CORE WIRE HAVING A FLATTENED PORTION TO PROVIDE PREFERENTIAL BENDING

Abstract

A guide wire configured for intravascular insertion includes a core wire having a flattened portion configured to allow the core wire to preferentially bend in at least one plane that passes through a longitudinal axis of the core wire. A distal most end of the flattened portion is spaced from a distal most end of the core wire. The guide wire may further include a sensor element configured to measure a physiological variable in a living body and a coil surrounding a portion of the core wire.

Claims

1. A guide wire configured for intravascular insertion, the guide wire comprising: a core wire having a flattened portion configured to allow the core wire to preferentially bend in at least one plane that passes through a longitudinal axis of the core wire, wherein a distal most end of the flattened portion is spaced from a distal most end of the core wire.

2. The guide wire of claim 1, wherein the core wire consists of only the flattened portion.

3. The guide wire of claim 1, wherein the core wire further comprises at least one rounded portion.

4. The guide wire of claim 1, wherein the core wire further comprises a first rounded portion and a second rounded portion, and the flattened portion is provided between the first rounded portion and the second rounded portion.

5. The guide wire of claim 4, wherein a cross-sectional area of the core wire decreases from the first rounded portion to the flattened portion, and wherein the cross-sectional area of the core wire increases from the flattened portion to the second rounded portion.

6. The guide wire of claim 4, wherein from the distal most end to a proximal end, the flattened portion comprises a first transition portion, a constantly flat portion, and a second transition portion, the first transition portion being disposed between the first rounded portion and the constantly flat portion, and the second transition portion being disposed between the constantly flat portion and the second rounded portion.

7. The guide wire of claim 4, wherein the flattened portion has a first length and each of the first rounded portion and the second rounded portion has a length shorter than the first length.

8. The guide wire of claim 4, wherein a cross-section of each of the first rounded portion, the flattened portion and the second rounded portion is symmetrical with respect to at least one plane that passes through the longitudinal axis of the core wire.

9. The guide wire of claim 4, wherein the first rounded portion, the flattened portion and the second rounded portion are integrally formed from a single piece.

10. The guide wire of claim 6, wherein the constantly flat portion has a length greater than a length of each of the first transition portion and the second transition portion.

11. The guide wire of claim 6, wherein the constantly flat portion has an approximately rectangular cross-section.

12. The guide wire of claim 1, wherein the core wire is configured to preferentially bend in a plane that passes through the longitudinal axis of the core wire and extends in an up-down direction of the core wire.

13. The guide wire of claim 12, wherein the core wire is configured to preferentially bend in an up direction to a same degree as the core wire is configured to preferentially bend in a down direction.

14. The guide wire of claim 1, wherein the core wire further comprises a second flattened portion, and wherein the flattened portion and the second flattened portion have different dimensions.

15. The guide wire of claim 1, wherein the flattened portion is not twisted.

16. The guide wire of claim 1, further comprising: a sensor element configured to measure a physiological variable in a living body; and a coil, wherein a portion of the core wire is disposed within the coil.

17. The guide wire of claim 16, wherein the portion of the core wire disposed within the coil comprises the flattened portion.

18. The guide wire of claim 16, further comprising a jacket proximal to the coil, wherein the coil is attached to an inner circumference or an outer circumference of the jacket.

19. The guide wire of claim 18, wherein the portion of the core wire disposed within the coil further comprises a connector portion configured to mate with a distal end of the jacket.

20. The guide wire of claim 1, wherein the core wire is made out of stainless steel, nitinol, or cobalt chromium.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The features, aspects and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

[0023] FIG. 1 is a schematic drawing showing a system for intravascular measurement.

[0024] FIG. 2 shows an exemplifying sensor mounted on a guide wire that may be used in the system of FIG. 1.

[0025] FIG. 3 is an isometric view of a distal end of a sensor guide wire according to one embodiment of the invention, where a core wire includes a flattened portion.

[0026] FIG. 4A is a side view of the core wire and coil of FIG. 3.

[0027] FIG. 4B illustrates the cross-sections of the portions of the core wire taken through the lines A-A, B-B, C-C, D-D, E-E, and F-F of FIG. 4A.

[0028] FIG. 5A is another side view of the core wire and coil of FIG. 3.

[0029] FIG. 5B is an enlarged side view of the section I of FIG. 5A.

[0030] FIG. 5C is an enlarged side view of the section II of FIG. 5A.

[0031] FIG. 6 is a top view of the core wire and coil of FIG. 3.

[0032] FIG. 7A is a side view of an overall length of the core wire of FIG. 3.

[0033] FIG. 7B is an enlarged side view of the Detail A of FIG. 7A.

[0034] FIG. 8 illustrates the core wire of FIG. 3 including exemplary dimensions.

[0035] FIG. 9 illustrates the distal most end of the core wire of FIG. 3 thermally welded to the coil of FIG. 3.

DETAILED DESCRIPTION

[0036] Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present invention is not limited to the details or methodology set forth in the description or illustrated in the figures.

[0037] FIGS. 3-8 illustrate preferred embodiments of the invention that can be used instead of the core wire 103 of FIG. 2. A sensor mounted on a guide wire including the core wire illustrated in FIGS. 3-8 may be used, for example, in the system of FIG. 1.

[0038] The sensor element 108 is connected to the microcables or optical signal lines 109, for transmitting signals between the sensor element 108 in the distal part of the guide wire and the connector 112 at the proximal end of the hollow tube 102. Examples of suitable microcables are described, for example, in U.S. Patent Application Publication No. 2010/0228112, U.S. Patent Application Publication No. 2011/0213220, and U.S. Patent Application Publication No. 2012/0289808, all of which are hereby incorporated by reference in their entireties for their teachings related to microcables in guide wire assemblies and the structure and use of guide wire assemblies.

[0039] The diameter of the sensor guide wire 101 preferably varies between about 0.25 to about 2.5 mm; for use in coronary arteries, for example, the diameter is normally about 0.35 mm. In the context of length, width, diametrical, and other spatial dimensions, the modifier “about” can include a deviation of plus or minus 0 to 10% of the amount it modifies, preferably plus or minus 0 to 5% of the amount it modifies.

[0040] Referring to FIGS. 3-6, a portion of the core wire 208 including a flattened portion 208B (which will be described below) is disposed within a coil 206 at the distal end of the sensor guide wire 101. However, as seen in the figures, the flattened portion is not provided at the distal most end of the core wire 208. Instead, a distal most end of the flattened portion 208B is spaced from a distal most end of the core wire 208, for example, by a length of a portion 208A (described in further detail below). The core wire 208 may be made out of stainless steel, nitinol, or cobalt chromium. The core wire 208 may be made by grinding. The geometry of the core wire illustrated in FIGS. 3-6 is the geometry of the core wire 208 prior to being shaped by a surgeon.

[0041] As seen in the legend provided in FIG. 3, the sensor guide wire 101 and the core wire 208 can be move along three axes, namely, in a front-back direction, an up-down direction, and a right-left direction. The sensor guide wire 101 and the core wire 208 can also be rotated.

[0042] Referring to FIG. 3, the core wire 208 is disposed within the coil 206. The coil 206 may extend to a distal tip such as the dome-shaped tip 107 seen in FIG. 2, but the distal portion of the coil 206 has been removed from FIG. 3 for clarity. The coil 206 corresponds to the second coil 105 of FIG. 2. The portion of the core wire 208 disposed within the coil 206 may comprise a first portion 208A at a distal end portion, a second portion 208B proximal to the first portion 208A, and a third portion 208C proximal to the second portion 208B. The first portion 208A (i.e., the distal most end portion) of the core wire 208 may serve as a weld paddle. The second portion 208B is the flattened portion of the core wire 208. As used herein, the term “flattened portion” refers to a portion of the core wire having at least one planar surface (and sometimes two or more planar surfaces). The second portion 208B is not twisted.

[0043] A length (in the front-back direction) of the first portion 208A, the second portion 208B, and the third portion 208C may be, for example, approximately 0.2 mm to 1 mm, 5 mm to 15 mm, and 15 to 25 mm, respectively. In one example, a length (in the front-back direction) of the first portion 208A, the second portion 208B, and the third portion 208C may be 0.5 mm, 15 mm to 16.5 mm, and 13 mm, respectively. It may be preferable to make the first portion 208A as small as possible. In another example, the second portion 208B (i.e., the flattened portion) is approximately half the length of the portion stretching from the first portion 208A to a connector portion 209. As illustrated in FIGS. 3-6, the second portion 208B is the portion of the core wire 208 having the greatest length, followed by, in order of decreasing length, the third portion 208C and the first portion 208A. However, in other embodiments, the length of each portion with respect to the remaining portions can be altered in order to change the overall mechanical properties, such as flexibility, torqueability and pushability, of the sensor guide wire 101.

[0044] The portions 208A-208C of the core wire 208 may be connected (e.g., by welding), integrally formed or a combination thereof. In one embodiment, the core wire 208 (i.e., the first portion 208A, the second portion 208B and the third portion 208C) may be integrally formed from a single piece (e.g., a single piece of metal). In other words, from the first portion 208A to the connector portion 209, the core wire 208 is formed of the same material. In another embodiment, the core wire 208 may be formed from at least two pieces (e.g., multiple pieces of metal). In the embodiments in which the core wire 208 is formed from multiple pieces of metal, each of the first portion 208A, the second portion 208B and the third portion 208C may be formed of the same metal or of different types of metal with respect to one another. In addition, each of the first portion 208A, the second portion 208B and the third portion 208C may be individually formed from a separate piece of metal. Alternatively, two of the first portion 208A, the second portion 208B and the third portion 208C may be formed from one piece of metal, while the remaining portion is formed from a separate piece of metal.

[0045] The core wire 208 may optionally include a connector portion 209 configured to connect with the jacket or sleeve 106. In embodiments in which the sensor guide wire does not include a jacket or sleeve 106, the connector portion 209 may connect to a braided portion or the hollow tube 102 (if a braided portion is not provided). As discussed above, the core wire 208 may be longer than the hollow tube 102, and may extend from a proximal connector, through the jacket or sleeve 106, and to the dome-shaped tip 107 of the sensor guide wire 101. In other words, the portion of the core wire illustrated in FIGS. 3-6 may be the portion of the core wire present within the coil 206. The overall length of the core wire 208 is illustrated, for example, in FIG. 7A. In FIG. 3, one or more sensor elements 108 (not shown) are mounted just proximal of the connector portion 209. For example, the sensor element 108 may be mounted in a chip pocket 210 of FIGS. 7A and 8.

[0046] The first portion 208A is the portion located at the distal most end of the core wire 208. In one embodiment, the coil 206 is attached to the core wire 208 by thermal welding the first portion 208A to the coil 206 (see FIG. 9). For example, the first portion 208A and the coil 206 may be melded together by laser or plasma welding. No solder is added, thereby increasing the ease of manufacturing by decreasing the amount of material required. Because the core wire 208 is thermally welded to the coil 206 without the addition of solder, a distal most end of the flattened portion 208B is spaced from a distal most end of the core wire 208, for example, by a distance equal to the length of the first portion 208A (which may be, for example, 0.5 mm, 1.0 mm, 1.5 mm or 2.0 mm). Providing such a spacing between the distal most end of the flattened portion 208B and the distal most end of the core wire 208 provides enough core wire material to be thermally welded to the coil, without impacting the strength of the flattened portion 208B or the rest of the core wire 208. As seen in FIG. 9, the distal most end of the core wire 208 becomes spherical when thermally welded to the coil 206.

[0047] In one embodiment, the first portion 208A, the second portion 208B and the third portion 208C have the cross-sections illustrated in FIG. 4B. As seen in FIG. 4B, the first portion 208A and the third portion 208C are rounded (i.e., have a circular or ovular cross-section). The second portion 208B (i.e., the flattened portion of the core wire 208) includes a first flattened portion 208B(1) at a distal end of the flattened portion 208B, a second flattened portion 208B(2) proximal to the first flattened portion 208B(1), a third flattened portion 208B(3) proximal to the second flattened portion 208B(2), and a fourth flattened portion 208B(4) proximal to the third flattened portion 208B(3).

[0048] In one embodiment, the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be integrally formed from a single piece (e.g., a single piece of metal). In another embodiment, the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be formed from at least two pieces (e.g., multiple pieces of metal). In the embodiments in which the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) are formed from multiple pieces of metal, each of the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be formed of the same metal or of different types of metal with respect to one another. In addition, each of the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be individually formed from a separate piece of metal. Alternatively, the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be formed from one piece of metal, while the remaining flattened portion(s) is formed from at least one separate piece of metal.

[0049] A length (in the front-back direction) of the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be, for example, approximately 0.1 mm to 1 mm, 0.5 mm to 3 mm, 3 mm to 13 mm, and 0.5 mm to 3 mm, respectively. In one example, a length (in the front-back direction) of the first flattened portion 208B(1), the second flattened portion 208B(2), the third flattened portion 208B(3) and the fourth flattened portion 208B(4) may be 0.3 mm, 1.5 mm, 13 mm, and 2 mm, respectively. The third flattened portion 208B(3) is longer than the first flattened portion 208B(1), the second flattened portion 208B(2) and the fourth flattened portion 208B(4). The second flattened portion 208B(2) may have, for example, a length of 1.5 mm, a width (in the right-left direction) of 0.05 mm to 0.15 mm, and a height (in the up-down direction) of 0.01 mm to 0.05 mm. The third flattened portion 208B(3) may have, for example, a length of 13 mm, a width (in the right-left direction) of 0.09 mm, and a height (in the up-down direction) of 0.025 mm.

[0050] As seen in FIGS. 3 and 4, the first flattened portion 208B(1) and the second flattened portion 208B(2) are round to flat transition portions disposed between the rounded first portion 208A and the third flattened portion 208B(3), which has a substantially constant rectangular or square cross-section. The third flattened portion 208B(3) is planar prior to being shaped by a surgeon. The fourth flattened portion 208B(4) is a flat to round transition portion disposed between and the third flattened portion 208B(3) and the rounded third portion 208C.

[0051] As seen in FIG. 5B, from the first portion 208A (located proximate to the dome-shaped tip 107) to the third flattened portion 208B(3), the cross-sectional area of the core wire 208 decreases and the core wire 208 becomes progressively more flat. As seen in FIG. 5C, from the third flattened portion 208B(3), the cross-sectional area of the core wire 208 increases and the core wire 208 because progressively more round.

[0052] As seen in FIG. 4B, the cross-section of each of the first portion 208A, the second portion 208B (including the flattened portions 208B(1)-208B(4)), and the third portion 208C are symmetrical with respect to at least one plane that passes through the longitudinal axis of the core wire 208.

[0053] As discussed in the Background section, the sensor guide wire 101 has to be steered often several feet into a patient, for example, from an opening in the femoral artery in the leg of the patient up to the heart through tortuous blood vessels. The mechanical characteristics (such as maneuverability, steerability, torqueability, and pushability) of a sensor guide wire 101 are very important to a surgeon because the surgeon grasps the proximal end of the sensor guide wire 101 (sticking outside the patient), and by manipulating the proximal end, steers the distal end of the sensor guide wire 101, which is often several feet away, in the front-back direction, the up-down direction, and the right-left direction in order to reach its target (e.g., the heart). Because the distal end of the sensor guide wire 101 is going to be inserted furthest into the patient, it is desirable to make the distal end of the sensor guide wire 101 as flexible as possible so that the sensor guide wire 101 can be easily and predictably maneuvered in a tortuous path.

[0054] Because the core wire 208 includes the straight and flat portion 208B(3), it is relatively easy to maneuver the core wire 208 in the front-back direction and the up-down direction by manipulating the proximal end of the sensor guide wire. However, it is more difficult to maneuver the core wire 208 in the right-left direction by manipulating the proximal end of the sensor guide wire because the core wire 208 is stiffer in the right-left direction than in the up-down direction. In other words, there is preferential movement in the up-down direction, as compared to the right-left direction. As a result, the core wire 208 exhibits preferential bending in a plane extending along the up-down direction. In some embodiments, the core wire 208 exhibits preferential bending in the up direction to the same degree as the core wire 208 exhibits preferential bending in the down direction. This preferential bending allows a physician to bend the sensor guide wire 101, in particular, the core wire 208 in a predictable direction. In particular, torque supplied to the proximal end of the core wire 208 is transmitted along the length of the core wire 208 and enables the core wire 208, in particular, the flattened portion 208B (which may be shaped) to be easily reoriented to point in the desired direction. Moreover, the core wire 208 resists bending in the right-left direction, thereby allowing the surgeon to more easily route the core wire 208 to the target. The flattened portion 208B improves re-shapeability by providing a consistent and preferential bending plane. In addition, the flattened portion 208B allows the sensor guide wire 101 to retain less permanent deformation when subjected to bending conditions. The flattened portion 208B also lowers the cross-sectional area moment of inertia, which in turn reduces the force to buckle the dome-shaped tip 107 and improves the durability of the dome-shaped tip 107 by reducing the stresses experienced during bending.

[0055] In the embodiments of FIGS. 3-6, the core wire 208 includes both a round proximal portion (i.e., the third portion 208C) and a flattened portion (i.e., the second portion 208B) that is distal to the third portion 208C. The round proximal portion provides a certain level of stiffness for steerability in tortuous anatomies and the flattened portion provides a shaping region where the physician can manipulate the core wire to preferentially bend in an up-down direction in curves or bends to meet the needs of the use scenario.

[0056] FIG. 8 illustrates an example of the sensor guide wire 101 described in the embodiments above, including illustrative dimensions having units of millimeters.

[0057] Although not illustrated, the core wire 208 may have different configurations, provided that the core wire 208 includes at least one flattened portion (or other shape that has a preferential bending direction, such as an elongated ellipse). For example, the entire core wire 208 may be flat. In another example, the core wire 208 may include a flattened portion and at least one rounded portion. As used herein, the term “rounded portion” refers to a portion of the core wire having a circular or ovular cross-section. In other words, the rounded portion of the core wire does not include any flattened portions.

[0058] In yet another example, the core wire 208 may include a first rounded portion (e.g., the first portion 208A), a second rounded portion (e.g., the third portion 208C), and a flattened portion (e.g., the second portion 208B) provided between the first rounded portion and the second rounded portion. In another example, the core wire 208 may include a plurality of flattened portions and at least one rounded portion. A first flattened portion may have the same dimensions as a second flattened portion, or the first flattened portion may have different dimensions from the second flattened portion. The first flattened portion and the second flattened portion may be immediately adjacent to each other or the first flattened portion and the second flattened portion may be separated by at least one rounded portion. In other embodiments, the core wire 208 may include more than two flattened portions.

[0059] The core wire 208 may have more than three portions, or the core wire 208 may have fewer than three portions. For example, the first portion 208A and/or the third portion 208C may be omitted. In the case where the third portion 208C is omitted, the proximal end of the second portion 208B may directly connect to the connector portion 209 or extend to and mate with the jacket or sleeve 106. Any portion except for the second portion 208B (i.e., the flattened portion) may be omitted. In addition, as discussed above, additional flattened and rounded portions may be added.

[0060] In some embodiments, the entire core wire 208 may be flat (i.e., the core wire 208 may consist of only the flattened portion 208B).

[0061] The core wire described in any of the embodiments may also be used with a guide wire without a sensor or a guide wire with or without a braided portion. The core wire described in any of the embodiments may also be used with a guide wire without a coil.

[0062] The construction and arrangements of the core wire, as shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. Features of one embodiment may be combined with a feature of another embodiment.

[0063] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise form provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention.