the delivery catheter, each of these components may provide additional features and functionality when present. Thenosecone118 is located at the distal end of the delivery catheter and is preferably provided with a generally blunt,atraumatic tip120 to facilitate passage of the catheter through the patient's vasculature while minimizing damage to the vessel walls. Thenosecone118 is preferably formed of any suitable biocompatible material. In several preferred embodiments, the nosecone is formed of a relatively soft elastomeric material, such as a polyurethane, a polyester, or other polymeric or silicone-based material. In other embodiments, the nosecone is formed of a more rigid material, such as a plastic, a metal, or a metal alloy material. The nosecone may be coated with a coating material or coating layer to provide advantageous properties, such as reduced friction or increased protection against damage. It is also advantageous to provide the nosecone with an atraumatic shape, at least at its distal end, or to form thenosecone118 of materials that will provide the atraumatic properties while still providing structural integrity to the distal end of the device. Thenosecone118 preferably includes a plurality ofthroughholes122 that extend through the length of the nosecone to allow passage of a plurality oftethers124, which are described more fully below. A pair ofslots119 are formed on the exterior of thenosecone118. Theslots119 provide a pair of surfaces for a wrench or other tool to grasp thenosecone118 to enable manual manipulation of thenosecone118, for purposes to be described below.
• Theretainer ring116 is a generally cylindrically shaped ring that is located generally between the slottedtube110 and thenosecone118. More precisely, when thedeployment mechanism104 is in the fully contracted state shown inFIGS. 3 and 3A, theretainer ring116 preferably overlaps aledge126 formed on the distal end of the slottedtube110. Alternatively, the inner diameter of theretainer ring116 may be formed slightly larger than the outer diameter of the slottedtube110, thereby allowing the distal ends of the slottedtube110 to slide within theretainer ring116 without the need for aledge126. In this way, theretainer ring116 prevents the distal ends of the slottedtube110 from bowing outward due to pressure caused by the prosthetic valve being stored within thedeployment mechanism104.
• The proximal end of theretainer ring116 engages abearing128 that is formed integrally with thenosecone118, and that allows thenosecone118 to rotate inside and independently from theretainer ring116. As described below, the slottedtube110 is rotated relative to thenosecone shaft136 and the wrapping pins130 during some operations of the deployment mechanism, primarily during the expansion and contraction of the prosthetic valve. Without the bearing128 (or a suitable alternative), the prosthetic valve would tend to bind up within the deployment mechanism and prevent relative rotation between the slottedtube110 and the wrapping pins130. Thus, the provision of thebearing128 engaged with theretainer ring116 facilitates this rotation of the slottedtube110, which engages theretainer ring116.
• Additional features of the interior of the deployment mechanism are illustrated in the cross-sectional view shown inFIGS. 3A-G. A plurality of fixed wrapping pins130 are attached to awrapping pin hub132 and extend longitudinally from thehub132 toward the distal end of the catheter. The preferred embodiment of the delivery catheter includes three wrappingpins130, although more or fewer are possible. Thehub132 is attached to awrapping pin shaft134 that extends proximally from thehub132 beneath theouter sheath112 of thecatheter shaft106. Thus, movement or rotation of thewrapping pin shaft134 causes longitudinal movement or rotation of thehub132 and the three wrapping pins130. Awrapping pin stabilizer133 is slidably attached to the outer surfaces of each of the wrapping pins130. Thepin stabilizer133 is a generally disc-shaped member having acenter hole133aand three equally spacedthroughholes133bto accommodate the three wrapping pins130. As described below, in certain orientations of thedeployment mechanism104, thepin stabilizer133 provides support and stability to the wrapping pins130 extending distally from thewrapping pin hub132.
• Turning toFIGS. 3D-F, in several of the preferred embodiments, thetethers124 extend through or are otherwise engaged with the wrapping pins130. The Figures illustrate several methods by which this is done. In the closed configuration, shown inFIG. 3D, thewrapping pin130 includes acentral lumen131athrough which thetether124 extends. Thelumen131aextends through the length of thewrapping pin130 and through thehub132, allowing the tether to extend proximally to thehandle mechanism102. In the open configuration, shown inFIG. 3E, thewrapping pin130 includes achannel131bformed on its underside. Thetether124 is able to be received in thechannel131b, although it is not necessarily retained therein. In the guided configuration, shown inFIG. 3F, thewrapping pin130 includes achannel131bformed on its underside. Atether guide135 is located in thechannel131b,and is preferably attached to thehandle housing152 by welding, adhesive, or other suitable method. Thetether124 is routed through theguide135, and is thereby retained within theguide135.
• Anosecone shaft136 is located internally of thewrapping pin shaft134. Thenosecone118 is attached to thenosecone shaft136, and thenosecone shaft136 is slidably received through thewrapping pin hub132. However, thenosecone shaft136 is fixed to thewrapping pin stabilizer133. Thus, longitudinal movement of thenosecone shaft136 causes longitudinal movement of thenosecone118 and thepin stabilizer133, independent of any of the other components of thedeployment mechanism104. However, rotation of thehandle housing152 causes rotation of thenosecone118, thepin stabilizer133, and the wrapping pins130. Thenosecone shaft136 is hollow, thereby defining aguidewire lumen137 through its center.
• A plurality of wrappingpin sockets138 are formed on the proximal side of thenosecone118. Eachsocket138 is generally cylindrical and has a size adapted to receive the distal portion of awrapping pin130 therein. When the distal ends of the wrapping pins130 are engaged with theirrespective sockets138, thesockets138 provide support and rigidity to the wrapping pins130. This support and rigidity is particularly needed during the wrapping and unwrapping of the prosthetic valve, as described more fully below. During those operations, a large amount of strain is imparted to each of the wrapping pins130, which strain is absorbed in part by thesockets138 formed in thenosecone118. Eachsocket138 is also provided with ahole140 that provides access to arespective throughhole122 in thenosecone118. As described more fully below, this provides a passage for atether124 that is contained within each wrappingpin130 to extend through thehole140 in each socket, through thethroughhole122 to the distal end of thenosecone118.
• Although it is not shown in the cross-sectional view inFIG. 3A, aprosthetic valve30 such as the type described herein in relation to FIGS.1A-C—and in the '126 application—may be retained on the wrapping pins130 in the interior of the slottedtube110. A suitable method for loading thevalve30 into the device will be described below. Thevalve30 is retained in a contracted, multi-lobe state (see, e.g.,FIG. 1C) in which each “lobe” is generally wrapped around arespective wrapping pin130, and held in place there by engagement with the interior surface of the slottedtube110.
• Turning now toFIGS. 4-6, thehandle mechanism102 will be described. Thehandle mechanism102 includes a slottedtube grip150 that is fixedly connected to theouter sheath112 while being slidably and rotatably mounted on ahandle housing152. Thehandle housing152 is a generally cylindrical hollow shaft. The slottedtube grip150 is preferably formed of or covered with a corrugated polymer or rubber material to provide the ability to easily grasp and manipulate thegrip150. Similarly, awrapping pin grip154, also preferably formed of or covered with a corrugated polymer or rubber material, is slidably mounted to thehandle housing152. Thewrapping pin grip154 includes abolt156 that extends through aslot158 formed in thehandle housing152, to engage the proximal end of thewrapping pin shaft134. Atether grip160 is slidably mounted over the proximal end of thehandle housing152. Thetether grip160 is also generally cylindrical, having a slightly larger diameter than thehandle housing152, thereby allowing thetether grip160 to slide over thehandle housing152 in a telescoping manner. A lockingscrew162 extends through aslot164 formed in thetether grip160 and into the side of thehandle housing152 near its proximal end. The lockingscrew162 allows the user to fix the position of thetether grip160 relative to thehandle housing152 by screwing the lockingscrew162 down.
• Three tether clamps166 extend from the proximal end of thetether grip160. Eachtether clamp166 is independently clamped to atether124 that extends through the catheter to its distal end, as explained in more detail herein. Eachtether clamp166 also includes a spring mechanism (not shown) that provides independent tensioning for eachtether124. The proximal end of thenosecone shaft136 extends out of the proximal end of thetether grip160, between the three tether clamps166, terminating in a small cylindricalnosecone shaft grip168. Theguidewire108 is shown extending out of the proximal end of thenosecone shaft136.
• The preferred embodiment of the valve delivery catheter so described is intended to be used to deliver and deploy a prosthetic device, such as a prosthetic heart valve, to a patient using minimally invasive surgical techniques. Turning toFIGS. 6-11, a representative method of use of the device will be described. The device is intended to be introduced to the vasculature of a patient over a standard guidewire that has been previously introduced by any known technique, with access via the femoral artery being the preferred method. The guidewire is advanced to the treatment location under x-ray or other guidance, such as to the root of a heart valve, such as the aortic valve. Once the guidewire is in place, thevalve delivery catheter100 is advanced over the guidewire until thedeployment mechanism104 reaches the treatment location. During the delivery process, the deployment mechanism is in the fully contracted state shown, for example, inFIGS. 2 and 3.
• Once thedeployment mechanism104 is located near the treatment location, the valve deployment process begins. Theguidewire108 is initially left in place through the deployment process, and is not withdrawn until a particular point in the process defined below. The valve deployment process includes manipulation of the slottedtube grip150, wrappingpin grip154, andtether grip160 located on thehandle mechanism102, which cause a series of manipulations of the slottedtube110, wrappingpin hub132 and wrappingpins130, and thetethers124, in order to release and deploy the prosthetic valve in a manner that provides control during deployment and the ability to precisely position, re-position, and (if necessary) retrieve the prosthetic valve at any time during the deployment process.FIG. 6 illustrates several of the positions of the components of thehandle mechanism102 during the preferred deployment process. These positions correspond to several of the delivery steps illustrated inFIGS. 7-11.
• As noted elsewhere herein, it is possible to provide valves that are contracted into other sizes and orientations (such as two lobes or four or more lobes), which would also include a delivery catheter having a different number of slots in the slottedtube110 and a different number of wrapping pins130. For clarity, the present description will focus entirely upon thevalve30 having threepanels36 and threehinges52, and adelivery catheter100 having threeslots114 in the slottedtube110 and three wrapping pins130.
• Turning toFIGS. 6 and 7, the first step in deploying theprosthetic valve30 is to partially expand the contracted valve from the “tri-lobe” shape (seeFIG. 1C) to the “tri-star” shape (seeFIG. 1B). This is done by causing relative rotation between the slottedtube110 and the wrapping pins130. As shown inFIG. 6, this is done by rotating the slottedtube grip150 around the longitudinal axis of the delivery catheter, thereby causing the slottedtube110 to rotate around the wrapping pins130, which are maintained stationary. This relative rotation is facilitated by the provision of thebearing128 in thenosecone118 of thedeployment mechanism104, as illustrated inFIG. 3A. As the slottedtube110 rotates relative to the wrapping pins130, each of thevertices58 of theprosthetic valve30 is caused to extend outward through itsrespective slot114 in the slottedtube110. Rotation of the slottedtube grip150 is stopped when thevalve30 achieves the “tri-star” shape shown inFIG. 7. At all times during the process up to this point, the adjustable components on the handle mechanism (i.e., thetether grip160, thewrapping pin grip154, and the slotted tube grip150) are maintained in position “a”, wherein thetether grip160 is in its fully retracted position, and thewrapping pin grip154 and slottedtube grip150 are each in their fully advanced positions.
• Turning next toFIGS. 6 and 8, the next step in the deployment process is to retract the slottedtube110 to further expose theprosthetic valve30. This is done by retracting the slottedtube grip150 to position “b” (FIG. 6) while maintaining thewrapping pin grip154 andtether grip160 in the same position “b”. Retracting the slottedtube110 causes thevalve30 to become more exposed, but thevalve30 is maintained in the “tri-star” shape by the wrapping pins130 which continue to engage each of the threepanels36 of thevalve30. Although not shown inFIG. 8, the distal ends of the wrapping pins130 also remain seated in thewrapping pin sockets138 located in the proximal-facing portion of thenosecone118. In this “b” position, thewrapping pin stabilizer133 is located just proximally of thevalve30 and is just distal of thewrapping pin hub132.
• Next, turning toFIGS. 6 and 9, the wrapping pins130 are retracted by retracting thewrapping pin grip154 to position “c” (as shown in the Figure, transitioning from position “b” to position “c” requires no adjustment of either the slottedtube grip150 or the tether grip160). Retracting the wrapping pins130 causes the wrapping pins130 to become disengaged from thevalve30 and to retract to the interior of the slottedtube110. Thewrapping pin stabilizer133, which is fixed to thenosecone shaft136, slides along the length of the wrapping pins130 until maximum retraction of the wrapping pins130, which corresponds to the position shown inFIG. 9, with thestabilizer133 near the distal ends of each of the wrapping pins130. In this position, thestabilizer133 provides support and rigidity to thenosecone shaft136, which is otherwise only supported by thewrapping pin hub132. As shown, for example, inFIG. 9, thestabilizer133 effectively decreases the cantilever length of thenosecone shaft136, thereby providing it with increased stability. Thestabilizer133 also serves as a backing member for theprosthetic valve30, preventing thevalve30 from moving proximally as the wrapping pins130 are retracted. Further, thestabilizer133 also serves as a guide for thetethers124 as they extend from the distal ends of the wrapping pins130.
• The valve remains in the “tri-star” position due to the presence of thetethers124, the spacing of which is maintained by the holes in thestabilizer133 through which the wrapping pins130 andtethers124 extend. In the preferred embodiment shown inFIGS. 9 and 9A, atether124 extends through each of the wrapping pins130, through thehole140 in thesocket138, through thethroughholes122 in thenosecone118, and is looped around theguidewire108 on the distal side of thenosecone118. Thetethers124 each extend proximally through and within thecatheter shaft106 and is received and retained in itsrespective tether clamp166 near the proximal end of thecatheter100. In the position shown inFIG. 9, thetethers124 are all maintained sufficiently taut that they retain thevalve30 in the “tri-star” orientation shown in the Figure. This corresponds with position “c” of thetether grip160 relative to thehandle housing152, shown inFIG. 6.
• In an alternative embodiment, thetethers124 may be tensioned by manipulation of the distal connection of thetethers124 to theguidewire108. For example, rotation of thenosecone shaft136 will cause thetethers124 to wrap around theguidewire108, thereby providing tension to thetethers124. Other suitable methods for tensioning thetethers124 are also contemplated, as will be understood by those skilled in the art.
• Turning next toFIGS. 6 and 10, expansion of thevalve30 is obtained by loosening thetethers124 that otherwise hold thevalve30 in the “tri-star” position. This transition is achieved by advancing thetether grip160 to position “d”, as shown inFIG. 6. (Note: Transitioning from position “c” to position “d” requires no adjustment of either the slottedtube grip150 or the wrapping pin grip154). Advancement of thetether grip160 relative to thehandle housing152 creates slack in thetethers124, which slack is taken up by the radial expansion of thevalve30. In the typical deployment, thevalve30 will automatically fully expand to the deployment position shown inFIG. 10 when the tension is released from thetethers124. For those situations in which thevalve30 does not automatically expand, or when the valve only partially expands, one or more alternative mechanisms and/or methods may be utilized to obtain full expansion. Several of these preferred mechanisms and methods are described below in Section B.
• It is significant that, in the position shown inFIG. 10, thetethers124 no longer interfere with the expansion of thevalve30, but they remain in control of thevalve30. In this position, it is possible to make any final positional adjustments of thevalve30, if necessary. This can be done by simply advancing or withdrawing thecatheter100, which tends to drag or push thevalve30 along with it. This may also be facilitated by slight advancement of thewrapping pin grip154 and/or retraction of thetether grip160, each of which actions will tend to apply tension to thetethers154. In this manner, the valve position may be adjusted by the user while the valve is in its fully expanded state, under control of thetethers124.
• Alternatively, thevalve30 may be partially or fully contracted once again by increasing the tension on thetethers124, as by retracting thetether grip160 relative to thehandle housing152. (I.e., moving from position “d” to position “c” inFIG. 6). If necessary, thevalve30 may be fully contracted by retracting thetether grip160, and then thedeployment mechanism104 may be fully restored to the undeployed position by simply reversing the above steps, in order. (I.e., moving to position “c”, then position “b”, then position “a”). This reversal of the process includes a step of advancing the wrapping pins130 back over the contracted valve panels as thevalve30 is maintained in the “tri-star” shape. This process is facilitated by the presence of thetethers124, which act as guides for the wrapping pins130 to “ride up” over the edges of the valve panels under the guidance of thetethers124. Once the wrapping pins130 are in place, the slottedtube110 is advanced over thevalve30, with each of the vertices of the valve “tri-star” extending through itsrespective slot114. The slottedtube110 is then rotated relative to the wrapping pins130 andvalve30, causing the valve to transition to the fully contracted “tri-lobe” shape fully contained within the slottedtube110. At that point, the delivery catheter may be removed from the patient without deploying thevalve30. Any or all of these adjustment or removal steps may be taken, depending upon the clinical need or depending upon any situation that may arise during the deployment procedure.
• Turning toFIGS. 6 and 11, assuming that thevalve30 is placed in its final position and is ready to be released, the valve is released from thedelivery catheter100 by retracting theguidewire108 to a position such that the distal end of theguidewire108 no longer extends past the distal end of thenosecone118 of thedelivery catheter100. At this point, thetethers124 are released from their engagement with theguidewire108. Preferably, thetethers124 are then retracted at least into the wrapping pins130, and may alternatively be fully retracted through and from the proximal end of thedelivery catheter100. This is reflected as handle position “f” inFIG. 6, in which thetether grip160 is retracted at least to its initial position, and no change is made to the positions of either thewrapping pin grip154 or the slottedtube grip150. As shown inFIG. 11, thevalve30 is completely free from thedelivery catheter100. Thenosecone118 remains distal of thevalve30, and thenosecone shaft136 extends through the body of thevalve30.
• To complete the delivery process, the delivery catheter is preferably contracted to its pre-delivery state by advancing the wrapping pins130 into engagement with thenosecone118 by advancing thewrapping pin grip154 on the handle back to position “a”, then by advancing the slottedtube110 into engagement with theretainer ring116 by advancing the slottedtube grip150 on the handle back to position “a”. At this point, thedelivery catheter100 may be removed from the patient, leaving theprosthetic valve30 in place.
• B. Variations in Construction, Components, and/or Features of Delivery Device
• Preferred delivery catheters and methods of use are described above. A number of variations of several of the components, features, and other aspects of the device have been contemplated, and are described below.
• Turning first toFIGS. 12A-B, an alternative method of connecting thetethers124 to theguidewire108 is shown. In the embodiment described above, thetethers124 are looped over theguidewire108. In the embodiment shown inFIGS. 12A-B, eachtether124 has aneyelet125 formed at its distal end. Theeyelet125 is connected to the tether by an adhesive bond, or by crimping, or by any other suitable method. Eacheyelet125 has a hole formed at its distal end that is large enough to accommodate theguidewire108 extending therethrough. Theeyelet125 may have a generally curved shape to rest alongside thenosecone118, and a terminal end that is generally perpendicular to the longitudinal axis defined by theguidewire108.
• Turning toFIGS. 12C-D, anoptional recess131 may be formed in the distal end of each of the wrapping pins130. Therecess131 is preferably formed having a shape and size to accommodate theeyelet125 that is optionally provided at the distal end of each of thetethers124. Accordingly, when norecess131 is available (see, e.g.,FIG. 12C), theeyelet125 may be unable to be withdrawn into the lumen provided for passage of thetether124. When arecess131 is provided (see, e.g.,FIG. 12D), theeyelet125 is retracted into therecess131 and does not extend out of the distal end of thewrapping pin130.
• FIG. 12E illustrates an embodiment including a plurality of dual orredundant tethers124a-b. As shown in the Figure, a pair oftethers124a-bare provided on each of the panels of thevalve30. Thedual tethers124a-bmay be provided to increase tether strength, where needed, or to provide redundancy in the case of failure of one of the tethers.FIGS. 12F and 12G illustrate two possible methods for attaching thedual tethers124a-bto aguidewire108. In the first method, shown inFIG. 12F, acollar176 is formed near the distal ends of and is attached to both of thetethers124a-bnear their distal ends, thereby forming a loop through which theguidewire108 extends. In this construction, the loop will remain even if one of the tethers fails. In the second method, shown inFIG. 12G, each of thetethers124a-bincludes a separate attachment loop178a-b, through which theguidewire108 extends. In each method, thetethers124a-bare released when they are disengaged from theguidewire108 in the manner described above.
• Turning toFIG. 13, avalve stop142 may be provided on each of thetethers124. Eachvalve stop142 is in the form of a small cleat, barb, tab, or other transverse extension from thetether124. Thevalve stop142 is intended to provide another mechanism to prevent thevalve30 from slipping or migrating relative to thetethers124 when thetethers124 are in engagement with thevalve30. Thus, thevalve stop142 is located at a particular known position on eachtether124 to provide an optimal amount of control to thedevice100 when thetethers124 are engaged with thevalve30.
• FIGS. 14A-B illustrate tethers formed of linkages144 andtether sections146. Each tether includes aneyelet125 at its distal end connecting the tether to theguidewire108. Theeyelet125 is connected directly to afirst linkage member144a,which may comprise a relatively rigid member formed of a metallic material, a rigid polymeric material, or the like. The linkage144 is of a length sufficient to accommodate thevalve30 in its expanded state, as shown inFIG. 14A. Thefirst linkage144ais connected to atether section146 that extends through the length of thevalve30, and then connects to asecond linkage member144b.Thesecond linkage member144bthen connects to another section of thetether146, which extends proximally into the remainder of the delivery catheter. Eachlinkage member144a,144bincludes a pivot at each end thereof, thereby enabling thelinkage member144a,144bto pivot relative to the member to which it is attached. Thus, when the tethers are relaxed, thevalve30 is allowed to expand, as shown inFIG. 14A. However, when the tethers are pulled taut, thelinkages144a,144bpivot, thereby causing the tethers to become taut and to convert the valve to its “tri-star” shape, as shown inFIG. 14B. Preferably, thenosecone118 is provided with slots that accommodate thefirst linkage members144awhen they are pulled taut in the position shown inFIG. 14B.
• FIG. 15 illustrates a slight variation of the preferred embodiment described above. In this embodiment, thetethers124 each include aloop148 formed on their distal ends. Eachloop148 is adapted to engage theguidewire108. Thetethers124, in turn, are routed throughthroughholes122 formed in thenosecone118, as described above. Eachtether124 is then routed through a lumen formed in itsrespective wrapping pin130. This particular routing orientation provides a mechanical advantage over other routing orientation because the tethers are captured by thenosecone118 and wrappingpins130 in close relation to thevalve30. This orientation also results in less migration of the tethers from side-to-side relative to thevalve30.
• Turning next toFIGS. 16A-B, an alternative method for routing thetethers124 in and around thenosecone118 is to provide a plurality ofslots121 on the exterior of thenosecone118. Eachslot121 is adapted to receive and retain atether124 when thetethers124 are pulled taut. Theslots121 also allow the tethers to arise out of and disengage from itsrespective slot121, for example, when thetethers124 are slack and thevalve30 expands.
• FIG. 17 illustrates another embodiment containing tethers formed of two separate components, including a thick, or broadprimary tether124aand a thin, or narrowsecondary tether124b.Theprimary tether124amay be formed of a round or flat wire, and may be provided as either a straight component or it may be provided with a degree of shape memory. Thesecondary tether124bmay be made from a finer, smaller diameter material that is less traumatic to the vessel when it is pulled from between thevalve30 and the vessel. Thesecondary tether124bmay also be more easily retracted through the wrapping pins130. Although a two-component tether124 is shown, it should be appreciated that three or more components may also be incorporated to make up thetether124 and to obtain various performance characteristics.
• Turning next toFIGS. 18A-B, a pair ofloops170 are shown formed on the external surface of thevalve30. Theloops170 are intended to provide an engagement member on the surface of thevalve30 for thetethers124 to engage to prevent thetethers124 from migrating on the surface of thevalve30. For example, if thetether124 migrates from the centerline of avalve panel36, it may no longer have the ability to cause thevalve panel36 to invert or to restrain it in its inverted shape. By providing theloops170, such migration of thetethers124 is substantially prevented. It will be appreciated that mechanisms other thanloops170 may also be provided to restrain tether migration. For example, holes, barbs, slots, bumps, or other members may be provided on the surface or integrated into the body of thevalve panel36 to substantially restrain tether migration. One or more such members may be sufficient to provide sufficient restraining capability.
• Turning toFIGS. 19A-D, several alternative wrapping pin embodiments are illustrated. The alternative embodiments represent several methods by which wrapping pin deflection may be overcome. As shown, for example, inFIG. 19A, when thewrapping pin hub132 is rotated to cause wrapping up of aprosthetic valve30 by the wrapping pins130, an amount of torque “T” is imparted to thehub132, and a corresponding deflecting force “F” is imparted to the distal end of thewrapping pin130. The deflecting force “F” tends to cause thewrapping pin130 to deflect in the direction of the deflecting force “F”, which tends to interfere with the wrapping procedure. To counteract the deflection force, thewrapping pin130 may be formed having a gradual curving shape, as shown inFIG. 19B, to offset the deflection and to provide more even wrapping of thevalve30. The degree and nature of the curvature will vary depending upon the materials, sizes, and other properties of the delivery device and the valve, although the curvature will typically be directed toward the deflecting force. Alternatively, thewrapping pin130 may be attached to thehub132 at a fixed angle, or canted, as illustrated inFIG. 19C. Once again, the cant angle may be determined and will vary. Another alternative is shown inFIG. 19D, in which thewrapping pin130 is provided with an offset between its proximal and distal ends. Once again, the degree of offset may be varied according to need for a given device.
• Turning toFIGS. 20A-B, in several additional alternative embodiments, the wrapping pins330 are not fixed in shape or orientation relative to thehub332. In several such embodiments, the wrapping pins330 include articulatingsegments331 connected by rotatingjoints332, thereby allowing each wrappingpin330 to move radially relative to the longitudinal axis of the device. The concerted movement of the multiple wrapping pins330 (three pins being preferred, but more or fewer also being possible) allows the structure to act as a gripper for manipulating theprosthetic valve30. In the preferred embodiments, movement of each articulatedwrapping pin330 is independently controlled, thereby allowing the user to move each articulatedwrapping pin330 independently from a position generally comparable to that of the fixed wrapping pins330 illustrated in the drawings (seeFIG. 20A), to a position substantially radially outwardly spaced from the longitudinal axis of the device (seeFIG. 20B). Thus, the close-in position (FIG. 20A) is suitable for restraining the valve in its contracted or “tri-star” shape, while the radially spaced position (FIG. 20B) is suitable for releasing the valve to its expanded state, or for retrieving the valve from its expanded state in order to transition the valve back to its contracted state.
• FIGS. 21A-B illustrate an alternative construction for the slottedtube110. In this construction, each of thelongitudinal members180 forming the slottedtube110 includes aninternal base portion182 formed of a rigid material such as stainless steel or other metallic material, or a rigid polymeric material. Thebase portion182 is intended to provide strength and resiliency to the slottedtube110 to perform its functions of receiving, retaining, and manipulating thevalve30 in response to manipulations of the components contained on thehandle mechanism102 of the delivery catheter. Surrounding thebase portion182 of the slottedtube110 are a number ofair gaps184 and/or filledsections186 that are filled with a more flexible, less rigid material relative to the material forming thebase portion182. A wide variety of filler materials are possible, including several polymeric material such as polyurethane, or other soft materials such as one or more silicone based materials. The purpose for theair gaps184 and/or filledportions186 are to provide a less traumatic construction to reduce the likelihood of causing damage to thevalve30 or any of itspanels36 or hinges52 while the valve is being loaded, stored, or deployed. By providing anair gap184 or filledsections186 on the edges of thelongitudinal sections180 of the slottedtube110, thevalve30 is more protected during roll-up or deployment of the valve, during which time the edges of thelongitudinal members180 impose force against thevalve panels36 to cause them to roll up within thedeployment mechanism104 or to deploy out of the slottedtube110.
• Turning toFIG. 21C, another mechanism for protecting thevalve panels36 while they are retained within the slottedtube110 is comprised of a series ofrunners190 formed on the internal-facing surfaces of thelongitudinal members180 making up the slottedtube110. Therunners190 provide a raised surface upon which thepanels36 will ride to minimize the contact between thepanels36 and the slottedtube110. Therunners190 also serve to decrease friction between the two components and decrease the amount of abrasion that is imparted to the panels.
• FIGS. 22A-B illustrate another alternative construction for a portion of thedeployment mechanism104 of thedelivery catheter100. In this alternative construction, the wrapping pins130 are not needed. Instead, an inner slottedtube194 is provided coaxially with and interior to the outer slottedtube110. As the inner slottedtube194 is rotated relative to the outer slottedtube110, thevalve30 is converted from a “tri-star” shape to a “tri-lobe” shape, as shown, for example, inFIG. 22A. Reversing the relative rotation causes thevalve30 to extend out of the slots formed in each of the inner slottedtube194 and the outer slottedtube110 to form the “tri-star” shape shown inFIG. 22B. Thevalve30 may then be deployed by retracting both the inner slottedtube194 and the outer slottedtube110 relative to thevalve30, thereby allowing the valve to expand to its deployed state.
• FIGS. 23A-C illustrate an optional shape setnosecone shaft136. The shape setnosecone shaft136 includes a pre-set shape formed into the distal end of thenosecone shaft136 to facilitate the ability for the distal end of thedelivery catheter100 to pass over the aortic arch. This is particularly useful when thedelivery catheter100 is used for delivery of a prosthetic aortic valve. The shape set shown inFIG. 23A is generally in the form of a hook-shape, although other shapes is possible in order to improve the performance of the catheter. The shape set is also useful to stabilize the position of the catheter once it is delivered over the aortic arch. The shape set may be imparted by any mechanical or other method known to those skilled in the art. Anoptional tensioning member336 may be provided on the external surface of thenosecone shaft136. The tensioningmember336 is used to straighten the curvature of the shape setnosecone shaft136 under the user's control. For example, as a tension force “T” is imparted to thetensioning member336, such as by the user pulling proximally on thetensioning member336 from thehandle mechanism102, thenosecone shaft136 is straightened, as shown inFIG. 23C. The operation of the tensioningmember336 thereby provides the ability to manipulate the distal end of thedelivery catheter100 in a manner that provides an ability for the user to effectively steer the catheter over difficult or tortuous portions of the patient's vasculature. Other uses of the tensioningmember336 are described elsewhere herein.
C. Active Deployment of Undeployed and Not-Fully Deployed Valves
• Although typically aprosthetic valve30 such as those illustrated and described above in relation to FIGS.1A-C—and those described in the '126 application and elsewhere—will fully deploy once it is released from the delivery catheter, it sometimes occurs that the valve does not deploy, or does not fully deploy. In most of these circumstances, the failure to deploy or to fully deploy is due to the fact that one ormore panels36 of amulti-panel valve30 fails to change from its inverted state to its expanded state. One such example is illustrated inFIG. 24B, in which twopanels36 of a three-panelprosthetic valve30 have expanded, but theupper panel36 remains in a partially inverted state. Several mechanisms and methods for actively correcting these undeployed and not-fully deployed valves are described herein.
• Several of the described mechanisms take advantage of the fact that, in most circumstances of non-full deployment, only a point contact is needed to cause the valve to fully expand. Accordingly, it may not be necessary to fully occlude the vessel in order to cause the valve or similar prosthetic device to fully expand. Thus, in most of the mechanisms and methods described, fluid flow or perfusion is still allowed through the valve and vessel as the active deployment procedure takes place. This is to be distinguished from the deployment methods applicable to most stent-like prosthetic devices in which fibrillation is induced to decrease flow during the deployment procedure. No such fibrillation is required for delivery and deployment of the prosthetic valves and similar devices described herein, nor for the active deployment mechanisms and methods described.
• Turning toFIGS. 24A-C, a firstsuch mechanism200 includes acollar202 and a plurality ofwire forms204 extending proximally from thecollar202. Themechanism200 is intended to ride closely along thenosecone shaft136 on any of the embodiments of thedelivery catheter100 described herein. As themechanism200 is advanced distally, it will enter and pass through the body of the partially-expandedvalve30. Once it is located there, thecollar202 may be retracted proximally, as shown by the arrow “A” inFIG. 24A, thereby causing the wire forms204 to bow radially outward, (see, e.g.,FIGS. 24A and 24C), engaging anyinverted panels36 of thevalve30 and causing them to expand to the fully expanded state. Preferably, thecollar202 is retracted by a tether or other control member that is connected to thecollar202 and that extends proximally to the handle where it can be manipulated by the user. Once thevalve30 is fully expanded, thecollar202 is advanced distally to cause the wire forms204 to return to their unbowed state. Themechanism200 may then be retracted into thedelivery catheter100. In alternative embodiments, thecollar202 may be provided with threads that engage threads formed on thenosecone shaft136. Any other engagement providing relative movement between thecollar202 and thenosecone shaft136 is also suitable.
• As an alternative to the wire forms204 shown in the above embodiment, a continuous segment of metallic or polymeric material having sufficient elasticity to expand and contract in the manner shown may be used. Other alternatives including using only a single band or material, or two, three, or more bands. Other alternative constructions and materials capable of expanding and contracting in the involved space internal of the undeployed or partially deployedprosthetic valve30 are also contemplated, and are suitable for use as theactive deployment mechanism200 described herein.
• Another alternative construction for the active deployment mechanism is illustrated inFIGS. 25A-C. A partially deployedvalve30 includes anupper panel36 that has not yet fully deployed. Thedeployment mechanism200 comprises acollar212 and a plurality ofwire forms214 extending proximally from thecollar212. Prior to use, thecollar212 is located internally of thecatheter shaft106 along thenosecone shaft136, and the wire forms214 lie flat along thenosecone shaft136 proximally to thecollar212. (SeeFIG. 25A). Thecollar212 is advanced distally through the partially deployedvalve30 until thecollar212 engages the proximal side of thenosecone118, where further distal advancement is stopped. (SeeFIG. 25B). As additional distal-oriented force is applied to themechanism200, the wire forms214 are caused to bow radially outward within thevalve30 to cause theupper panel36 to fully deploy, as shown inFIG. 25C. Themechanism200 is then collapsed and retracted proximally.
• Turning toFIGS. 26A-E, several alternative balloon-based active deployment mechanism are described. The balloon-based systems include use of a balloon or other expandable member to cause an otherwise non-fully deployedvalve30 to expand to its fully expanded state upon deployment. Preferably, each of the balloons described herein includes an inflation lumen that is communicatively connected to thehandle mechanism102 or otherwise provided with a mechanism for selectively inflating the balloon(s) as needed.
• FIG. 26A illustrates a first embodiment in which aballoon220 is provided internally of aprosthetic valve30. Theballoon220 includes a pair ofbroad portions222athat correspond with the proximal and distal ends of thevalve30, and a narrowedwaist portion222bthat corresponds with the middle portion of thevalve30. Theballoon220 may optionally be provided in a fixed relationship with the valve body, as illustrated inFIG. 26B, wherein theballoon220 is packaged with thevalve30 as thevalve30 is loaded into the delivery catheter and delivered to a treatment location. Thus, if thevalve30 is found not to have fully expanded after deployment, theballoon220 may be inflated to cause full deployment.
• A number of optional balloon shapes and sizes are illustrated inFIGS. 26C-E. For example, inFIG. 26C, asingle balloon220 is shown having twolarge diameter portions222aand a narrow, orsmaller diameter portion222bconnecting the other two portions. InFIG. 26D, asingle balloon220 is shown, and would preferably extend through the entire length of thevalve30. InFIG. 26E, threeseparate balloons220a-care illustrated in an offset-tangent arrangement. The offset-tangent arrangement provides a number of benefits, including the ability to selectively inflate only one or more of theballoons220a-cdepending upon whichvalve panel36 requires expansion. Also, the offset-tangent arrangement removes the need to fully occlude the vessel, thereby allowing fluid to flow around the balloon structure.
• Turning toFIGS. 27A-B, in another alternative arrangement, a pair oftoroidal balloons226 are attached to the external surface of aprosthetic valve30 near its proximal and distal ends, respectively. The pair oftoroidal balloons226 may be selectively expandable in order to actively deploy an otherwise non-fully deployedprosthetic valve30. Upon expansion of the valve, theballoons226 may then be deflated and left in place to serve as a seal against thevessel wall230, as shown inFIG. 27B. Alternatively, thetoroidal balloons226 may be attached to the internal wall of theprosthetic valve30, and may then be selectively detached from thevalve30 after the valve has been fully deployed.
• FIG. 28 illustrates anotheractive deployment mechanism234 that includes aroller member236 and apincher member238, each of which may be included on the distal end of a shaft that may be included with, or separate from, thedelivery catheter100. Theroller236 andpincher238 advance along apanel36 until the components encounter ahinge52. Because of the diameter of theroller236 relative to thehinge52, when theroller236 andpincher238 engage thehinge52, they force thehinge52 to open, thereby causing thevalve panel36 to fully deploy.
• FIGS. 29A-B illustrate yet anotherdeployment mechanism242 that includes a wedge-shaped member having anupper guide244 and alower separator246. As with theprevious deployment mechanism234, thepresent embodiment242 be included on the distal end of a shaft that may be included with, or separate from, thedelivery catheter100. Thewedge mechanism242 is intended to be guided onto each of thehinges52 of the undeployed or not-fully deployedvalve30. Because of the relative size and shape of theseparator246 portion of the wedge, theseparator246 causes thehinges52 to open, thereby causing thevalve panels36 to expand to the fully deployed state.
• Turning next toFIG. 30, anotherdeployment mechanism250 includes atorsion spring252 mounted to the internal surface of thevalve30. Thetorsion spring252 may be integrated into and/or may form part of thehinge52 of thevalve30, but is provided with a pair ofarms254 that extend into the interior of thevalve30, and which are biased to force thevalve panels36 radially outward to fully deploy thevalve30. Thetorsion spring252 may be formed integrally with thevalve30, in which case it remains in place after valve deployment.
• Turning toFIGS. 31A-B, yet another active valve deployment mechanism256 includes amembrane balloon258 formed on or attached to the external surface of each of thelongitudinal members180 of the slottedtube110. The membrane balloons258 are selectively and independently inflatable, as needed to actively deploy one or more undeployed panels of aprosthetic valve30. As shown inFIG. 31A, the slottedtube110 is first inserted into thevalve30, then one or more of the membrane balloons258 is expanded. The expansion is initially to afirst state260 in which the membrane balloon engages thevalve body panels36, then, ultimately, to asecond state262 corresponding with full valve deployment. After deployment, the balloon may be deflated and the device removed from the patient's vasculature.
• Turning toFIG. 32, a still further alternative activevalve deployment mechanism266 includes a plurality of (preferably three)linkage members268, each including apivot270 allowing the linkage member to expand radially, such as under the expansion force of aninternal balloon272 or other expandable member. Thus, as thedeployment mechanism266 is inserted into the undeployedprosthetic valve30, it is able to be expanded by expanding or inflating theballoon272.
• FIGS. 33A-B illustrate anotheractive deployment mechanism276 that incorporates aballoon278 or other expandable member that is formed within the internal volume of thenosecone118. In its undeployed state, shown inFIG. 33A, theballoon278 does not extend past the distal end of thenosecone118. However, if needed to expand the undeployed or not-fully deployedvalve30, theballoon278 is expanded, as shown inFIG. 33B, thereby expanding thevalve30 to its expanded state.
• FIGS. 34A-C illustrate an active deployment mechanism that includes ayoke282 that is slidably engaged over thenosecone shaft136. A set of rotating linkages284a-fare connected to the slidingyoke282 such that, when theyoke282 slides proximally along thenosecone shaft136, as shown by the arrows “A” inFIG. 34A, the linkages284a-fextend radially outward from theshaft136. In the preferred embodiment, the free ends284d-fof each of the linkages284a-fare selectively attached to a respective panel of thevalve30 by a temporary mechanism. For example, the free ends284d-fof the linkages may be attached to the valve panels by thetethers124, such that when thetethers124 are retracted, the valve panels are released from the linkages284a-f. Thenosecone118 is preferably hollow to accommodate the mechanism prior to deployment.
• Another optional active deployment mechanism utilizes the shape setnosecone shaft136 and tensioningmember336 shown inFIGS. 23A-C. In the case of avalve30 that does not fully deploy, it may be possible to manipulate thetensioning member336 to cause either thenosecone118, thenosecone shaft136, or some other portion of thedeployment mechanism104 to engage the undeployed portion of the valve sufficiently to cause it to fully deploy. In a particularly preferred method, thetethers124 associated with all of the fully deployed panels are allowed to remain slack, while thetether124 associated with the undeployed panel is pulled taut to apply tension to the tether. By doing so, thenosecone118 and therespective wrapping pin130 are pulled to the respective distal and proximal edges of the valve panel, creating a relatively rigid linkage between the components. Once this is done, the tensioning member336 (or other suitable steering mechanism) is actuated in order to cause the relatively rigid linkage to bias the still-inverted panel radially outward to the expanded position. This process may be repeated for each panel that is not fully expanded.
• Finally, another alternative active deployment mechanism is to pressurize the aorta (or other treatment vessel) to cause the tissue defining the vessel to expand, thereby providing an adequate (increased) volume within which thevalve30 or other device is able to expand to its fully expanded state. Pressurization of the aorta (or other vessel) may be obtained by simply occluding the vessel, or by actively pressuring the vessel using an external source.
• The preferred embodiments of the inventions that are the subject of this application are described above in detail for the purpose of setting forth a complete disclosure and for the sake of explanation and clarity. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. Such alternatives, additions, modifications, and improvements may be made without departing from the scope of the present inventions, which is defined by the claims.

Claims (29)

1. Apparatus for delivering a prosthetic device to a treatment location within a patient by way of the patient's vasculature, comprising:

a catheter having proximal and distal ends, the distal end of said catheter being adapted to carry a prosthetic device, said prosthetic device having a longitudinal axis, a fully contracted state for delivery to a treatment location, and an expanded state for deployment at the treatment location, and

one or more tethers associated with said distal end of said catheter, said one or more tethers adapted to axially engage and to selectively restrain said prosthetic device.

2. The apparatus ofclaim 1, wherein said tethers are adapted to selectively restrain said prosthetic device in a partially contracted state different from said fully contracted state.

3. The apparatus ofclaim 2, wherein said prosthetic device comprises a multi-segment support member having segments that invert to form the partially contracted state.

4. The apparatus ofclaim 3, wherein said prosthetic device comprises a three-paneled, three-hinged support member, and wherein said partially contracted state comprises a tri-star.

5. The apparatus ofclaim 1, wherein said tethers are adapted to selectively restrain said prosthetic device in its expanded state.

6. The apparatus ofclaim 1, further comprising a tubular member carried on the distal end of said catheter and substantially surrounding said prosthetic device, said tubular member provided with a plurality of slots, a portion of said prosthetic device selectively extending through at least one of said plurality of slots when said prosthetic device is in a partially contracted state different from said fully contracted state.

7. The apparatus ofclaim 6, wherein rotation of said tubular member relative to said prosthetic device causes a portion of said prosthetic device to extend through at least one of said plurality of slots.

8. The apparatus ofclaim 7, further comprising a control member located on the proximal end of said catheter, said control member configured to cause rotation of said tubular member relative to said prosthetic device.

9. The apparatus ofclaim 8, wherein said control member is configured to retract said tubular member in a proximal direction relative to said prosthetic device such that the tubular member no longer substantially surrounds said prosthetic device.

10. The apparatus ofclaim 9, wherein said tethers are adapted to selectively restrain said prosthetic device in said partially contracted state.

11. The apparatus ofclaim 10, wherein said prosthetic device comprises a multi-segment support member having segments that invert to form the partially contracted state.

12. The apparatus ofclaim 11, wherein said prosthetic device comprises a three-paneled, three-hinged support member, and wherein said partially contracted state comprises a tri-star.

13. The apparatus ofclaim 6, further comprising a hub carrying a plurality of wrapping pins extending distally from said hub and being substantially surrounded by said tubular member, wherein said prosthetic device is carried on said wrapping pins when the prosthetic device is in its fully contracted state and its partially contracted state.

14. The apparatus ofclaim 13, wherein said prosthetic device is transformed from its fully contracted state to its partially contracted state by relative rotation between said tubular member and said hub carrying a plurality of wrapping pins.

15. The apparatus ofclaim 13, further comprising a control member located on the proximal end of said catheter, said control member configured to cause rotation of said tubular member relative to said prosthetic device.

16. The apparatus ofclaim 15, wherein said control member is configured to retract said tubular member in a proximal direction relative to said prosthetic device such that the tubular member no longer substantially surrounds said prosthetic device, and further wherein said control member is configured to independently retract said plurality of wrapping pins in a proximal direction relative to said prosthetic device such that the prosthetic device is no longer carried on said wrapping pins.

17. The apparatus ofclaim 16, wherein said tethers are adapted to selectively restrain said prosthetic device in said partially contracted state when said plurality of wrapping pins are retracted.

18. The apparatus ofclaim 17, wherein said prosthetic device comprises a multi-segment support member having segments that invert to form the partially contracted state.

19. The apparatus ofclaim 18, wherein said prosthetic device comprises a three-paneled, three-hinged support member, and wherein said partially contracted state comprises a tri-star.

20. The apparatus ofclaim 1, further comprising a deployment member adapted to convert the prosthetic device to its fully expanded state after the prosthetic device has been disengaged from the catheter.

21. The apparatus ofclaim 20, wherein said deployment member comprises a first movable member adapted to movably engage a shaft portion of said catheter, and a radially expandable member that is able to be selectively expanded radially by moving said movable member along said shaft portion.

22. The apparatus ofclaim 21, wherein said radially expandable member is caused to expand when said movable member moves distally along said shaft portion.

23. The apparatus ofclaim 20, wherein said deployment member comprises an inflatable member that is selectively located internally of said prosthetic device such that inflation of said inflatable member causes said prosthetic device to transition to its fully expanded state.

24. The apparatus ofclaim 23, wherein said deployment member comprises a plurality of inflatable members.

25. The apparatus ofclaim 23, wherein said inflatable member comprises a balloon having at least two portions having different radial dimensions.

26. The apparatus ofclaim 20, wherein said deployment member comprises an inflatable member that is selectively attached externally of said prosthetic device such that inflation of said inflatable member causes said prosthetic device to transition to its fully expanded state.

27. The apparatus ofclaim 20, wherein said deployment member comprises a roller that engages an interior surface of said prosthetic device, and a pincher that engages an external surface of said prosthetic device.

28. The apparatus ofclaim 20, wherein said deployment member comprises a separator that engages an internal surface of said prosthetic device, and a guide member that engages an external surface of said prosthetic device.

29. The apparatus ofclaim 20, wherein said deployment member comprises a torsional spring attached to a hinge formed on said prosthetic device.

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