US20210170162A1 - Percutaneous heart pump - Google Patents

Abstract

Disclosed herein are heart pumps that can include a catheter body and an impeller coupled with a distal end of the catheter body. The impeller can include a tip that is resealable or that includes a resealable member. The heart pump can also include a diffuser disposed between the distal end of the catheter body and the impeller, wherein the diffuser includes a flow directing surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application is a continuation of U.S. patent application Ser. No. 13/345,597, filed on Jan. 6, 2012, entitledPercutaneous Heart Pump,which claims priority to U.S. Provisional Application Ser. No. 61/430,537 filed Jan. 6, 2011, entitledPercutaneous Heart Pump,the contents of each of which are hereby incorporated by reference herein for all purposes.
BACKGROUND OF THE INVENTIONField of the Invention
• This application is directed to heart pumps that can be applied percutaneously.
Description of the Related Art
• Heart disease is a major health problem that claims many lives per year. After a heart attack, only a small number of patients can be treated with medicines or other non-invasive treatment. However, a significant number of patients can recover from a heart attack or cardiogenic shock if provided with mechanical circulatory support.
• In a conventional approach, a blood pump having a fixed cross-section is surgically inserted a heart chamber, such as into the left ventricle of the heart and the aortic arch to assist the pumping function of the heart. Other known applications involve providing for pumping venous blood from the right ventricle to the pulmonary artery for support of the right side of the heart. The object of the surgically inserted pump is to reduce the load on the heart muscle for a period of time, which may be as long as a week, allowing the affected heart muscle to recover and heal. Surgical insertion, however, can cause additional serious stresses in heart failure patients.
• Percutaneous insertion of a left ventricular assist device (“LVAD”), a right ventricular assist device (“RVAD”) or in some cases a system for both sides of the heart (sometimes called “biVAD”) therefore is desired. Conventional fixed cross-section ventricular assist devices designed to provide near full heart flow rate are too large to be advanced percutaneously, e.g., through the femoral artery. There is an urgent need for a pumping device that can be inserted percutaneous and also provide full cardiac rate flows of the left, right, or both the left and right sides of the heart when called for.
SUMMARY OF THE INVENTION
• In one embodiment, a heart pump is provided that includes a catheter body, a housing, an impeller, and a diffuser. The catheter body includes a proximal end, a distal end, and an elongate body extending therebetween. The housing is coupled with the distal end of the catheter body and comprises a distal opening and a proximal opening. The impeller assembly is coupled with the distal end of the catheter body and positioned within the housing. The diffuser can include a flow directing surface. The diffuser is disposed between the distal end of the catheter body and the impeller. The diffuser is configured to be positioned within the housing and adjacent the proximal opening.
• In another embodiment, a heart pump is provided that includes a catheter body comprising a proximal end, a distal end, and an elongate body extending therebetween. The pump also includes an impeller coupled with the distal end of the catheter body and comprising an axial lumen passing through a distal end of the impeller. The impeller comprises a tip positioned at the distal end of the impeller, the tip comprising a resealable member having a resealable path.
• In another embodiment, a heart pump is provided that comprises a catheter body, an impeller, and a sheath. The catheter body has a proximal end, a distal end, and an elongate structure extending therebetween. The impeller is coupled with the distal end of the catheter body. The sheath is disposed over at least a portion of the distal end of the catheter body. The sheath also has an expandable distal end.
• In another embodiment, a catheter assembly is provided that includes a catheter body, an impeller, and a deployment device. The catheter body comprises a proximal end, a distal end, and an elongate structure extending therebetween. The impeller is configured for relative motion in an axial direction, and is located at the distal end of the catheter body. The deployment device is located at the proximal end of the catheter assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
• A more complete appreciation of the subject matter of the present inventions and the various advantages thereof can be realized by reference to the following detailed description, in which reference is made to the accompanying drawings in which:
• FIG. 1 illustrates one embodiment of a heart pump configured for percutaneous application and operation;
• FIG. 1A is a plan view of one embodiment of a catheter assembly adapted to be used with the heart pump ofFIG. 1;
• FIG. 2 is a detail view of a distal portion of the catheter assembly illustrated inFIG. 1A;
• FIG. 3 is an exploded view of a portion of an impeller assembly of the catheter assembly ofFIG. 1A;
• FIG. 4A is a cross-sectional view of a distal portion of the catheter assembly, taken through thesection plane4A-4A shown inFIG. 2;
• FIG. 4B is a detail view of the distal portion of the catheter assembly, taken at4B-4B shown inFIG. 4A;
• FIG. 5 is a cross-sectional perspective view of a bearing assembly of the catheter assembly ofFIG. 1A;
• FIG. 6 is a cross-sectional view of a bearing housing of the bearing assembly ofFIG. 5;
• FIG. 7 is a perspective view of one embodiment of a catheter body that can be used to house a drive shaft and to convey an infusant to the bearing housing ofFIG. 5;
• FIGS. 7A-7C show variations of the catheter body ofFIG. 7;
• FIG. 8 illustrates a surface configuration of one embodiment of a bearing adapted to enhance or control flow of an infusant in the bearing assembly ofFIG. 5;
• FIG. 9 illustrates one embodiment of an impeller assembly;
• FIGS. 9A, 9B-1, 9B-2, 10 and 10A illustrate details of further embodiments of impeller blades;
• FIG. 11 is a cross-sectional view of a proximal portion of the catheter assembly, taken through the section plane11-11 onFIG. 1A;
• FIGS. 12, 12A, and 12B are cross-section views similar to that ofFIG. 11, illustrating an infusant outflow path;
• FIGS. 13A-B are cross-sectional views of two embodiments of a blood pump that includes a diffuser;
• FIGS. 14A-B are partial cross-sectional views illustrating one embodiment of a blood pump including a retractable impeller assembly in deployed and retracted configurations, respectively;
• FIGS. 15A-B illustrate a deployment device disposed at the proximal end of a catheter assembly illustrated inFIGS. 14A-B in deployed and retracted configurations, respectively;
• FIG. 15C is a cross-sectional view of a structure for actuating the deployment device illustrated inFIGS. 15A-B;
• FIGS. 15D-F illustrate further embodiments of deployment devices that can actuate the catheter assembly between deployed and retracted configurations;
• FIGS. 16A-C are cross-sectional views of three embodiments of a self-sealing impeller tip; and
• FIGS. 17A-D are perspective views of variations of a sheath assembly having an expandable distal portion.
• A more detailed description of various embodiments of components for heart pumps useful to treat patients experiencing cardiac stress, including acute heart failure, are set forth below.
DETAILED DESCRIPTION
• Major components of heart pumps that can be applied percutaneously to a patient are described below in Section I. Section II describes various structures that facilitate the rotatable support of a cantilevered impeller. Section III describes various structures that facilitate deployment and/or retrieval of one or more components of thedistal end108 of theheart pump10 within the cardiovascular system. Section IV describes various methods and techniques in connection with specific structures of heart pumps
I. Overview of Heart Pumps
• FIG. 1 illustrates one embodiment of aheart pump10 that includes acatheter assembly100 having aproximal end104 adapted to connect to amotor14 and a distal end108 (seeFIG. 1A) adapted to be inserted percutaneously into a patient. Themotor14 is connected by asignal line18 to acontrol module22 that provides power and/or control signals to themotor14. As discussed further below, theheart pump10 in various embodiments has aninfusion system26 and apatient monitoring system30.
• Theinfusion system26 can provide a number of benefits to theheart pump10 which are discussed below. In one embodiment, theinfusion system26 includes a source ofinfusant34, afluid conduit38 extending from theinfusant source34 to theproximal end104 of thecatheter assembly100 and afluid conduit42 extending from the proximal end of thecatheter assembly100 to awaste container46. The flow of infusant to and from thecatheter assembly100 can be by any means, including a gravity system or one or more pumps. In the illustrated embodiment, theinfusant source34 includes anelevated container50, which may be saline or another infusant as discussed below. Flow from theelevated container50 can be regulated by apressure cuff54 to elevate the pressure of the fluid in thecontainer50 to increase flow or by apinch valve58 or by other means.
• Thepatient monitoring system30 can be used to monitor the operation of the patient and/or thepump10. For example, thepatient monitoring system30 can include auser interface60 coupled with a source ofdata64. Thedata source64 can include one or more patient conditions sensors, such aspressure sensors68 that are in pressure communication with the patient and/or operating components within the patient. In one embodiment, thepressure sensors68 fluidly communicate by aconduit72 that extends between the sensors and a proximal portion of thecatheter assembly100. Theconduit72 can include a plurality of separable segments and can include avalve76 to enable or disable the pressure communication to thesensors68.
• Theheart pump10 is adapted to provide an acute or other short-term treatment. A short-term treatment can be for less than a day or up to several days or weeks in some cases. With certain configurations thepump10 can be used for a month or more.
• Thecatheter assembly100 extends between theproximal end104 and thedistal end108. Animpeller assembly116 disposed at thedistal end108 is configured to pump blood to convey blood from one body cavity to another. In one arrangement, theimpeller assembly116 conveys blood proximally through or along a portion of thecatheter assembly100 to provide assistance to the left ventricle of the heart. In another embodiment, theimpeller assembly116 conveys blood distally through or along a portion of thecatheter assembly100 to provide assistance to the right ventricle of the heart. Theheart pump10 is useful as a heart assist device for treating patients with acute heart failure or other heart maladies. Theheart pump10 also can be used in connection with a surgical treatment to support the patient without providing full cardiovascular bypass. A patient could be supported on the device for longer term with proper controls and design.
• Thecatheter assembly100 is provided with a low profile configuration for percutaneous insertion. For example, thedistal end108 of thecatheter assembly100 can be configured to have about an 11 French (approximately 3.5 mm) size in a first configuration for insertion and an expanded configuration, such as up to about 21 French (approximately 7 mm), once positioned in the body. The larger size facilitates greater flow rates by theimpeller assembly116 as discussed below.
• Thecatheter assembly100 is configured to enable thedistal end108 to reach a heart chamber after being inserted initially into a peripheral vessel. For example, thecatheter assembly100 can have a suitable length to reach the left ventricle and sufficient pushability and torquability to traverse the intervening vasculature. Thecatheter assembly100 may includes amultilumen catheter body120 that is arranged to facilitate delivery and operation of theimpeller assembly116. Further details concerning various embodiments of thecatheter body120 are discussed below in connection withFIGS. 7-7C.
• A drive system is provided to drive an impeller within theimpeller assembly116. The drive system includes amotor14 and a suitably configured drive controller (not shown) disposed within thecontrol module22. Themotor14 is in various embodiments is configured to be disposed outside the patient, e.g., adjacent to theproximal end104 of thecatheter assembly100. In one advantageous embodiment, the drive system employs a magnetic drive arrangement. Themotor14 is arranged to generate magnetic fields that will be sensed by permanent magnets disposed within theproximal end104 of thecatheter assembly100. This arrangement facilitates very efficient generation of torque used to drive theimpeller assembly116, as discussed below.
• Some embodiments described herein could be incorporated into a system in which a motor is miniaturized sufficiently to be inserted into the patient in use, including into the vasculature. Such an embodiment could be operated by disposing control signal lines within the proximal portion of thecatheter body120. Also, it may be useful to provide the capability to measure blood pressure at thedistal end108 using a device disposed at theproximal end104. For example, a pressure sensor at the distal end can communicate with a device outside the patient through a lumen of thecatheter body120. Various details of these optional features are described in U.S. Pat. No. 7,070,555, which is incorporated by reference herein for all purposes and in its entirety.
• In another embodiment, a mechanical interface can be provided between the motor and theproximal end104 of thecatheter assembly100. The mechanical interface can be between themotor14 and a drive shaft positioned at the proximal end of thecatheter assembly100.
• A torque coupling system is provided for transferring torque generated by the drive system to theimpeller assembly116. The torque coupling system is discussed further in Section II(C)—Torque Coupling System (as discussed below), but in general can include magnetic interface between themotor14 and adrive assembly146 disposed at theproximal end104 of thecatheter assembly100. Thedrive assembly146 is coupled with a proximal end of anelongate drive shaft148 in one embodiment. Thedrive shaft148 extends between thedrive assembly146 and theimpeller assembly116. A distal portion of thedrive shaft148 is coupled with theimpeller assembly116 as discussed below in connection with one embodiment illustrated inFIGS. 4A and 4B.FIG. 11 shows one manner of coupling the proximal end of thedrive shaft148 with thedrive assembly146.
• As discussed above, theheart pump10 may also includes aninfusion system26. Figure lA shows that theinfusion system26 can include aninfusion inflow assembly150 provided adjacent to theproximal end104 in one embodiment. Theinfusion assembly150 can be one component of an infusion system that is configured to convey one or more fluids within thecatheter assembly100. The fluids can be conveyed distally within thecatheter assembly100, e.g., within thecatheter body120, to facilitate operation of theimpeller assembly116, some aspect of a treatment, or both. In one embodiment, the infusion system is configured to convey a lubricant, which can be saline, glucose, lactated Ringer's solution, acetated Ringer's solution, Hartmann's solution (e.g., including compound sodium lactate), and D5W dextrose solution. In another embodiment, the infusion system is configured to convey a medication, or a substance that both acts as lubricant and medication. As sometimes used herein “infusant” is intended to be a broad term that includes any fluid or other matter that provides performance enhancement of a component of theheart pump10 or therapeutic benefit, and can be wholly or partly extracted from the system during or after operation of the pump.
• In one embodiment, theinfusion inflow assembly150 includes acatheter body154 having a luer or othersuitable connector158 disposed at a proximal end thereof and an inflow port in fluid communication with one or more lumens within thecatheter assembly100. A lumen extending through thecatheter body154 is adapted to be fluidly coupled with a fluid source connected to theconnector158 to deliver the fluid into thecatheter assembly100 and through one or more flow paths as discussed below in connection withFIGS. 4A, 4B, and 7-7C.
• FIGS 1A and 12 show that thecatheter assembly100 in various embodiments also includes an outlet positioned at a location that is outside the patient when theheart pump10 is in use to allow infusant to be removed from the pump and from the patient during or after the treatment. The outlet can be fluidly coupled with an infusant return flow path in thecatheter body120 through a fluid port144 disposed at theproximal end104.
• Thecatheter assembly100 can also include asheath assembly162 configured to constrain theimpeller assembly116 in a low profile configuration in a first state and to permit theimpeller assembly116 to expand to the enlarged configuration in a second state. Thesheath assembly162 has aproximal end166, adistal end170, and anelongate body174 extending therebetween. In one embodiment, theelongate body174 has a lumen extending between the proximal anddistal ends166,170, the lumen being configured to be slidably disposed over thecatheter body120. The arrangement permits thesheath assembly162 to be actuated between an advanced position and a retracted position. The retracted position is one example of a second state enabling theimpeller assembly116 to expand to an enlarged configuration. The advanced position is one example of a first state that enables theimpeller assembly116 to be collapsed to the low profile configuration. In some embodiments, aluer102 or other suitable connector is in fluid communication with theproximal end166 of thesheath assembly162. Theluer102 can be configured to deliver fluids to thecatheter assembly100, such as priming fluid, infusant, or any other suitable fluid.
• FIG. 1A illustrates a retracted position, in which thedistal end170 of theelongate body174 is at a position proximal of theimpeller assembly116. In an advanced position, thedistal end170 of theelongate body174 is positioned distal of at least a portion of theimpeller assembly116. Thesheath assembly162 can be configured such that distal advancement of thedistal end170 over theimpeller assembly116 actuates theimpeller assembly116 from an enlarged state to a more compact state (or low profile configuration), e.g., causing a change from the second state to the first state, as discussed above.
• FIGS. 4A & 4B show theelongate body174 as a single layer structure from the inner surface to the outer surface thereof. In another embodiment, theelongate body174 has a multilayer construction. In one arrangement, theelongate body174 has a first layer that is exposed to thecatheter body120 and a second layer exposed that corresponds to an outer surface of thecatheter assembly100. A third layer can be disposed between the first and second layers to reinforce theelongate body174, particularly adjacent to the distal end thereof to facilitate collapse of theimpeller assembly116. In another construction, a reinforcing structure can be embedded in an otherwise continuous tubular structure forming theelongate body174. For example, in some embodiments, theelongate body174 can be reinforced with a metallic coil.
• FIG. 2 show that animpeller housing202 is disposed at thedistal end108. Theimpeller housing202 can be considered part of theimpeller assembly116 in that it houses an impeller and provides clearance between the impeller and the anatomy to prevent any harmful interactions therebetween. Thehousing202 and the impeller are also carefully integrated to maintain an appropriate flow regime, e.g., from distal to proximal or from proximal to distal within the housing.
• FIGS. 1A and 2 also show that thedistal end108 of thecatheter assembly100 includes anatraumatic tip182 disposed distal of theimpeller assembly116 in one embodiment.FIG. 1A shows that theatraumatic tip182 can have an arcuate configuration such that interactions with the vasculature are minimally traumatic. Thetip182 can also be configured as a positioning member. In particular, thetip182 can be rigid enough to help in positioning theimpeller assembly116 relative to the anatomy. In one embodiment, thetip182 is rigid enough that when it is urged against a heart structure such as the ventricle wall, a tactile feedback is provided to the clinician indicating that theimpeller assembly182 is properly positioned against the heart structure.
II. Impeller Rotation and Support
• Theimpeller assembly116 can take any suitable form, but in various embodiments includes animpeller200 adapted to move a fluid such as blood from an inlet to an outlet of thecatheter assembly100. In certain embodiments theimpeller200 can be cantilevered or otherwise supported for rotation primarily at one end.
• FIG. 3 shows that theimpeller200 includes ashaft204, a central body orhub208, and one ormore blades212.
• Theshaft204 andhub208 can be joined in any suitable fashion, such as by embedding a distal portion of the shaft within thehub208. Theblades212 can be spaced out proximal to distal along the axis of the shaft. In some embodiments, theblades212 are provided in blade rows.FIG. 9 shows that the distal end of theshaft204 can extend at least to an axial position corresponding to one of the blade rows. In some embodiments, theshaft204 can be solid. In other embodiments, theshaft204 has a lumen extending axially through the hub so that a guidewire can be passed through thecatheter assembly100. Details of variations with a lumen are discussed further in U.S. application Ser. No. 12/829359, filed Jul. 1, 2010, titledBlood Pump With Expandable Cannula,which is hereby incorporated by reference herein in its entirety and for all purposes.
A. Infusant Delivery and Removal System
• The operation and duty cycle of theimpeller assembly116 can be lengthened by providing a hydrodynamic bearing for supporting theshaft204. A hydrodynamic bearing can be supported by a lubricant, such as isotonic saline, which can be delivered in a continuous flow. The lubricant can be delivered through the infusion system to an outside surface of theshaft204. The infusant may be directed onto the shaft from a radially outward location. In some arrangements, the lubricant flow is controlled such that of a total lubricant volume introduced into the proximal end of the cannula, a first portion of the total volume of the lubricant flows proximally along theshaft204. In some embodiments, a second portion of the total volume flows distally along the shaft, the first volume being different from the second volume. The second portion of the total volume can be substantially equal to the total volume introduced into the proximal end of the cannula less the first volume.
• FIGS. 3 to 8 show various structures for providing rotational support of a proximal portion of theshaft204 within the distal portion of thecatheter assembly100. For example, as shown inFIG. 3, a bearingassembly220 can be disposed at adistal end224 of themultilumen catheter body120. In one embodiment, the bearingassembly224 includes a housing228 (as shown inFIG. 4B) and one or more bearings configured to support the proximal portion of theshaft204. The bearingassembly224, as illustrated in more detail inFIG. 4B, includes a plurality ofbearings232a,232bdisposed within the bearinghousing228. Various materials that can be used for the bearings are discussed below.
• FIG. 6 shows that the bearinghousing228 has alumen234 extending therethrough with a proximalenlarged portion236aand a distalenlarged portion236b.Thehousing228 comprises a shoulder defining anarrow portion240 of thelumen234 disposed between theenlarged portions236a,236b.The first andsecond bearings232a,232bcan be disposed within theenlarged portions236a,2366bof the bearinghousing228.
• In one arrangement, the proximal end of the shaft204 (e.g., as shown inFIG. 4A) is received in and extends proximally of thesecond bearing232b.In some embodiments there can be one bearing (e.g., only bearing232a), while in other embodiments bothbearings232aand232bcan be used. In some embodiments, the bearing(s), e.g.,bearings232aand/or232b,can be friction fit or interference fit onto theimpeller shaft204. Accordingly, theshaft204 can be supported for rotation by thebearings232a,232bas well as in thenarrow portion240 of thehousing228. In embodiments where the bearing(s)232a,232bare friction or interference fit onto the shaft, the bearing(s)232a,232bcan be configured to rotate with theshaft204 relative to the bearinghousing228. Further, the bearing(s)232a,232bcan have a relatively large clearance with the bearinghousing228. The clearance between theshaft204 and the bearinghousing228, at regions that are not coupled with the bearing, can be in the range of about 0.0005 to about 0.001 inch. In certain embodiments, the clearance can be within a larger range, such as at least about 0.0005 inches, about 0.001 inches or up to about 0.005 inches. In embodiments with multiple bearing(s)232a,232b,the clearance can be different for thebearings232a,232b,such as providing a larger clearance at theproximal bearing232a.
• In other embodiments, such as inFIG. 5, the bearing(s)232a,232bmay not be friction or interference fit onto theshaft204. In these embodiments, the bearing(s)232a,232bmay be disposed within the bearinghousing228, for example by an interference or press fit. Theshaft204 may then rotate with respect to the bearing(s)232a,232b,and there can be a clearance between theshaft204 and the bearing(s)232a,232b.The clearance between theshaft204 and thebearings232a,232bcan be in the range of about 0.0005 to about 0.001 inch. In certain embodiments, the clearance can be within a larger range, such as at least about 0.0005 inches, about 0.001 inches or up to about 0.005 inches. The clearance can be different for thebearings232a,232b,such as providing a larger clearance at theproximal bearing232a.In certain embodiments, the bearinghousing228 may provide a thrust surface for bearing axial loads. In other embodiments, there may be other bearings located either distally or proximally of the bearinghousing228 that are configured to bear axial loads. In other embodiments, the fit between thebearings232a,232band theshaft204 can be tight, which can also assist in bearing axial loads in some aspects.
• At least the proximal portion of theshaft204 can be made of a material that will not corrode or otherwise be made to be inert when immersed in the lubricant or other infusant. The material may be one that will not corrode in isotonic saline. Suitable materials may include a wide variety of metals, including alloys, and at least saline-resistant stainless steel and nickel-based alloys. Also, theshaft204 could be made as a composite to include advantageous properties of a plurality of materials. In some cases theshaft204 could be formed as a polymer. The class of polymers selected would include those that can form ashaft204 of a certain stiffness suitable in this application. For example, polycarbonate or PEEK could be used. In certain configurations, the polycarbonate, PEEK, or other suitable polymer can provide enhanced performance by being combined with a second material or structure. A glass or carbon filled polycarbonate or other stiff polymer could also be used.
• As discussed above, a hydrodynamic bearing between theshaft204 and thebearings232a,232bmay be utilized in various embodiments. In one such arrangement, a continuously replenished fluid film is provided at least between the inner wall of the bearing housing and an adjacent moving structure, such as the impeller shaft or an outer surface of a bearing. For example, the bearinghousing228 can be configured to permit a lubricant to be delivered therethrough into thelumen234. The bearing housing232 can include a plurality ofchannels260 disposed therein extending proximally from a plurality ofports264 located at thenarrow portion240 of thehousing228. Eachport264 can communicate with one of thechannels260 to provide fluid communication into thelumen234.
• As shown inFIG. 5, thechannels260 can be formed in the wall of thehousing228. In one embodiment, thechannels260 are formed as open depressions, e.g., as flutes, extending along thehousing228. In this embodiment, thechannels260 can be enclosed by a separate structure, such as a separate outer sleeve, that is disposed around thehousing228.FIG. 4B shows that aproximal portion268 of theimpeller housing202 can be sized to tightly fit over the outer surface of the bearinghousing228, enclosing the radially outward portion of thechannels260. In this arrangement, at least a portion of a flow path is formed between an outer surface of the bearing housing232 and a separate outer sleeve.
• Fluid communication between theport264 in the bearinghousing228 and theinfusion inflow assembly150 can be by any suitable combination of lumens within thecatheter assembly100. For example, in one embodiment, each of thechannels260 has aproximal port272 that communications with anannular space274 formed in thecatheter assembly100. Theannular space274 can be formed between a plurality of separate overlaid structures in thecatheter assembly100.FIG. 4A and 4B show that theannular space274 is formed between anouter surface278 of themultilumen catheter body120 and an inner surface of theproximal length268 of thehousing202.
• Fluid communication is provided in thecatheter assembly100 between thespace274 and theinfusion inflow assembly150. For example, a plurality oflumens282 formed in themulti-lumen catheter body120 can be dispersed circumferentially about thecatheter body120 at a peripheralcircumferential region284, as illustrated inFIGS. 7-7C. The peripheral position of thelumens282 enables a central area of thecatheter body120 to be dedicated to acentral lumen286. By providing a plurality ofsmaller lumens282 located at the periphery, a relatively large flow rate can be delivered through a relatively small circumferential band (when considered in cross-section) of thecatheter body120. Each of thelumen282 has a distal port290 that communicates with thespace274.
• A proximal portion of thelumens282 can take any suitable form. For example, thelumens282 can communicate at their proximal end with a flow diverting structure (not shown) that is in fluid communication with theinfusion inflow assembly150. As described herein, in some embodiments thelumen282 can be disposed circumferentially about thecentral lumen286. Thecatheter assembly100 can include a flow diverting structure or connector, e.g., disposed about the proximal end of thecatheter body120 that is configured to divert the infusant into thelumens282 for distally directed flow therein. In other embodiments, thecatheter assembly120 can include a flow diverting structure disposed adjacent the distal end thereof that is configured to divert the infusant into thelumens282 from thecentral lumen286 for proximally directed flow in thelumens282.
• FIG. 5 includes arrows that illustrate the flow of infusant into the bearingassembly220. In one arrangement, the inflow of infusant is indicated by anarrow300 which is shown pointing distally within one of thechannels260 of the bearinghousing228. The infusant flow enters the bearing housing through theports264. Although flow is shown in onechannel260, corresponding flow may be provided in each of a plurality ofchannels260 disposed around thecentral lumen234. Anarrow304 illustrates that at least a portion of the infusant delivered through theport264 may flow generally proximally within the bearinghousing228. Anarrow308 illustrates that at least a portion of the infusant delivered through theport264 may flow generally distally within the bearinghousing228.
• FIG. 5 illustrates thearrows304,308 as proximally and distally directed, respectively. However, the high speed rotation of theimpeller shaft204 within thehousing228 will create a thin film of lubricant spacing theimpeller shaft204 from the surfaces of thebearings232a,232b.This thin film will extend all the way around theshaft204 and thus each portion of the flow will have a spiral or helical flow direction.
• Thebearings232a,232bcan have different configurations to enhance the performance of thepump10. For example, theproximal bearing232acan be longer along the longitudinal axis of the bearinghousing228 than thedistal bearing232b.A longerproximal bearing232ais believed to better control runout of theshaft204. Better runout control on theshaft204 is believed to enhance the control of the position of theblades212 relative to thehousing202. Less runout reduces excessive variation in the gap between theblades212 and thehousing202, providing biocompatibility benefits such as reduced hemolysis.
• In some embodiments, such as those inFIG. 5 where thebearings232a,232bare not friction fit or interference fit onto theshaft204, thedistal bearing232bhas a smaller inner diameter than theproximal bearing232a.If theshaft204 has a constant diameter, the smaller inner diameter should provide greater control of angular deflection of the shaft. Controlling angular deflection can enhance relative position control of theblades212 andhousing202, providing blood handling benefits such as reduced hemolysis. A smaller clearance could also be provided by enlarging the diameter of theshaft204 at the axial position of the distal bearing. In some embodiments, the larger inner diameter of thebearing232benables a larger volume of lubricant to flow proximally and a lesser volume to flow distally in thelumen234.
• The continuous introduction of lubricant maintains a constant, predictable and durable rotational bearing state between stationary component, e.g., the bearinghousing282, and a moving component, e.g., theshaft204, a component of thebearings232a,232b,or both theshaft204 and a component of thebearings232a,232b.Also, continuous lubricant inflow provides a means for removing heat generated by the relative motion between theshaft204 and the bearings. Also, the infusant can create fluid pressure within thecatheter assembly100 that can push debris generated within or by thepump10 out of the bearinghousing220. Enhancing the volume of infusant that flows along the path indicated by thearrow304 enhances the likelihood that debris generated by or present in the pump will be removed from the proximal end rather than to be trapped inside the distal portion of thecatheter assembly100.
• Another technique for controlling infusant flow in thelumen234 is to locate theport264 between thebearings232a,232band closer to one of the bearing. For example, theports264 can be located adjacent to theproximal bearing232ain one embodiment. This provides a shorter path of egress out of thenarrow portion240 of the bearinghousing228 in the proximal direction.
• Other strategies for controlling the flow of infusant within the bearinghousing228 include modifying a surface within one or more of thebearings232a,232b.FIG. 8 shows asurface modification233 provided in a bearing232ato enhance proximally directed flow. Thesurface modification233 comprises a plurality of axially orientedgrooves235 in one embodiment. In another embodiment, thesurface modification233 includes one or more spiral grooves. The spiral grooves can be formed with a groove entrance that is substantially parallel with a flow direction of infusant between thebearings232a,232bsuch that a reduction of velocity of the flow is minimized. In one embodiment, each spiral groove includes at least about 3 turns disposed on the inner surface of the bearing between the proximal and distal ends of the bearing. In another embodiment, each spiral groove has adjacent turns that are spaced apart by a minimum pitch of 0.125 inches (3.2 mm). In another embodiment, each spiral groove has an axial density of about 32 turns per inch (about 1.3 turns per mm). The grooves are formed in thesurface237 of the bearing232aupon which theimpeller shaft204 is supported. Thegrooves235 locally enlarge the clearance between theshaft204 and thesurface237 so that a greater volume of infusant can flow distal-to-proximal across the bearing232a.Thesurface modification233 reduces back-pressure limiting the distal-to-proximal flow across the bearing232a.
• In other embodiments, it may be desirable to enhance distally directed flow. For example, the infusant may be provided with a fluid intended to be delivered to the patient. In such embodiments, thesurface modification233 can be provided on thedistal bearing232b.In certain embodiments, both proximal anddistal bearings232a,232bare provided with flow enhancing modifications to enhance heat transfer or purging of the bearingassembly220. In such embodiments, one of the bearings may have a greater degree of flow enhancement provided on the bearing surface.
• The arrangement of the bearingassembly220 can be a factor in selecting an appropriate infusant. Saline is a preferred infusant, but other sufficiently biocompatible infusants could be used. Other embodiments are configured such that little or no infusant flows out of the pump into the patient. For such embodiments, other infusant fluids can be used, such as glucose.
• FIG. 7 illustrates further features of thecatheter body120. Thecatheter body120 comprises an innermost portion320 that defines thecentral lumen286. The innermost portion320 is disposed within, e.g., circumferentially surrounded by, the peripheralcircumferential region284. A continuous outercircumferential region324 can be provided around the peripheralcircumferential region284 to fully enclose thelumens282, discussed above.FIGS. 4A and 4B illustrate that a distal end of the innermost portion320 is configured to be received and secured within a proximal portion of thelumen234 within the bearinghousing228.FIG. 4B illustrates that a region of overlap can be provided between a distal portion of the innermost portion320 and a proximal portion of the bearinghousing228. This construction provides a continuous lumen defined in part by thecentral lumen286 of thecatheter body120 and in part by thelumen234 of the bearing housing. In another arrangement, the bearinghousing228 and thecatheter body120 are joined by a coupler that enhances the sealing between infusant inflow through thelumens282 and thechannels260 and the infusant outflow through thecentral lumen286. As discussed further below, this continuous lumen provides a space for the rotation of theshaft204 of theimpeller assembly116 and thedrive shaft148 of the torque coupling system.
• The physical connection between the bearinghousing228 and thecatheter body120 can be achieved in any suitable manner.FIG. 3 illustrates that in one arrangement, a slideable connection is provided. In this arrangement, arod332 is provided between the bearinghousing228 and thecatheter body120. Therod332 can have any suitable configuration, but may have a proximal end configured to be received in a recess or lumen formed in thecatheter body120 and adistal end340 configured to couple with the bearinghousing228.FIG. 3 shows that thedistal end340 of therod332 can be configured to engage with a feature of the bearinghousing228 so that a limited range of sliding is permitted.
• In one embodiment, the bearinghousing228 has anelongate channel342 configured to receive a middle portion of therod332 and anenlarged depression344 located at the distal end of thechannel342. Thedepression344 has a width W that is sufficient to receive a wide distal end of therod332. Thedepression344 can be configured to have an axial length along thehousing228 that can define a range of motion of the bearinghousing228 relative to thecatheter body120.
• In one arrangement, the bearinghousing228 is positioned relative to thecatheter body120 and therod332 such that the distal portion of therod332 is located at the distal end of thedepression344. Thereafter, thecatheter assembly100 can be manipulated such that the bearinghousing228 moves distally relative to thecatheter body120 and therod332 such that the distal portion of therod332 is located at the proximal end of thedepression344. In the distal position, theimpeller assembly116 is located more distally than in the proximal position. As discussed further below, this enables a variety of techniques for unfurling theimpeller blades212 within thehousing202.
B. Bearing Configurations
• Any suitable bearing can be used in thecatheter assembly100. The provision of an infusant for hydrodynamic support enables a wide range of bearing materials to be used. If saline or other more corrosive infusant is used, the bearing must be carefully configured to not degrade within the expected duty cycle of thepump10. Some polymeric materials are advantageously not degraded by isotonic saline, and are acceptable materials from this perspective. Under the fluid-dynamic conditions, a hydrodynamic bearing that is supported by a biocompatible infusant such as isotonic saline is preferred. It is believed that certain polymer bearings in combination with isotonic saline can support such conditions as 35,000-50,000 psi-ft/min for an appropriate duty cycle. Other aspects that can guide the choice of bearing configurations include minimizing thermal expansion, given the heat that could be generated in theheart pump10, and minimizing moisture absorption.
• Any suitable polymeric material may be used for thebearings232a,232b.The polymeric material can include a homopolymer, a copolymer, or a mixture of polymers. The polymeric material can include thermoplastic or thermoset polymers. Examples of polymers that can be used forbearings232a,232binclude, but are not limited to, one or more of a polyketone, a polyether, a polyacetal, a polyamide-imide, a polyacetal, polyether ether ketone (PEEK), polytetrafluoroethylene (PTFE), and polyphenylene sulfide (PPS).
• The polymeric material can also include (e.g., can be mixed, combined, and/or filled with) one or more additives such as a reinforcer and a lubricant. Specific additives include, but are not limited to, graphite, carbon fiber, glass fiber, and PTFE. Those of ordinary skill in the art may appreciate that the additives may be polymeric or non-polymeric. In some embodiments, the polymeric material used forbearings232aand/or232bcan include PEEK, carbon fiber, PTFE, and graphite. In other embodiments, the polymeric material can include PPS and glass fiber. In yet other embodiments, the polymeric material can include a polyamide-imide polymer, carbon fiber, and graphite. The polymeric material can include any suitable amount of additive(s). For example, the polymeric material can include a total amount of additive(s) in the range of from about 1 wt % to about 50 wt %, based on the total weight of the polymeric material. In other embodiments, the polymeric material used forbearings232a,232bmay not include any additives.
• The polymeric material chosen forbearings232a,232bcan have particular characteristics that advantageously affect the performance of the bearings. For example, in order to minimize thermal expansion caused by the heat generated in theheart pump10, a preferred material would be subject to a minimum of dimensional change, and can have a coefficient of thermal expansion in the range of from about 1.2×10⁻⁵° F⁻¹to about 25.2>10⁻⁵° F¹. In other embodiments, the polymer used forbearings232a,232bhas a coefficient of friction in the range of from about 0.15 to about 0.3. In another example, in order to minimize or prevent water absorption, the selected polymeric material can have a water adsorption in the range of from about 0.01% to about 0.4% over a 24 hour period. In yet another example, the polymeric material can be suitable for high pressure and velocity performance, and can have a limiting pressure-velocity (PV) in the range of from about 20,000 psi-ft/min to about 50,000 psi-ft/min.
• The polymeric material used forbearings232a,232bmay be commercially available. Examples of suitable, commercially-available polymeric materials include, but are not limited to, Ketron PEEK-HPV, Turcite A, Turcite X, Turcite T X, Rulon L R, Rulon J, Rulon 641, Rulon A R, Techtron HPV PPS, Ryton PPS, Torlon 4301, and Torlon 4501. In some embodiments, the polymeric material used forbearings232a,232bis Ketron PEEK-HPV.
• Of course, other bearing configurations and/or materials would be suitable under other conditions, e.g., with less corrosive infusants or if a hydrostatic or non-hydraulic bearing is used.
C. Torque Coupling Systems
• A torque coupling system is provided to rotate theimpeller200 at a high rate to move blood from inside a heart camber to a location within a patient's vasculature in amounts sufficient to sustain the patient or provide treatment to the patient. The torque coupling system couples theimpeller200 with the motor136, which may be disposed outside the patient. It is expected that theimpeller200 and thedrive shaft148 are to be rotated at 25,000-30,000 revolutions per minute for a period of seven to ten days. To provide reliable performance under these conditions, isotonic saline or other lubricant is provided between thedrive shaft148 and stationary components therearound.
• FIGS. 11 and 4B illustrate proximal anddistal portions400,404 of thedrive shaft148. Theproximal portion400 is coupled with thedrive assembly146 such that rotation of thedrive assembly146 rotates thedrive shaft148. Thedistal portion404 ofdrive shaft148 is coupled with theimpeller shaft204 such that rotation of thedrive shaft148 causes rotation of theimpeller shaft204. Thedrive shaft148 also includes anelongate body408 that extends between the proximal anddistal portions400,404. Theelongate portion408 comprises alumen412 extending therethrough.
• The size of theelongate body408 may be as small as possible to minimize the cross-sectional profile of thecatheter assembly100. The cross-sectional profile of thecatheter assembly100 corresponds to the crossing profile of the catheter assembly, which limits where the system can be inserted into the vasculature. Thelumen412 is sized to permit a guidewire to be advanced therethrough in some embodiments. The use of a guidewire is optional, but may simplify insertion.
• In one embodiment, theelongate body408 comprises a multi-layer construction. In some embodiments, each layer can include at least one coil wire or a plurality of coil wires all wound in a same orientation. For example, a two-layer, counter-wound wire construction is particularly advantageous. A first layer (e.g., an inner layer) of theelongate body408 is provided by a coiled wire of nickel-molybdenum-chromium alloy, such as 35NLT or MP35N. In other embodiments, the wire material can be MP35N LT. In one embodiment, the wire has a 0.008 inch diameter and the coil has a 5 filar right-hand wound construction. The outer diameter of the first layer may be about 0.071 inch. A second layer (e.g., an outer layer) of theelongate body408 can include the same material as the first layer, disposed on the outside of the first layer. The first and second layers can be wound in the same direction, or in opposite directions. For example, in some embodiments the first layer (e.g., an inner layer) can be left-hand wound and the second layer (e.g., an outer layer) can be right-hand wound, or vice versa. In other embodiments, both the first and second layers can be left-hand wound. In yet other embodiments, both the first and second layers can be right-hand wound. The wound coil wire construction can advantageously facilitate proximal and/or distal flow of infusant along the outer layer of theelongate body408. For example, the outer layer can be constructed such that the infusant travels along the coil and/or in the direction of the winding. Those skilled in the art may appreciate that, depending on the direction of rotation of theelongate body408, the infusant flow can advantageously be directed either proximally or distally. The second layer may be a 5 filar left-hand wound construction. In one embodiment, each layer is formed using a 0.008 inch diameter wire, in the above-noted coiled configuration. In other embodiments, theelongate body408 can include three or more coil wire layers, wherein the layers are wound in alternating directions. In some embodiments, the outer diameter of the second layer can be between about 0.072 inch and about 0.074 inch, while in other embodiments the diameter can be much larger or smaller. In some aspects, for example, the outer diameter of the second layer can be about 0.073 inch. The inner diameter of theelongate body408 can be at least about 0.039 inch in some implementations. In some embodiments, one or more ends of theelongate body408 can be welded and square cut, for example, with a 0.1 inch maximum weld length on each end. The length of theelongate body408 can vary, but in some embodiments, the length can be between about 47 inches and 48 inches, for example, about 47.5 inches.
• Other materials and other constructions are possible. Theelongate body408 can be made of other non-ferrous metals or other corrosion resistant material or constructions with appropriate modulus. Other materials that could meet the corrosion requirements include stainless steel (e.g.,302,304, or316). In certain embodiments, theelongate body408 can have a structure that enables other materials to be used. For example varying at least one of coil layers, filars, wire diameter, and coil diameter may enable an otherwise less robust material to operate below the fatigue stress of that material.
• In another embodiment, a four layer construction is provided. The four layers comprise three wire-wound layers, e.g., similar to the arrangement described above, but included a third wound layer on the outer surface of the second layer. A low friction layer can be disposed on the outside surface of theelongate body408. One material that could be used as a low-friction layer is PTFE, known commercially as Teflon®. The low-friction layer should be configured to have sufficient wear resistance, such as by selection of the appropriate PTFE material, e.g. polyphenylene sulphone-filled PTFE, and/or by insuring appropriate infusant flow is maintained during the entire duration of use of the device in order to prevent undesirable local elevated temperature of the PTFE material.
• Thedrive shaft148 operates within themultilumen catheter body120. Because thedrive shaft148 is rotated at a very high rate when in use within themultilumen catheter body120, the configuration of the surface forming thecentral lumen286 is important. In some embodiments, this inner surface has high lubricity and high wear resistance. One material that can be used for the inner surface of thecatheter body120 is high density polyethylene (HDPE), which provides sufficient lubricity and wear resistance. In one embodiment, the entiremultilumen catheter body120 is formed of HDPE. PTFE provides good lubricity and could be used if made sufficiently wear resistant. One way to increase the wear resistance of PTFE is to impregnate it with polyphenylene sulphone (PPSO₂), another is to gamma irradiate the material. One way to increase the lubricity of Polyimide materials is to impregnate it with Graphite, another is to impregnate it with Graphite and PTFE.
• FIG. 4B shows aclearance412 between theelongate body408 of thedrive shaft148 and the inner surface of themultilumen catheter body120. Theclearance412 may be about 0.005 inch. Along a diameter between opposite sides of the inner surface of thecentral lumen286 and outer surface of theelongate body408 includes about 0.010 inch of space or diametric clearance. A larger minimum clearance may be desirable if the crossing profile can be enlarged or if other structures of thecatheter assembly100 can be made thinner or eliminated to allow more room between theelongate body408 and thecentral lumen286.
• FIGS. 11 and 12 show further details of thedrive assembly146, which is disposed at theproximal end104 of thecatheter assembly100. Thedrive assembly146 includes adrive housing450 having a recess orcavity454 disposed therein. Thecavity454 is configured for mounting arotor support shaft458 for rotation therein. Thesupport shaft458 has a proximal end and a distal end and a plurality of components mounted thereon. The distal end of thesupport shaft458 has arecess462 formed therein to receive a proximal end of thedrive shaft148. Thesupport shaft458 may also have alumen466 disposed therein for slideably receiving a guidewire.
• Arotor470 is mounted on an outer surface of thesupport shaft458 betweensleeve bearings474a,474b,as shown inFIG. 12. Therotor470 can take any suitable form, but in one embodiment includes anelongate magnet476 disposed between proximal anddistal flywheels478a,478b.
• The proximal end of thesupport shaft458 has a taperedport480 for receiving the guidewire. The proximal end can be configured for engaging the motor136 in some embodiments. In other embodiments, a magnetic field is induced by the motor136 in a manner that creates torque and rotation of theshaft458.
• Aninfusant outflow path482 is provided within thedrive assembly146. Theoutflow path482 is provided between an outer surface of thesupport shaft458 and aninner surface486 of the distal bearing. Theflow path482 continues from thedistal bearing474b.radially outwardly along thrust surfaces490a.The flow path continues proximally between the outer surface of therotor470 and the inner surface defining thecavity454. Theflow path482 continues radially inwardly along thethrust surface490atoward thesupport shaft458. Theflow path482 continues proximally between thesupport shaft458 and theproximal bearing474a.Proximal of the bearing474a,the flow of infusant exits thecatheter assembly100 through an outflow port144 through which it can be directed to thewaste container46 or discarded. The flow path is shown in more detail inFIGS. 1, 12, 12A, and 12B.
III. Structures that Facilitate Deployment and Retreival
• Thecatheter assembly100 can include one or more features that facilitate the deployment and/or retrieval of one or more components of thedistal end108 of the heart catheter assembly100 (e.g., theimpeller assembly116 or a portion thereof).
A. Optionally-Expandable Diffuser
• As shown inFIGS. 13A and 13B, the pump can include adiffuser502a,502b.As illustrated inFIG. 13A, in some embodiments thediffuser502ais connected to theimpeller hub208. For example, thediffuser502acan be integral, or form a unitary structure, with theimpeller hub208. In another example, the proximal end of theimpeller hub208 can include thediffuser502a.As illustrated inFIG. 13B, in other embodiments, thediffuser502bis separate from (e.g., not connected to) theimpeller hub208.
• Thediffuser502a,502bcan be disposed between the distal end of the elongate body of the catheter body and the impeller. Thediffuser502a,502bcan be configured to be positioned within thehousing202 and adjacent to the proximal opening of the housing. In some embodiments, thediffuser502a,502bcan be axially aligned with the proximal opening of thehousing202. Advantageously, this configuration can maximize the flow directing capabilities of thediffuser502a,502b,as discussed further herein. Thediffuser502a,502bcan be located adjacent the proximal end of thehub208. Thediffuser502a,502bcan include aproximal end504a,504b.and adistal end505a,505b.Theproximal end504a,504b.of thediffuser502a,502bcan be positioned adjacent the distal end of the bearing housing228 (e.g., over abearing516 and/or a front thrust washer518). As shown inFIG. 13A, theproximal end504acan be separated from the bearing516 by agap522. Thegap522 can have an axial length generally equal to the length of thebearing516. Thegap522 can also be generally cylindrical with a longitudinal axis that is aligned with the longitudinal axis of theimpeller shaft204. Thedistal end505a,505bcan be located adjacent the proximal end of theimpeller hub208. Thediffuser502a,502bcan include a flow directing surface. For example, anouter surface513 of thediffuser502a,502bcan form a curved line from theproximal end504a,504b.to thedistal end505a,505b,as illustrated inFIGS. 13A-B. As viewed from the proximal or distal end, thediffuser502a,502bcan have a generally circular cross sectional shape. As shown inFIGS. 13A and 13B, the diameter of thediffuser502a,502bcan be greatest in the mid section and can taper to a smaller diameter in the distal and/or proximal directions. Thediffuser502a,502bcan have a maximum diameter that is generally greater than the diameter of thehub208 and/or the bearinghousing228. The diameter of theproximal end504a,504b.can be generally equal to the diameter of the bearinghousing228. The diameter of thedistal end505a,505bcan be generally equal to the diameter of thehub208. Thediffuser502a,502bmay be referred to herein as a bulge, and in various embodiments can have a radially enlarged portion disposed downstream of the impeller.
• Advantageously, the relatively large diameter and/or the curved outer surface can assist in directing (e.g., diffusing) fluid flow out of thehousing202. The geometry of thediffuser502a,502b(e.g., the radius of curvature of the outer surface) can be optimized to control desired fluid properties such as boundary layer flow, laminar flow, and pressure gradients and to reduce outlet flow losses.
• Thediffuser502a,502bcan include awall511. Thewall511 can include aninner surface512 and theouter surface513, described above. Thewall511 can have a thickness extending from theinner surface512 to theouter surface513. In some embodiments, thewall511 can have a generally uniform thickness along the axial length of thediffuser502a,502b.One advantage of a generally uniform wall thickness is that thediffuser502bcan be more easily expanded and/or collapsed, as described herein. In other embodiments, thewall511 can have a variable thickness along the axial length of thediffuser502a,502b.For example, as illustrated inFIG. 13A, the thickness of thewall511 can increase in the distal direction. One advantage of a variable thickness wall is that it can have variable structural strength. For example, a wall having a thickness that increases distally can advantageously have greater strength in areas that are most exposed to oncoming blood flow.
• Theinner surface512 can define achamber506 through which theimpeller shaft204 can pass. As shown inFIG. 13A, thediffuser502acan form part of the proximal end of thehub208 of the impeller200 (e.g., thehub208 can be connected to thediffuser502a). Thus, thediffuser502acan rotate with therotating hub208. Thediffuser502acan also include aproximal cavity outlet508. As shown inFIG. 13B, thediffuser502bcan be a component separate from theimpeller200. In this embodiment, thediffuser502bcan be stationary when thehub208 is rotating. Thediffuser502bcan also include adistal cavity outlet510.
• There can be many advantages to including adiffuser502athat is connected to theimpeller hub208. For example, the unitary construction can be easier to manufacture and/or assemble. As described herein, the distal end of thediffuser502acan be relatively thick and strong (e.g., stiff). In addition, it can be advantageous for the infusant to exit thecatheter assembly100 at theproximal outlet508, which is generally at the downstream end of thediffuser502a.
• There can also be advantages to including adiffuser502bthat is a structure separate from and not directly attached to theimpeller hub208. In some embodiments, thediffuser502bcan be made from a material that is different from the material used to makeimpeller hub208. For example, thediffuser502bcan be made from a material that is relatively more flexible (softer) than the material of theimpeller hub208. In other embodiments, thewall511 ofdiffuser502bcan have a generally uniform thickness. These features ofdiffuser502bcan facilitate the expansion and/or contraction of thediffuser502b,described further herein.
• As shown inFIGS. 13A and 13B, thediffuser502a,502bcan be generally hollow, as defined by thechamber506. Thediffuser502a,502bcan be sufficiently hollow and can be made of a relatively flexible material (e.g., a polymer or elastomer) to be expandable and/or collapsible. For example, the maximum diameter of thediffuser502a,502bcan expand from a first diameter to a second diameter. Advantageously, thecollapsible diffuser502a,502bcan have a deployed, expanded configuration, and a retracted, collapsed configuration. In the deployed, expanded configuration, thediffuser502a,502bcan have a maximum diameter (e.g., as measured at the mid-section or bulge) that is generally greater than the diameter of thehub208 and/or the bearinghousing228. In the retracted, collapsed configuration, thediffuser502a,502bcan have a reduced diameter. For example, in the retracted, collapsed configuration, thediffuser502a,502bcan have a maximum diameter that is generally less than or equal to the diameter of thehub208 and/or the bearinghousing228. Although described as having a diameter, those skilled in the art may appreciate that while retracted and/or collapsed, thediffuser502a,502bmay not have a generally circular cross section. A collapsible diffuser can be advantageous compared to a non-collapsible diffuser because a collapsible diffuser can allow the overall structure to maintain and low profile for the purpose of retracting back into a sheath and for insertion into and/or removal from a patient.
• In some embodiments, the relatively flexible material itself may not be significantly expandable (e.g., stretchable and/or elastic). Rather, the terms “expandable” and “collapsible” can refer to the overall expansion and/or collapse of thechamber506 of thediffuser502a,502b.In other embodiments, the relatively flexible material itself may be significantly expandable (e.g., balloon-like).
• Thechamber506 can be configured (e.g., sized) to allow fluid (e.g., infusant) flow through thediffuser502a,502b.Thediffuser502a,502bcan be configured for fluid communication with a fluid, such as an infusant, that passes through the bearingassembly220. The bearingassembly220 illustrated inFIGS. 13A and 13B can have many, if not all, of the same features as described with respect to the bearingassembly220 illustrated inFIG. 5. As shown inFIGS. 13A and 13B, the infusant can follow aninfusant path514a,514b.out of the bearingassembly220 and into thediffuser502a,502bvia a passage orcavity520 between the bearing516 and thewasher518. For at least a portion of theinfusant path514a,514b,the infusant can travel distally. In some embodiments, at least a portion of theinfusant path514a,514b.can be non-helical (e.g., generally linear). In other embodiments, at least a portion of theinfusant path514a,514b.can be generally helical. The helical shape of theinfusant path514a,514b.can be caused at least in part by rotation of one or more components of the impeller assembly116 (e.g., theimpeller shaft204 and/or impeller hub208).
• As illustrated inFIG. 13A, theinfusant path514acan extend from theproximal end504ato thedistal end505aand can return back to theproximal end504ato exit theproximal outlet508 via thegap522. The portion of theinfusant path514athat extends from theproximal end504ato thedistal end505ais helical (e.g., can encircle theimpeller shaft204 one or more times along the axial length of the path). The return portion of theinfusant path514acan be non-helical (e.g., generally linear). The return portion of theinfusant path514acan be non-helical at least in part because the return portion can follow the curvedinterior surface512 of thediffuser wall511. In use, the infusant can exit the bearingassembly220 at thecavity520 to enter thechamber506. At least a portion of the infusant can then followinfusant path514ato travel helically around theimpeller shaft204 in the distal direction until thedistal end505ais reached. The infusant then changes direction and turn around to flow proximally along the non-helical return portion of theinfusant path514aand through thegap522 to exit the pump via theproximal cavity outlet508. Although shown as a single distal-to-proximal line, in some embodiments, exit flow can be induced along and generally following the shape of theinner surface512 to theproximal cavity outlet508. In use, as the infusant passes through thegap522, the infusant can act as a hydrodynamic bearing (e.g., in addition to the hydrodynamic bearing that may be present between the impeller shaft and the bearing housing as described herein). This hydrodynamic bearing can generally be in the shape of a cylinder that extends axially, as defined by thegap522. Advantageously, this hydrodynamic bearing can reduce friction between thediffuser502aand the bearinghousing228.
• As illustrated inFIG. 13B, theinfusant path514b.can extend from theproximal end504b.to thedistal end505b.As illustrated inFIG. 13B, the infusant path514b.is helical (e.g., can encircle theimpeller shaft204 one or more times along the axial length of the path). In use, as shown inFIG. 13B, generally all of the infusant flows proximally to distally within a distal portion of the bearingassembly220 and exits the bearing assembly at thecavity520 to enter thechamber506. In various embodiments, a portion of the infusant flows proximally within a proximal portion of the bearingassembly220 through a space between thedrive shaft148 and thecatheter body120. This return flow is discussed above, e.g., in connection witharrow304 inFIG. 8. At least a portion of the infusant then follows theinfusant path514b.to travel helically around theimpeller shaft204 in the distal direction and out through thedistal cavity outlet510. As illustrated inFIG. 13B, thedistal cavity outlet510 defines a gap between thedistal end505bofdiffuser502band the proximal end ofimpeller hub208. In use, as the infusant passes through thedistal cavity outlet510, the infusant can act as a hydrodynamic bearing. This hydrodynamic bearing can generally be in the shape of a cylinder having a length extending axially along the length of the gap and a radius corresponding to the cross sectional radius of the gap. Advantageously, this layer of infusant between the diffuser and the impeller hub can reduce friction between thediffuser502band theimpeller hub208 when the pump is in operation.
• As described herein, thediffuser502a,502bcan be expandable. In some embodiments, one or more forces exerted by the infusant can be used to expand thediffuser502a,502b.The flow rate of the infusant can be sufficient to establish an area of positive pressure within thediffuser502a,502b,thereby allowing at least a portion of the infusant to exit adjacent to a distal end of the device. In some embodiments, the static pressure of the infusant entering thechamber506 can cause thediffuser502a,502bto expand. In any of these embodiments, aninflated diffuser502a,502bcan be deflated by interrupting and/or discontinuing the flow of infusant into thediffuser502a,502band by allowing the infusant to exit the diffuser via theproximal outlet508 or thedistal outlet510. In some embodiments, the wall is elastic but the pliability is relatively low such that upon removal of the infusant flow a transition from expanded to low profile is rapid. Thediffuser502a,502bself-collapses displacing the infusant out of thechamber506 through one or more small apertures. In addition to promoting quick deflation, the relatively low pliability will provide a uniform diffuser profile, e.g., will not be deformed or deflected by any varying pressure or flow rate of the blood from theimpeller200. A lower infusant pressure configuration can also be provided by increasing the pliability of the structure forming thediffuser502a,502b.The structure can be of enhanced pliability by material selection or constructions (e.g., by being thinner or adopting other balloon-like features).
• In other embodiments, the centrifugal force exerted by the infusant as it travels along thehelical path514a,514b.can be used to expand thediffuser502a,502b.As illustrated inFIG. 13A, thediffuser502acan be connected to theimpeller assembly116.
• In these embodiments, thediffuser502aand theimpeller assembly116 can be rotated. In use, when theimpeller assembly116 and thediffuser502aare rotated, the infusant can also rotate due to, e.g., shear forces generated from the fluid contact with therotating diffuser502aand/or therotating impeller shaft204. The rotating infusant can exert a pressure on theinner surface512 to thereby expand thediffuser502afrom the collapsed configuration to the expanded configuration. Thus, in some embodiments, thediffuser502acan be centrifugally expanded. In yet other embodiments, thediffuser502acan be expanded using a combination of static and centrifugal forces.
• As illustrated inFIG. 13B, thediffuser502bmay not be rotatable. In these embodiments, when theimpeller shaft204 is rotated, the infusant can also rotate due to, e.g., shear forces generated from the fluid contact with therotating impeller shaft204. As described herein, the rotating infusant can exert a pressure on theinner surface512 to thereby expand thediffuser502bfrom the collapsed configuration to the expanded configuration. Thus, in some embodiments, thediffuser502bcan be centrifugally expanded. In yet other embodiments, thediffuser502bcan be expanded using a combination of static and centrifugal forces.
• Infusant exiting thediffuser502a,502bcan be continuously replenished with additional infusant via the flow path514. If theimpeller shaft204 stops rotating, the pressure generated from rotation can decrease to match the pressure acting on the outside of thediffuser502a,502b,thereby allowing thediffuser502a,502bto collapse.
• In yet other embodiments, thediffuser502a,502bcan be expanded and/or inflated by a combination of static and centrifugal forces. For example, thediffuser502a,502bcan be expanded and/or inflated by a combination of the static force of the infusant as it enters thechamber506 and the centrifugal force of the infusant as it travels along the helical path514.
B. Relatively Axially-Moveable Impeller Housing
• As illustrated inFIG. 14B, when the impeller and thediffuser502 are in the proximal position, at least a portion of the impeller (e.g., theblades212 and/or the hub) and/or thediffuser502 may be relatively positioned in a portion of thehousing202 having minimal or no coating, such as anoutlet802 of the housing202 (e.g., the outlet through which blood is pumped). In some embodiments, thehousing202 can be moved axially relative to the impeller and/or thediffuser502. In some embodiments, thehousing202 is moved axially over the impeller and the impeller is stationary. Those skilled in the art may appreciate that in some embodiments, thehousing202 may not be configured to move axially relative to the impeller and/or the diffuser502 (e.g.,housing202 is fixed or stationary relative to impeller and/or the diffuser502). For example, thehousing202 and thediffuser502 can be spaced apart by a relatively constant axial distance in all operational states, or at least in a collapsed and an expanded state.
• As illustrated inFIGS. 14A and 14B and as described herein, therod332 provided between thecatheter body120 and the bearinghousing228 enables a slideable engagement between thecatheter body120 and the bearinghousing228. The distal end of thecatheter body120 can be connected to theproximal portion268 of theimpeller housing202. Thecatheter body120 can translate distally from a proximal position to a distal position, and vice versa, by the application of an axial force described further herein. As described herein, for example with respect toFIGS. 4A-4B, thecatheter body120 can be coupled to theproximal portion268 of theimpeller housing202. For example, theproximal portion268 of theimpeller housing202 can be fitted over the distal end of thecatheter body120.
• In the proximal position, illustrated inFIG. 14A, the axial position of theoutlet802 can be proximal of the axial position of theproximal-most blade212. In the distal position, illustrated inFIG. 14B, the axial position of theoutlet802 can generally correspond to the axial position of theproximal-most blade212. Advantageously, therod332 and theenlarged depression344 can control the axial distance over which theimpeller housing202 is capable of sliding. Therod332 can also advantageously prevent the bearinghousing228 from rotating with theimpeller shaft204.
• Those skilled in the art may appreciate that the axial movement of thecatheter body120 and theimpeller housing202 relative to the impeller and/or thediffuser502 can have the same relative effect as axially moving the impeller and/or thediffuser502 relative to thecatheter body120 or theimpeller housing202, even if the impeller and/or the diffuser are not actually moved axially. Accordingly, in some embodiments thecatheter body120 in the proximal position can be referred to as the deployed position of the impeller and/or thediffuser502. Thecatheter body120 in the distal position can be referred to as the retracted position of the impeller and/or thediffuser502.
• The ability of the impeller and/or thediffuser502 to be retracted and deployed relative to the impeller housing can have many advantages. For example, axial movement of the impeller housing relative to the impeller and/or the diffuser can reduce the profile of the pump to ease insertion and retrieval. In some embodiments, in the retracted position, theimpeller hub208,blades212, and/ordiffuser502 can be positioned at the same axial location as a portion of thehousing202 that does not have a covering (e.g., the outlet802). Accordingly, the cross-sectional area of thecatheter assembly100 measured at the axial position of thediffuser502 in the retracted position, for example, is comparatively smaller than when it is in the deployed position. The smaller cross sectional area can be advantageous for minimizing trauma to a user during insertion into and/or retrieval from the body.
• In other embodiments, the retracted position of the impeller and/or the diffuser can be distal of the deployed position of the impeller and/or the diffuser. In some embodiments, the impeller housing can have a rigidity that varies axially. For example, the impeller housing can have a proximal portion that is more rigid (e.g., less flexible) than a distal portion. In these embodiments, the impeller and/or the diffuser can reside in the proximal, rigid portion while in the deployed position. The impeller and/or the diffuser can reside in the distal, flexible portion while in the retracted position. Advantageously, when the impeller and/or the diffuser reside in the flexible portion of the impeller housing, this portion of the pump may be collapsed to a lower profile than would otherwise be achievable if the impeller and/or the diffuser remained in the rigid portion of the impeller housing.
• As described herein, the catheter body can be coupled to the impeller housing. The retraction and deployment (e.g., movement between proximal and distal positions) of the impeller housing can be controlled by manipulation of a proximal end of the catheter assembly that results in an application of axial force to the catheter body. For example, the impeller housing can be moved axially by the rotational force applied by a nut disposed at the proximal end of the catheter assembly. A section of the proximal end of the catheter assembly is illustrated inFIGS. 15A and 15B.
• In some embodiments, axial force is applied to the catheter body via animpeller deployment assembly800. The impeller deployment assembly includes anut804 that is engaged with a portion of the catheter assembly, such as aflow diverter806. As described herein, theflow diverter806 can be a part of theinfusion inflow assembly150, illustrated inFIG. 1. The distal end of theflow diverter806 can be connected to a proximal portion of the catheter body. In some embodiments, thenut804 can be engaged with apin808. Thepin808 can penetrate through the wall of thedrive housing450 and can be coupled with or fixedly attached to theflow diverter806. Thenut804 can be disposed over at least a portion of thedrive housing450 and/or theflow diverter806. Thenut804 can include an internal engagement structure that is configured to engage the flow diverter806 (e.g., via the pin808). In some embodiments, the internal engagement structure can include internal threading. In other embodiments, the internal engagement structure can include acam track812 having first and second ends (e.g., a proximal end and a distal end), as illustrated inFIG. 15C. In these embodiments, thepin808 can be configured to travel along thecam track812. The internal engagement structure can be generally helical. Thedrive housing450 can also include alongitudinal channel810 along which thepin808 can travel.
• As illustrated inFIGS. 15A and 15B, thedrive housing450 can contain thesupport shaft458 and thedrive shaft148. Thedrive housing450 can also capture thenut804. For example, a retention structure can be formed in the outside surface of thehousing450 to prevent thenut804 from slipping proximally or distally relative to thehousing450. One embodiment of a retention structure is illustrated below in connection with the deployment device ofFIGS. 15D-F but can be included with thedeployment device800 as well. Thepin808 can penetrate the wall of thedrive housing450 and permit axial translation of theflow diverter806 by acting as a cam. In some embodiments, thesupport shaft458 and thethread advance nut804 may be rotatable but not translatable relative to thedrive housing450.
• In use, a rotational force can be applied to thenut804. This application of rotational force can be converted into an axial force that is applied to theflow diverter806 and the catheter body. As described herein, thepin808 can be fixedly attached to theflow diverter806 at one end and have a second end disposed within the inner surface of thenut804 along the cam track thereof. The rotation of thenut804 in a first direction (e.g., clockwise or counter-clockwise) can cause thepin808 to translate from a proximal position (e.g., proximal end) to a distal position (e.g., distal end) in thelongitudinal channel810. Accordingly, theflow diverter806, the catheter body, and the impeller housing can also translate from a proximal position to a distal position. As described herein, the distal translation of the catheter body and the impeller housing can improve the ease of the retraction of the impeller hub and the blades into the impeller housing. In embodiments where theoutlet802 is generally free of a polymeric coating, relative movement of at least a portion of the impeller and/or the diffuser proximally into theoutlet802 or distally into a more flexible region of the impeller housing (i.e., mid section of the housing where there is less strut material) can advantageously reduce the profile of the pump upon collapsing into the sheath. In addition, axial adjustment of the impeller housing relative to the impeller can advantageously promote more efficient flow dynamics. In some embodiments, the impeller is positioned closer to theoutlet802 than the middle portion of the housing in order to improve flow dynamics.
• A rotational force applied to thenut804 in a second direction (e.g., counter-clockwise or clockwise) can cause thepin808 to translate from the distal position to the proximal position. Accordingly, theflow diverter806, thecatheter body120, and theimpeller housing202 can also translate from a distal position to a proximal position. As described herein, the proximal translation of thecatheter body120 and theimpeller housing202 can effectively result in the deployment of theimpeller hub208 and theblades212.
• FIGS. 15D-F illustrate another embodiment of adeployment device850 that can be used to manipulate or deploy a distal structure of the catheter assembly and/or the impeller housing. As with thedeployment device800, thedeployment device850 can be used to actuate theimpeller200 between retracted and deployed configurations.
• As discussed above, the catheter assembly can include aflow diverter852 that is part of the infusion system. Theflow diverter852 may be coupled with aproximal portion122 of thecatheter body120. In one embodiment, the proximal end of theproximal portion122 is inserted into arecess854 formed at a distal852aend of theflow diverter852. The connection between theproximal portion122 of thecatheter body120 theflow diverter852 can be further made secure by astrain relief856 disposed at the junction and extending distally thereof. Thestrain relief856 overlaps a proximal length of theproximal portion122 and absorbs movements of the portions of the catheter assembly to isolate the connection between theflow diverter852 and the catheter body. Acap860 can be used to securely couplestrain relief856 to theflow diverter852. Aproximal portion862 of theflow diverter852 is received within arecess864 of thehousing450. Aseal device866, such as an0-ring, may be provided between theproximal portion862 of theflow diverter852 and inside surface of therecess864 to prevent infusion from exiting thehousing450 in an undesirable manner.
• Theflow diverter852 also includes alumen868 that extends from aproximal end852bto thedistal end852athereof. Thelumen868 is configured to permit a proximal portion of thedrive shaft148 to reside therein. In some embodiments,flow diverter852 is configured to cause some infusant to flow proximally in thelumen868 between thedrive shaft148 and the inner surface of theflow diverter852 that forms thelumen868 to lubricate and cool the drive shaft. Theflow diverter852 can be configured to cause most or substantially all of the infusant entering the diverter through the lumen in thecatheter body154 to flow distally between thecatheter body120 and thedrive shaft148. In one arrangement, thelumen868 is enlarged from a location proximal of where thecatheter body154 couples with theflow diverter852 toward thedistal end852aof the flow diverter. This enlargement creates a path of least resistance toward the distal direction to divert the flow distally. In one embodiment, thelumen868 is further enlarged at a location between where thecatheter body154 couples with theflow diverter852 and therecess854 such that a substantially continuous lumen can be formed to keep flow resistance at the junction between theflow diverter852 and theproximal portion122 of thecatheter body120 to a minimum.
• Thedeployment device850 includes aguide track872 on aproximal portion862 of theflow diverter852, aguide member874, and anactuator876. Theguide track872 can comprise an axially oriented slot or recess formed in the outside surface of theproximal portion862. Theguide track872 may be configured to slidably receive aguide member874 such that relative movement can be provided between theguide track872 and aguide member874. A portion of theguide member874 may extend through sidewall of thedrive housing450 such that the axial position of theguide member874 can be fixed and relative movement is provided by movement of theflow diverter852 relative to the guide member. In one embodiment theguide member874 is a pin that has one end received in a small hole in thedrive housing450 and the other end disposed in theguide track872.
• Theactuator876 is configured to translate rotational motion thereof into axial motion of theflow diverter852. For example, theactuator876 can comprise a nut that includes internal threads that are engaged with external threads on the outside surface of theflow diverter852. In various embodiments, a proximal portion of theactuator876 is anchored to thedrive housing450 to prevent the actuator876 from moving axially along the drive housing. In one embodiment a retention structure882 is provided between the actuator876 and thedrive housing450. One embodiment of the retention structure882 is illustrated in detail B ofFIG. 15D. In particular, the retention structure882 includes an inwardly protruding member884 that is received in an annular recess formed in the outside surface of thedrive housing450. The protruding member890 can include an inwardly protruding ring having n diameter that is less than the diameter of theactuator876 distally and proximally of the protruding member884.
• FIGS. 15E-F illustrate operation of the deployment device.FIG. 15E corresponds to an expanded configuration of thecatheter assembly100. In this position, thepin874 is positioned at the distal end of theguide track872 and theflow diverter852 is in a proximal position. Because theflow diverter852, thecatheter body120, and the impeller housing are coupled together so that they move in unison, thecatheter body120 and the impeller housing are also positioned in a relatively proximal position. Relative axial movement is permitted between the impeller and the catheter body, as well as between the diffuser and the catheter body. Also, because thecatheter body120, theflow diverter852, and the impeller housing move in unison, relative axial movement is permitted between the impeller (and/or diffuser) and the impeller housing. As a result, the impeller will be in a more distal position relative to the impeller housing when thecatheter assembly100 is in the configuration ofFIG. 15E. The more distal position moves the impeller into the largest volume portion of the impeller housing enabling the impeller to expand.
• FIG. 15F corresponds to a collapsed configuration of thecatheter assembly100. In this position, thepin874 is positioned at the proximal end of theguide track872 and theflow diverter852 is in a distal position. This causes the impeller to be in a more proximal position relative to the housing when the catheter assembly is in the configuration ofFIG. 15F. This more proximal position moves the impeller into engagement with the inside surface of the housing tending to collapse the impeller.
• To move from the expanded configuration ofFIG. 15E to the collapsed configuration ofFIG. 15F, theactuator876 is rotated in a manner that causes the threads to act upon each other which creates axial movement of thecatheter body120 and theimpeller housing202.
C. Impellers Having Self-Sealing Impeller Tips and Lumens With Valves
• In some embodiments, thetip602 ofimpeller hub208 can be self-sealable or resealable (e.g., configured to automatically effectively form a seal to substantially stop the flow of a fluid in the absence of direct action by a user or operator to form the seal), as illustrated inFIGS. 16A-C. As illustrated inFIGS. 16B-C, thetip602 ofimpeller hub208 can include a resealable member having a resealable path therethrough.
• As shown inFIG. 16A, theimpeller tip602 can be made of an elastomeric material (e.g., a silicone or polyisoprene polymer). As shown inFIG. 16A, thetip602 can include aresealable path604 that extends along the length of the tip. Theresealable path604 can extend from the outer surface at the distal end oftip602 to the impeller shaft, which can be hollow. Thehollow shaft extension606 is shown inFIGS. 16A and 16B connected by theresealable path604 to thetip602 and is connected at its proximal end to theimpeller shaft204. Thus, theresealable path604 can extend from theimpeller shaft204 to the outer surface of thetip602. Theresealable path604 can be configured for guidewire passage. Theresealable path604 can generally pass through the center of rotation of theimpeller tip602.
• Theresealable path604 can be created using a very small diameter, e.g., a 32 gauge (0.00925 inch or 0.235 mm) wire or pin. In some embodiments, theresealable path604 can be created without coring the impeller tip602 (e.g., without punching out or otherwise removing a cylinder of material). Theresealable path604 can be self-sealable. For example, theresealable path604 can close or seal automatically, without the use of additional tools or implements. Theresealable path604 can be self-sealable due to the elastomeric properties of the material used for impeller tip602 (e.g., a silicone or polyisoprene polymer) and/or the diameter of theresealable path604. In some embodiments, circumferential and radial forces of the tip material and/or external pressure forces (illustrated with arrows at612) exerted while thecatheter assembly100 is implanted can also contribute to sealing theresealable path604.
• In some embodiments, thetip602 orresealable member622,624 can be made of the same material as the rest of the impeller system (e.g., hub, blades, shaft, and/or shaft extension). In other embodiments, thetip602 orresealable member622,624 can be made from a different material than the rest of the impeller system (e.g., hub, blades, shaft, and/or shaft extension). For example, thetip602 orresealable member622,624 can be made of a material that is more elastomeric (e.g., has greater elasticity) than the material from which theimpeller shaft204 and/orshaft extension606 are formed. In another example, thetip602 orresealable member622,624 can be made from a polyisoprene polymer and at least a portion of the impeller shaft204 (e.g., the distal end) and/orshaft extension606 are formed from an acrylonitrile butadiene styrene (ABS) polymer or a polycarbonate polymer.
• In some embodiments where theimpeller tip602 comprises aresealable member622 that is made separately from the rest of the impeller system, theresealable member622 can include one or more proximally-extendingtabs616. The one ormore tabs616 can be disposed about the proximal end ofresealable member622. In some embodiments, theresealable member622 can include one generallycylindrical tab616 that is disposed about the proximal end of theresealable member622. The one ormore tabs616 can be configured to mate with (e.g., can engage and/or be disposed within) one or more of the correspondingrecesses618 disposed on the distal end of a portion of the impeller assembly116 (e.g., thehub208,shaft204, and/or shaft extension606). As illustrated inFIG. 16B, therecess618 can be bounded by the surfaces of thehub208 and theshaft extension606. The one ormore recesses618 can be disposed about the distal end ofimpeller assembly116. In some embodiments, the distal end of theimpeller assembly116 can include onerecess618. For example, therecess618 can be a generally cylindrical channel surrounding at least a portion of theshaft extension606.
• Engagement of theresealable member622 with the distal end of theimpeller assembly116 as illustrated inFIG. 16B can have many advantages. For example, aninterface620 between theresealable member622 and the distal end of theimpeller assembly116 can be non-planar. Accordingly, anon-planar interface620 can have a greater surface area than an otherwise similar interface that is planar. The increased surface area can advantageously increase the connection strength between theresealable member622 and the distal end of theimpeller assembly116. In one embodiment, theinterface620 can be much longer than the radial distance from thelumen610 to the outer surface of thehub208. For example, theinterface620 can be at least about twice as long as this radial distance.
• As illustrated inFIG. 16B,resealable member622 can include avalve608 that extends proximally into anaxial lumen610. One valve structure that can be used is a duck bill valve. Thelumen610 can pass through one or more components of the distal end of theimpeller assembly116, such as theimpeller shaft204, theimpeller shaft extension606, and/or thehub208. Thelumen610 can have a diameter that is greater than the diameter of theresealable path604. Thelumen610 may also not be self-sealing. Thevalve608 can be tapered or otherwise have a reduced cross section compared to thelumen610. As a result, the impeller tip can also include one ormore corners614 where thelumen610 extends distally to overlap with thevalve608. The outer surface ofvalve608 can be separated by a distance from the inner surface of theresealable member622. Advantageously, where the pressure within thelumen610 is greater than the pressure outside thecatheter assembly100, the internal pressure can be exerted onvalve608 to closeresealable path604. The proximal extension of thevalve608 into thelumen610 can also promote easier entry of a guidewire into thelumen610 when the guidewire is introduced from the distal end of the pump. Other valves structures that may be used in place of thevalve608 are discussed in US application Ser. No. 12/829,359 and in U.S. Pat. No. 7,022,100, which are incorporated by reference herein for all purposes and in its entirety.
• Another embodiment of animpeller tip602 that includes aresealable member624 is illustrated inFIG. 16C. Theresealable member624 can have aresealable path630 therethrough. Theresealable member624 can optionally include a distal tapered portion. As described herein, the impeller can be coupled with the catheter body through adrive shaft148, which can be disposed or received within the axial lumen of the impeller or within theimpeller shaft204. As illustrated inFIG. 16C, a distal portion of a shaft, e.g., thedrive shaft148 or theimpeller shaft204, can be disposed or received within theresealable member624. Theimpeller tip602 can further include anon-resealable portion626 having anon-resealable path628 extending therethrough (e.g., a path that generally does not seal or close once it has been opened or created, and/or remains permanently open allowing fluid to pass therethrough). Theresealable path630 and thenon-resealable path628 can be co-linear (e.g., coaxial). As illustrated inFIG. 16C, thenon-resealable portion626 can extend distally of theresealable member624. In some embodiments, thenon-resealable portion626 can partially or fully surround an outer surface of theresealable member624. For example, theresealable member624 can be partially or entirely contained within thenon-resealable portion626. As illustrated inFIG. 16C, thenon-resealable portion626 can include the distal-most portion of theimpeller tip602. In some embodiments, thenon-resealable portion626 can be a unitary structure that includes the hub and one or more blades of the impeller. In one embodiment, thenon-resealable portion626 can include the entire impeller body except for theresealable member624. For example, as discussed above, the impeller can include a hub disposed between the impeller blades and theimpeller shaft204. The impeller hub can surround theresealable member624.
• Advantageously, theimpeller tip602 can be configured to receive a guidewire through both the resealable path and thenon-resealable path628. In some embodiments, the resealable path (when open) and/or the non-resealable path can have a diameter that is no more than one-half the diameter of the guidewire. Where theimpeller tip602 includes aresealable member624 disposed therein, the resealable member can be advantageously protected from the trauma to which the outer surface of theimpeller tip602 may be exposed. In addition, the distally-extending non-resealable path can act as a guide or channel that directs the guidewire through the impeller. Furthermore, as discussed herein, the tapered shape of the distal portion of theresealable member624 can help to reseal theresealable member624, as radial forces extending inwards can surround the tapered portion and help to close the resealable path. Note in this case that the non-resealable member, also made of an elastomeric material (but different actual material), retains a level of elasticity that can stretch to a lesser degree than the resealable material to accommodate passage of the guidewire.
• Theimpeller tip602 illustrated inFIG. 16C can be manufactured by first molding a soft and/or elastomeric material over at least a portion of thedrive shaft148 of theimpeller shaft204 to form theresealable member624. Some suitable materials for forming themember624 include polyurethane and silicone. Some materials having low durometer, e.g., below60A, can be used for theresealable member624. In some embodiments, the material can have a durometer in the range of from about25A to about55A. For example, the material can be a polyurethane or a silicone polymer having a durometer below60A (e.g., in the range of from about25A to about55A). In some embodiments with a polyurethane material, the hardness can be for example, about25A, about35A, about45A, or about55A. In other embodiments, a silicone material can be used for thetip602 and/or theresealable member622,624. The silicone material can have a hardness ranging from about20A to about60A. In some embodiments, the hardness can be about38A. As described above, theresealable member624 can optionally be formed to include a distal tapered portion. The rest of the impeller, or a portion thereof, can then be molded over theresealable member624 and thedrive shaft148. The remainder of theimpeller tip602 can be formed from a second material (e.g., a second polymer) that is different from the material used to form theresealable member624. Thenon-resealable path628 and theresealable path630 can be created after the impeller is molded over thedrive shaft148 or theimpeller shaft204. A variety of methods and/or tools can be used to create these paths, including but not limited to a drill, a needle, or a small gauge screw. In some embodiments, thepaths628,630 can be formed from a proximal end to a distal end of a wall of the impeller hub, e.g., distal of the distal most blade. In other embodiments, thepaths628 can be formed from a distal end of the impeller toward a proximal end of the impeller.
• In use, those skilled in the art may appreciate that non-sealable (e.g., non-resealable or non-self-sealing) devices may require a constant flow of infusant in the distal direction to prevent the proximal flow of fluid or blood into the device. Advantageously, a resealable tip can allow for guidewire passage through the center of thecatheter assembly100 to ease insertion without requiring a constant flush of infusant. The tip in various embodiments the resealable tip self-seals when the guidewire is removed. Valves discussed herein provide the advantage of preventing blood from entering other portions of thecatheter assembly100, such as theimpeller shaft204 or thelumen234 or the bearinghousing228. In various embodiments, valves are configured to be actuated from an at least partially open configuration to a closed configuration, such as by application of a force or pressure on one side thereof.
D. Sheath Having Expandable Distal End
• As described herein, the pump can include a sheath assembly. The sheath assembly can control the collapse and expansion of the impeller and/or the impeller housing. In some embodiments, the distal end of the sheath assembly can optionally include one or more structures that aid in the deployment and/or retrieval of the impeller assembly.
• In some embodiments, as shown inFIGS. 17A to 17D, the sheath assembly can include an expandabledistal end170a,170b,170c.For example, the distal end can expand when a radial force is applied, and can contract when the radial force is removed. The distal end may also be able to expand and/or contract repeatedly. When expanded, thedistal end170a,170b,170ccan have a conical and/or funnel-like configuration. When not expanded, thedistal end170a,170b,170ccan have a generally cylindrical (e.g., generally constant diameter) configuration, for example as illustrated inFIG. 17A. To assist with expansion and/or contraction, thedistal end170a,170b,170cor portions thereof may be made from materials having a different flexibility and/or elasticity (e.g., more or less flexible and/or elastic) than the material(s) used for all or a portion of the remainder of the sheath assembly. In some embodiments, thesheath assembly162 can have at least one configuration where it is at least partially disposed over the impeller housing, catheter assembly, and/or impeller assembly. Advantageously, the conical and/or funnel-like configuration can aid the deployment and/or retraction of the impeller assembly and/or impeller housing as described herein.
• As illustrated inFIG. 17A, thedistal end170acan include one or more axial slits702 (e.g., 2, 3, or 4 slits).Slit702 can extend proximally from thedistal end170aat least partially along the length of theelongate body174. Thedistal end170acan also include a plurality of elongate members704 (e.g., 2, 3, or 4 elongate members). Eachelongate member704 can be joined at one end (e.g., proximal end) to the sheath assembly. Eachelongate member704 can also have adistal end705 that is outwardly deflectable away from axis708. Theelongate members704 can be separated from each other by theslits702. Eachelongate member704 can have a width that is defined by the distance betweenslits702 and a length defined by the length of eachadjacent slit702. In some embodiments, theelongate members704 andslits702 can be generally equally spaced circumferentially about theelongate body174. In some embodiments, theelongate members704 can each have a length that is generally equal to or greater than the axial length of the outlet portion of the impeller housing. For example, in some embodiments, theelongate members704 can each have a length in the range of from about 0.25 in. up to about 2.0 in. In other embodiments, theelongate members704 can each have a length in the range of from about 0.5 in to about 0.75 in. Theelongate members704 and/or at least a portion of the sheath assembly162 (e.g., the portion of thesheath assembly162 that connects to elongate members704) can be made from a relatively elastic material (e.g., any of the elastomeric polymers described herein).
• In use, an outwardly-acting radial force resulting from the radial stiffness of the impeller housing can be applied to theelongate members704 which causes theelongate members704 to deflect outwards, as illustrated inFIG. 17B. For example, the axial movement of the impeller housing in the proximal direction into the sheath assembly (or distal movement of the sheath over the expanded impeller housing) can cause theelongate members704 to deflect outwards. The outward deflection of theelongate members704 can result in the conical or funnel-like configuration of thedistal end170awhen sheathed over an expanded section of the impeller housing. When theelongate members704 are deflected outwards, the width of each slit702 can increase at the distal end to define agap709. In some embodiments, theelongate members704 can be self-collapsing. For example, theelongate members704 can be configured to return to their original configuration when the internal outward-acting radial forces are released (e.g., where theelongate members704 are made of a relatively elastic material).
• As illustrated inFIG. 17C, thedistal end170bof the sheath assembly can include an deformable structure706 (e.g., a webbing) that at least partially covers one ormore slits702. In some embodiments, the deformable (e.g., stretchable, expandable, flexible, and/or elastic)structure706 can surround, coat, and/or cover at least a portion of thedistal end170b(e.g., the elongate members704). As illustrated inFIG. 17C, thedeformable structure706 can be an elastomeric coating (e.g., incorporating those elastomeric materials described herein). In other embodiments, thedeformable structure706 can include a spring, such as a semi-circular spring member having a straight or oscillatory pattern. In use, thedeformable structure706 can be configured to return theelongate members704 to their original, non-conical configuration and/or prevent over-deflection of theelongate members704 beyond their elastic limit.
• In some embodiments, theelongate members704 can be stiffer (in the circumferential and/or axial direction(s)) than the proximally-adjacent portion of the sheath assembly. Advantageously, the stiffer material can prevent or inhibit the distal-most end of the sheath assembly from folding over itself when it encounters resistance (e.g., advancing the sheath over an expanded cannula housing). In one embodiment, one or moreelongate members704 can be reinforced with a plurality of wires that extend to the distal-most tip of theelongate member704. In another embodiment, one or moreelongate members704 can be made from a polymer that is stiffer than the material (e.g., a second polymer) of the proximally-adjacent portion of the sheath assembly.
• As illustrated inFIG. 17D, in some embodiments thedistal end170cofsheath assembly162 can include anintegral funnel710 having a distal, conically-shapedportion711. As described further herein, theintegral funnel710 can be expandable and/or collapsible. Advantageously, theintegral funnel710 can assist in deployment and retraction of the housing while minimally increasing the profile of the pump. Theintegral funnel710 can be connected to anon-expandable portion712 of the sheath, for example, at adistal-most tip714. Theintegral funnel710 can include anouter layer713 and aninner layer715 that converge at aninterface717. Theintegral funnel710 can be layered over anouter surface716 and over aninner surface718 of thenon-expandable portion712. Accordingly, as illustrated inFIG. 17D, at least a portion of theinner layer715 can reside, at least temporarily, within the lumen of thesheath assembly162. The integral funnel708 can be connected to either theouter surface716 or theinner surface718 of the sheath. In some embodiments, thefunnel710 can be a distal extension ofdistal end170 that is folded over thenon-expandable portion712.
• Theintegral funnel710 can be slideable over theouter surface716 and/or theinner surface718 of thenon-expandable portion712. The contact surfaces between thenon-expandable portion712 and theintegral funnel710 and/or between theouter layer713 and theinner layer715 can be lubricated, e.g., using a silicone lubricant, to establish and/or maintain slideability and/or low friction. Theintegral funnel710 can be made from a thin, flexible material, such as a polyurethane polymer. In some embodiments, theintegral funnel710 can be made from a material that is more flexible and/or elastic than the material that is used for all or a portion of the remainder of the sheath assembly. In some embodiments, the material used for theintegral funnel710 can have one or more membrane-like qualities. In use, the axial movement of the housing202 (not shown) can frictionally engage theintegral funnel710, causing theintegral funnel710 to deploy or retract. For example, in embodiments where theouter layer713 is affixed to thenon-expandable portion712 of the sheath, axial movement of thehousing202 in a distal direction can cause theinner layer715 to translate distally (e.g., slide distally along theinner surface718 of the sheath), thus deploying the conical portion711 (e.g., pulling theconical portion711 out of the sheath). Axial movement of the housing in a proximal direction can cause theinner layer715 to translate proximally (e.g., slide proximally along theinner surface718 of the sheath), thus retracting theconical portion711 into the sheath (e.g., pulling theconical portion711 into the sheath). The thin, flexible material of theconical portion711 can advantageously allow theconical portion711 to deform upon retraction into the sheath.
• In embodiments where theinner layer715 is affixed to the non-expandable portion of the sheath, axial movement of thehousing202 can cause theouter layer713 to translate. For example, distal movement of the housing can cause theouter layer713 to slide distally along theouter surface716 of the sheath. Proximal movement of the housing can cause theouter layer713 to slide proximally along theouter surface716 of the sheath.
• In some embodiments where thefunnel710 is a distal extension of thenon-expandable portion712 that is folded over thenon-expandable portion712, thefunnel710 can slide distally as thenon-expandable portion712 is moved proximally. In use, as thenon-expandable portion712 is moved proximally, thefunnel710 can slide distally to unfold and surround theimpeller assembly116.
IV. Methods
• Various methods and techniques are discussed above in connection with specific structures of heart pumps. The following elaborates on some aspects of these techniques and methods. The following discussion is to be read in light of and freely combined with the foregoing discussion.
A. Retracting and Deploying the Impeller Housing By Way of the Impeller Deployment Assembly at the Proximal End of the Catheter Body
• As discussed above, in various embodiments theheart pump10 is inserted in a less invasive manner, e.g., using techniques that can be employed in a catheter lab. Various general techniques pertinent to theheart pump10 are described in U.S. patent application Ser. No. 12/829,359, filed on Jul. 1, 2010, and entitled Blood Pump With Expandable Cannula, which is incorporated by reference herein in its entirety and for all purposes.
• Because thecatheter assembly100 is to be delivered through a small access site, it can be important to ensure that the impeller housing is reliably deployed and retracted, as described above. A clinician may begin a heart pumping procedure by introducing thecatheter assembly100 into the patient percutaneously, e.g., by urging the catheter assembly through the femoral artery and into a heart chamber. Because the impeller and impeller housing are advanced through a narrow artery in some embodiments, the impeller and impeller housing can initially be inserted into the patient in a retracted, or collapsed (or low profile), state, as described above. Once the distal end of the catheter assembly100 (including the impeller housing) has reached the desired operating location (e.g., a heart chamber), the clinician can deploy the impeller housing into an advanced or expanded configuration.
• One method of deploying the impeller and/or diffuser is by using theimpeller deployment assembly800, which can be located near the proximal end of the catheter assembly. As shown inFIGS. 15A and 15B, the clinician can rotate the nut804 (clockwise or counter-clockwise depending on the threading) such that thenut804 translates from a distal position to a proximal position. In turn, theflow diverter806, the catheter body, and the impeller housing can also translate from a distal position to a proximal position and thereby advance the impeller distally into a wider portion of the impeller housing to allow for deployment of theimpeller hub208 andblades212. Thus, in some embodiments, the clinician can deploy the impeller, located at a distal end of the catheter assembly, by rotating a nut disposed near the proximal end of the catheter assembly.
• In some embodiments, theimpeller200 andhousing202 can be axially displaced relative to their operational positions during delivery of the distal end to the heart (e.g., the impeller and housing can be delivered to the vasculature in an axially separated configuration). As used in this context, “axially displaced” includes configurations where there is axial movement of theimpeller200 relative to any portion of thehousing202 prior to or during the process of delivery. For example, axial displacement includes conditions in which theimpeller200 is moved from a first position near a proximal end port (outlet for left side support or inlet for right side support) of thehousing202 to a second position distal the first position. The second position can be one that is still between the proximal end port and a distal end port (inlet for left side support or outlet for right side support) of thehousing202. The first position may be the operational position of theimpeller200 relative to thehousing202. Axial displacement also includes conditions in which the impeller is located proximal of an operational position, e.g., at a location proximal of a proximal end port of thehousing202, including being disposed within a non-expandable portion of the heart pump. When the clinician delivers the distal end of the heart pump to the heart chamber, rather than delivering the distal end with the impeller housing disposed over the impeller blades, the impeller housing can be in a proximally displaced position or retracted configuration (or distally displaced position or advanced configuration in other embodiments) with respect to the impeller, such that it is axially moved from the operational position, as discussed above.
• In some embodiments, the impeller and the housing can be delivered in series (with the impeller being delivered before the housing, or vice versa). For example, in one embodiment, theimpeller housing202 is first advanced into position, e.g., in the heart. Thehousing202 may then be expanded if the housing has expanded and compressed configurations. Thereafter theimpeller200 may be positioned, e.g., advanced through a catheter body similar to thecatheter body120 to be positioned within theimpeller housing202. Thereafter theimpeller200 can be rotated by a source of rotational energy. In various embodiments, the source of rotational energy can comprise a motor positioned outside of the patient to drive a shaft similar to theshaft148. In other embodiment, the source of rotational energy can comprise a motor that is miniaturized to be positionable within the patient, as discussed in U.S. Pat. No. 7,070,555, which is incorporated by reference herein for all purposes and in its entirety. In another embodiment, the distal end of theimpeller200 can be configured to be advanced into position in the patient and, at a later stage of a procedure, theimpeller housing202 can be positioned thereover. In one technique, theimpeller200 is positioned in the heart chamber (or wherever the procedure is to occur), the clinician can then advance the impeller housing over the impeller blades and begin operating the heart pump. For removal of the catheter assembly from the patient after the procedure, the clinician can retract or displace the impeller housing proximally to axially displace and/or separate the impeller from the impeller housing.
• The configurations enabling displaced or serial delivery also can decouple the design of theimpeller housing202 from the complexities of the design of theimpeller200. For example, theimpeller housing202 can have a greater range of expansion from a collapsed state to an expanded state. If no structures are disposed inside thehousing202 in the collapsed state, greater compression and a lower crossing profile can be achieved compared to where thehousing202 must be sized in the collapsed state to accommodate theimpeller200 in its collapsed state. This provides one or more of the benefits of access through smaller vessels, in smaller patients, or a larger expanded size in standard patients through typical access (e.g., femoral vessel). Similarly, greater compression of theimpeller200 may be possible if theimpeller200 is delivered using a dedicated compression sheath or device that is not required to expand and/or to be present around the impeller during operation. As a result, larger blades may be delivered from the same collapsed profile, providing the advantages of higher flow discussed above. More details of serial delivery of blood pumps are discussed in U.S. Pat. No. 7,022,100, which is incorporated by reference herein for all purposes and in its entirety.
• Once the impeller is deployed, the clinician can conduct the procedure, e.g., by running the heart pump within a heart chamber. Once the procedure is finished, the clinician can remove the catheter assembly from the patient by retracting the impeller. The clinician can simply rotate thenut804 in a direction opposite to that rotated for deploying the impeller. The nut can then translate from the proximal position to the distal position, which in turn can cause theflow diverter806, the catheter body, and the impeller housing to also translate from the proximal position to the distal position. The impeller can thereby be retracted proximally into an area near theoutlet802 to reduce the profile of the pump upon collapsing into the sheath. Thus, the clinician can both deploy and retract the impeller by rotating a nut located near the proximal end of the catheter assembly.
• B. Controlling the Collapse and Deployment of the Impeller Housing with the Sheath Assembly
• As mentioned above in Section IV(A), it can be advantageous in certain embodiments to enable a clinician to deploy and retract the impeller assembly prior to and after a heart procedure. One method of collapsing the impeller housing can be performed by advancing thesheath assembly162 distally over the impeller housing to collapse the impeller assembly, e.g., for removal of the catheter assembly from the patient after a heart procedure. As mentioned above,elongate body174 of thecatheter assembly162 can be slidably disposed over thecatheter body120. The clinician can distally advance theelongate body174 over the impeller housing, or alternatively proximally retract thecatheter body120 such that the impeller housing collapses into theelongate body174 of thesheath assembly162.
• AsFIGS. 17A-D illustrate, the sheath assembly can have expandable distal ends170a,170b,170c,that expand when a radial force is applied. Thus, when the clinician advances theelongate body174 of the sheath over the impeller housing, the impeller housing can contact thedistal end170 and can induce a radial force that causes the distal ends170a,170b,170c,to expand in order to aid in retraction of the impeller assembly. Similarly, when the clinician slides theelongate body174 in a proximal direction, the impeller assembly can deploy through thedistal end170 of thecatheter assembly162, because the distal ends170a,170b,170c,can contract when a radial force is removed (or not applied). Thus, the clinician can reliably deploy and retract the impeller assembly by sliding theelongate body174 of the sheath relative to thecatheter body120. In other embodiments, the sheath assembly need not have expandable distal ends as described above. The clinician can therefore simply deploy theimpeller assembly116 by providing relative motion between theelongate body174 of the sheath and the impeller assembly, e.g., by retracting theelongate body174 from the impeller assembly, and can collapse the impeller assembly by providing relative motion between theelongate body174 of the sheath and theimpeller assembly116, e.g., by advancing the elongate body over the impeller assembly. The distal end of theelongate body174 can therefore effectuate collapse of theimpeller assembly116 without using the expandable distal ends described above. In embodiments where the impeller assembly is self-expanding, the retraction of theelongate body174 from theimpeller assembly116 or extension of theimpeller assembly116 out of theelongate body174 can release the impeller assembly to self-expand.
• It will be apparent to those skilled in the art that various modifications and variations can be made in the present embodiments without departing from the scope or spirit of the advantages of the present application. Thus, it is intended that the present application cover the modifications and variations of these embodiments and their equivalents.

Claims (12)

1-23. (canceled)

24. A heart pump configured to be applied percutaneously, comprising:

a catheter assembly comprising a proximal end, a distal end, and an elongate body extending therebetween;

an impeller assembly comprising an impeller and a housing in which the impeller is disposed; and

a sheath assembly disposed over at least a portion of the distal end of the catheter body, the sheath assembly comprising an expandable distal end operable to facilitate collapsing and expanding the impeller housing.

25. The heart pump ofclaim 24, wherein the expandable distal end is configured to expand when a radial force is applied, and contract when the radial force is removed.

26. The heart pump ofclaim 24, wherein the expandable distal end has a conical configuration in an expanded position, and a cylindrical configuration in a non-expanded position.

27. The heart pump ofclaim 24, wherein the expandable distal end includes at least one axial slit.

28. The heart pump ofclaim 24, wherein the expandable distal end includes a plurality of elongate members.

29. The heart pump ofclaim 28, wherein each of the plurality of elongate members has a length that is greater than an axial length of an outlet portion of the impeller housing.

30. The heart pump ofclaim 28, wherein the plurality of elongate members are made of an elastic material.

31. The heart pump ofclaim 28, wherein the expandable distal end includes a deformable webbing extending between the plurality of elongate members.

32. The heart pump ofclaim 28, wherein the plurality of elongate members have a first stiffness that is greater than a second stiffness of a proximal portion of the sheath assembly.

33. The heart pump ofclaim 24, wherein the expandable distal end includes an integral funnel layered over an outer surface and an inner surface of a non-expandable portion of the sheath assembly.

34. The heart pump ofclaim 33, wherein the integral funnel is slidable relative to the inner surface and the outer surface of the non-expandable portion.

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