US6030371A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Catheters and method for nonextrusion manufacturing of catheters
Assignee: Philips Image Guided Therapy Corp
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Filing: 1997-08-22
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Granted: 2000-02-29
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Expires: 2017-08-22
Abstract
Abstract An apparatus and method for nonextrusion manufacturing of catheters that can be used to produce catheters having a simple or complex configuration. A polymer material in a particulate preform is applied in a layer over an outer surface of a core member. By applying the polymer material in a particulate preform, a composition of the polymer material can be varied continuously as it is being applied to provide a variable hardness over the length of the catheter. A fibrous reinforcement can be used having a constant or variable pitch and a constant or variable number of fibers and fiber types. Sensors can be easily placed in a wall of the catheter as the catheter is being fabricated, thereby allowing more sensors to be used without placing conductors in the lumen of the catheter. Deflection passages can be provided in a wall of the catheter for inserting a wire to deflect the catheter. The polymer material can be heated into molten form as it is being applied, or the core mandrel or liner can be heated to cause the polymer material to consolidate upon impact. A mandrel in the preferred embodiment is rotated about its longitudinal axis while a spray head and filament winding head traverse the length of the mandrel and apply polymer material and filament, respectively. Other arrangements can also be used, including a spray head and filament winding head that rotate about a continuous core mandrel, and a fluidized bed or other container into which a heated core mandrel is immersed. A plurality of mandrels can be placed side-by-side to form a multiple lumen tubing.
Inventors
- 👤 Matt D. Pursley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 07:25
CPC Classifications
A; A61; A61M; A61M25/00; A61M25/0009; A61M25/0012; B; B05; B05D; B05D1/00; B05D1/002; B05D1/34; B05D7/00; B05D7/20; B23; B23K; B23K26/00; B23K26/08; B23K26/0823; B29; B29C; B29C53/00; B29C53/80; B29C53/8008; B29C53/8066; B29C53/8075; B29D; B29D23/00; B29D23/001; A61M25/0043; A61M25/005; A61M25/0053; B05B; B05B13/00; B05B13/02; B05B13/04; B05B13/0442; B05C; B05C3/00; B05C3/02; B05C3/12; B05D1/02; B05D1/04; B05D1/06; B05D1/08; B05D1/10; B05D1/12; B05D2401/00; B05D2401/30; B05D2401/32; B05D3/00; B05D3/02; B05D3/0218; B29C2791/00; B29C2791/004; B29C2791/009; B29C53/56; B29C53/58; B29C53/60; B29C53/68; B29L; B29L2031/00; B29L2031/753; B29L2031/7542
Claims Analysis
Total Claims: 45
Claim 1
Independent Claim
128 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface; providing first and second polymer materials, said first polymer material having a different hardness than said second polymer material; applying a nonextruded layer comprising a mixture of said first and second polymer materials over a length of said outer surface of the core by spraying said polymer materials toward the core such that particles of said polymer materials cover the outer surface of the core and are consolidated to form the medical tubing; and changing a mixed ratio of said first polymer material to said second polymer material as said polymer materials ate being sprayed toward the core to provide a continuous transition of hardness over a length of the tubing.
Claim 2
Independent Claim
128 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface; providing first and second polymer materials, said first polymer material having a different hardness than said second polymer material; applying a nonextruded layer comprising a mixture of said first and second polymer materials over a length of said outer surface of the core by spraying said polymer materials toward the core such that particles of said polymer materials cover the outer surface of the core and are consolidated to form the medical tubing; and changing a mixed ratio of said first polymer material to said second polymer material as said polymer materials ate being sprayed toward the core to provide a continuous transition of hardness over a length of the tubing.
Claim 3
Dependent Claim
24 words
The method of making medical tubing according to claim 1, wherein said polymer materials are provided in powder form for applying to said core.
Claim 4
Dependent Claim
26 words
The method of making medical tubing according to claim 1, wherein said polymer materials are provided in a solution of solvent for applying to said core.
Claim 5
Dependent Claim
34 words
The method of making medical tubing according to claim 1, further comprising the step of placing a liner over a core mandrel before applying the layer of polymer material, said liner comprising said core.
Claim 6
Dependent Claim
28 words
The method of making medical tubing according to claim 1, further comprising the step of winding a filament about said core before applying the layer of polymer material.
Claim 7
Dependent Claim
25 words
The method of making medical tubing according to claim 1, further comprising the step of rotating the core while applying the layer of polymer material.
Claim 8
Independent Claim
85 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface; providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material impact on the outer surface of the core and are consolidated to form the medical tubing; and heating the polymer material into a molten state before the polymer material impacts on the outer surface of said core.
Claim 9
Independent Claim
85 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface; providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material impact on the outer surface of the core and are consolidated to form the medical tubing; and heating the polymer material into a molten state before the polymer material impacts on the outer surface of said core.
Claim 10
Dependent Claim
50 words
The method of making medical tubing according to claim 1, further comprising the steps of heating the core and spraying the polymer materials in powder form onto the heated core, wherein the polymer materials are consolidated on the core as a result of the heated core melting the polymer materials.
Claim 11
Dependent Claim
35 words
The method of making medical tubing according to claim 1, further comprising the step of selectively applying opacifier material to said core to form a plurality of opacifier rings along the length of the tubing.
Claim 12
Dependent Claim
35 words
The method of making medical tubing according to claim 1, further comprising the step of sizing the tubing by grinding or cutting an outer surface of the tubing after applying the layer of polymer material.
Claim 13
Dependent Claim
33 words
The method of making medical tubing according to claim 1, further comprising the step of sizing the tubing by passing a laser beam over a tangential surface of the layer of polymer material.
Claim 14
Dependent Claim
42 words
The method of making medical tubing according to claim 1, further comprising the step of providing a spray head to apply the layer of polymer material to the core, and rotating the spray head about the core while applying the polymer material.
Claim 15
Independent Claim
81 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface; providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material are consolidated to form the medical tubing; and grounding the core and charging the polymer material to cause the polymer material to cling to the core electrostatically as the polymer material is applied.
Claim 16
Independent Claim
81 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface; providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material are consolidated to form the medical tubing; and grounding the core and charging the polymer material to cause the polymer material to cling to the core electrostatically as the polymer material is applied.
Claim 17
Independent Claim
77 words
A method of making medical tubing having multiple lumens; comprising the steps of: providing a plurality of cores each having an outer surface; placing said plurality of cores in close proximity to each other; providing at least one polymer material; and applying a nonextruded layer of polymer material over a length of said outer surfaces of said plurality of cores such that particles of said polymer material are consolidated to form the medical tubing having multiple lumens.
Claim 18
Independent Claim
77 words
A method of making medical tubing having multiple lumens; comprising the steps of: providing a plurality of cores each having an outer surface; placing said plurality of cores in close proximity to each other; providing at least one polymer material; and applying a nonextruded layer of polymer material over a length of said outer surfaces of said plurality of cores such that particles of said polymer material are consolidated to form the medical tubing having multiple lumens.
Claim 19
Independent Claim
84 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface: providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material are consolidated to form the medical tubing; placing at least one conductor and at least one sensor over said nonextruded layer of polymer material; and applying a second nonextruded layer of polymer material over said conductor.
Claim 20
Independent Claim
84 words
A method of making medical tubing, comprising the steps of: providing a core having an outer surface: providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material are consolidated to form the medical tubing; placing at least one conductor and at least one sensor over said nonextruded layer of polymer material; and applying a second nonextruded layer of polymer material over said conductor.
Claim 21
Dependent Claim
60 words
The method of making medical tubing according to claim 15, further comprising the steps of: winding a first filament about said medical tubing before placing said conductor and said sensor; winding a second filament about said medical tubing after placing said conductor and said sensor; and applying said second nonextruded layer of polymer material over said filaments and said conductor.
Claim 22
Independent Claim
112 words
A method of making medical tubing, comprising the steps of: providing a gore having an outer surface; providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material are consolidated to form the medical tubing; forming at least one longitudinal passage in said nonextruded layer of polymer material; placing a resilient fiber into said longitudinal passage; and anchoring a distal end of said resilient fiber adjacent a distal end of said longitudinal passage, whereby the medical tubing can be deflected by applying a force to a proximal end of said resilient fiber.
Claim 23
Independent Claim
112 words
A method of making medical tubing, comprising the steps of: providing a gore having an outer surface; providing at least one polymer material; applying a nonextruded layer of said polymer material over a length of said outer surface of the core such that particles of said polymer material are consolidated to form the medical tubing; forming at least one longitudinal passage in said nonextruded layer of polymer material; placing a resilient fiber into said longitudinal passage; and anchoring a distal end of said resilient fiber adjacent a distal end of said longitudinal passage, whereby the medical tubing can be deflected by applying a force to a proximal end of said resilient fiber.
Claim 24
Independent Claim
95 words
A method of making a tubular structure, comprising the steps of: applying a nonextruded layer of polymer material over a length of a core substrate; and varying a composition and color of said polymer material while said layer of polymer material is being applied to thereby provide said layer of polymer material with a variable hardness and color over at least a portion of a length of the core substrate, whereby a change in the hardness of the layer of polymer material is indicated by a change in color of the layer of polymer material.
Claim 25
Independent Claim
95 words
A method of making a tubular structure, comprising the steps of: applying a nonextruded layer of polymer material over a length of a core substrate; and varying a composition and color of said polymer material while said layer of polymer material is being applied to thereby provide said layer of polymer material with a variable hardness and color over at least a portion of a length of the core substrate, whereby a change in the hardness of the layer of polymer material is indicated by a change in color of the layer of polymer material.
Claim 26
Dependent Claim
74 words
The method of making a tubular structure according to claim 18, further comprising the steps of: mixing a first polymer material with a second polymer material, said first polymer material having a different hardness than said second polymer material; and changing a mixed ratio of said first polymer material to said second polymer material as said layer of polymer material is applied to provide a variable hardness over a length of the tubular structure.
Claim 27
Dependent Claim
36 words
The method of making a tubular structure according to claim 19, further comprising the step of selectively mixing an opacifier material with the first and second polymer materials as said layer of polymer material is applied.
Claim 28
Dependent Claim
72 words
The method of making a tubular structure according to claim 18, further comprising the steps of: providing at least first and second polymers having different hardnesses and different colors; and selectively mixing said first and second polymers to vary a hardness in the layer of polymer material, whereby a transition in the hardness of the layer of polymer material is indicated by a change in color of the layer of polymer material.
Claim 29
Dependent Claim
73 words
The method of making a tubular structure according to claim 18, further comprising the steps of: forming at least one longitudinal passage in said nonextruded layer of polymer material; placing a resilient fiber into said longitudinal passage; and anchoring a distal end of said resilient fiber adjacent a distal end of said longitudinal passage, whereby the tubular structure can be deflected by applying a force to a proximal end of said resilient fiber.
Claim 30
Dependent Claim
14 words
A catheter comprising a tubular structure manufactured by the method defined in claim 18.
Claim 31
Dependent Claim
41 words
A catheter comprising a nonextruded layer of polymer material having a continuously changing hardness over at least a portion of a length of the catheter, wherein said layer of polymer material comprises different color shades providing a visual indication of hardness.
Claim 32
Dependent Claim
41 words
A catheter comprising a nonextruded layer of polymer material having a continuously changing hardness over at least a portion of a length of the catheter, wherein said layer of polymer material comprises different color shades providing a visual indication of hardness.
Claim 33
Dependent Claim
22 words
The catheter according to claim 24, further comprising a liner, said layer of polymer material covering an outer surface of said liner.
Claim 34
Dependent Claim
22 words
The catheter according to claim 24, wherein said layer of polymer material has a uniform thickness over said portion of the catheter.
Claim 35
Dependent Claim
18 words
The catheter according to claim 24, further comprising a reinforcement filament embedded within said layer of polymer material.
Claim 36
Dependent Claim
20 words
The catheter according to claim 24, further comprising at least one opacifier mark extending about a circumference of the catheter.
Claim 37
Dependent Claim
20 words
The catheter according to claim 24, further comprising a plurality of opacifier marks spaced along the length of the catheter.
Claim 38
Dependent Claim
14 words
The catheter according to claim 24, further comprising multiple lumens extending through the catheter.
Claim 39
Dependent Claim
43 words
A catheter comprising a nonextruded layer of polymer material having a continuously changing hardness over at least a portion of a length of the catheter, further comprising at least one conductor and at least one sensor embedded in said layer of polymer material.
Claim 40
Dependent Claim
43 words
A catheter comprising a nonextruded layer of polymer material having a continuously changing hardness over at least a portion of a length of the catheter, further comprising at least one conductor and at least one sensor embedded in said layer of polymer material.
Claim 41
Dependent Claim
83 words
A catheter comprising a nonextruded layer of polymer material having a continuously changing hardness over at least a portion of a length of the catheter, further comprising at least one longitudinal passage embedded in said layer of polymer material and a resilient fiber extending through said longitudinal passage, a distal end of said resilient fiber being anchored adjacent a distal end of the longitudinal passage, whereby the catheter can be deflected by applying a force to a proximal end of said resilient fiber.
Claim 42
Dependent Claim
83 words
A catheter comprising a nonextruded layer of polymer material having a continuously changing hardness over at least a portion of a length of the catheter, further comprising at least one longitudinal passage embedded in said layer of polymer material and a resilient fiber extending through said longitudinal passage, a distal end of said resilient fiber being anchored adjacent a distal end of the longitudinal passage, whereby the catheter can be deflected by applying a force to a proximal end of said resilient fiber.
Claim 43
Dependent Claim
21 words
The method of making medical tubing according to claim 3, wherein said polymer material is consolidated by driving off the solvent.
Claim 44
Dependent Claim
34 words
The method of making medical tubing according to claim 10, wherein said step of sizing the tubing comprises grinding or cutting the tubing to have a tapering thickness over a length of the tubing.
Claim 45
Dependent Claim
33 words
The method of making medical tubing according to claim 11, wherein said step of sizing the tubing comprises using the laser beam to create a tapering thickness over a length of the tubing.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2003-02-28 | 2003-08-30 | 2004-02-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2007-02-28 | 2007-08-30 | 2008-02-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2011-02-28 | 2011-08-30 | 2012-02-29 | $7700.00 | Window Closed / Lapsed |