MECHANICAL CIRCULATORY SUPPORT PUMP DRIVE WITH CORROSION PROTECTION

Abstract

A blood pump includes an impeller; a drive shaft coupled to the impeller and configured to rotate with the impeller; and a rotor coupled to the drive shaft and configured to rotate with the drive shaft. The rotor includes a driven magnet having an outer surface. A corrosion-resistant coating may be disposed on the outer surface of the driven magnet. A stator is disposed adjacent the rotor and configured to drive the rotor, causing the rotor to rotate; and a motor is configured to drive the stator. A protection assembly may be disposed adjacent the stator and configured to receive an end of the drive shaft, and may include a protection assembly housing enclosing a protective fluid chamber, the protective fluid chamber including the driven magnet and at least a portion of a bearing configured to engage the end of the drive shaft.

Claims

1. A blood pump, comprising: an impeller; a drive shaft coupled to the impeller and configured to rotate with the impeller; a rotor coupled to the drive shaft and configured to rotate with the drive shaft, the rotor comprising a driven magnet having an outer surface; a coating disposed on the outer surface of the driven magnet; a stator disposed adjacent the rotor and configured to drive the rotor, causing the rotor to rotate; and a motor configured to drive the stator.

2. The blood pump of claim 1, the coating comprising at least one of an amorphous silicone, a diamond-like coating, and a polymeric compound.

3. The blood pump of claim 1, wherein the rotor is integrated with the impeller.

4. The blood pump of claim 3, wherein the coating is disposed over an outside surface of the impeller.

5. The blood pump of claim 1, further comprising a protection assembly disposed adjacent the motor and configured to receive an end of the drive shaft, the protection assembly comprising a protection assembly housing enclosing a protective fluid chamber, the protective fluid chamber comprising the driven magnet and at least a portion of a bearing configured to engage the end of the drive shaft.

6. The blood pump of claim 5, the protection assembly housing comprising a cup washer having a base and peripheral wall extending away from the base, forming a cavity bounded, in part, by an inner surface of the peripheral wall and an inner surface of the base.

7. The blood pump of claim 6, wherein at least a portion of the protective fluid chamber is defined between the inner surface of the peripheral wall of the cup washer, an inner surface of the base of the cup washer, and at least a first side of the bearing.

8. The blood pump of claim 7, wherein the entire bearing is disposed within the protective fluid chamber.

9. A blood pump, comprising: an impeller; a drive shaft coupled to the impeller and configured to rotate with the impeller; a rotor coupled to the drive shaft and configured to rotate with the drive shaft, the rotor comprising a driven magnet having an outer surface; a stator disposed adjacent the rotor and configured to drive the rotor, causing the rotor to rotate; a motor configured to drive the stator; and a protection assembly disposed adjacent the motor and configured to receive an end of the drive shaft, the protection assembly comprising a protection assembly housing enclosing a protective fluid chamber, the protective fluid chamber comprising the driven magnet and a at least a portion of a bearing configured to engage the end of the drive shaft.

10. The blood pump of claim 9, the protection assembly housing comprising a cup washer having a base and peripheral wall extending away from the base, forming a cavity bounded, in part, by an inner surface of the peripheral wall and an inner surface of the base.

11. The blood pump of claim 10, wherein at least a portion of the protective fluid chamber is defined between the inner surface of the peripheral wall of the cup washer, an inner surface of the base of the cup washer, and at least a first side of the bearing.

12. The blood pump of claim 9, wherein the entire bearing is disposed within the protective fluid chamber.

13. The blood pump of claim 9, further comprising a coating disposed on the outer surface of the driven magnet.

14. The blood pump of claim 13, the coating comprising at least one of an amorphous silicone, a diamond-like coating, and a polymeric compound.

15. The blood pump of claim 14, wherein the rotor is integrated with the impeller.

16. The blood pump of claim 15, wherein the coating is disposed over an outside surface of the impeller.

17. A blood pump, comprising: an impeller; a drive shaft coupled to the impeller and configured to rotate with the impeller; a rotor integrated with the impeller and configured to rotate with the drive shaft, the rotor comprising a driven magnet having an outer surface; a coating disposed on the outer surface of the driven magnet; a stator disposed adjacent the rotor and configured to drive the rotor, causing the rotor to rotate; and a motor configured to drive the stator.

18. The blood pump of claim 17, wherein the coating is disposed over an outside surface of the impeller.

19. The blood pump of claim 17, the coating comprising at least one of an amorphous silicone, a diamond-like coating, and a polymeric compound.

20. The blood pump of claim 17, further comprising a protection assembly disposed adjacent the motor and configured to receive an end of the drive shaft, the protection assembly comprising a protection assembly housing enclosing a protective fluid chamber, the protective fluid chamber comprising the driven magnet and at least a portion of a bearing configured to engage the end of the drive shaft.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG. 1 depicts a cross-sectional side view of a portion of an illustrative percutaneous mechanical circulatory support device (also referred to herein, interchangeably, as a blood pump), in accordance with embodiments of the subject matter disclosed herein.

[0042] FIG. 2A depicts a perspective view of an illustrative percutaneous mechanical circulatory support device, in accordance with embodiments of the subject matter disclosed herein.

[0043] FIG. 2B depicts a cross-sectional side view of the circulatory support device depicted in FIG. 2A, in accordance with embodiments of the subject matter disclosed herein.

[0044] While the disclosed subject matter is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the subject matter disclosed herein to the particular embodiments described. On the contrary, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the subject matter disclosed herein, and as defined by the appended claims.

DETAILED DESCRIPTION

[0045] Embodiments of the subject matter disclosed herein include mechanical circulatory support device designs that facilitate protecting magnetic components thereof from corrosion, and may also facilitate protecting a patient from potentially cytotoxic materials and/or hemolysis. In embodiments, for example a magnetic rotor may be sealed from the environment by disposing a protective coating on the outside surface of the rotor and/or by encasing the rotor within a protection assembly housing. A protective fluid may be used to provide a fluid film at bearing surfaces such as, for example, to minimize corrosion. According to embodiments, any number of different types of protective fluids may be used such as, for example, hydrophobic, water-insoluble lubricants (e.g., perfluoropolyether or poly-alpha-olefins classes of synthetic lubricants).

[0046] FIG. 1 depicts a cross-sectional side view of a portion of an illustrative percutaneous mechanical circulatory support device 100 (also referred to herein, interchangeably, as a blood pump), in accordance with embodiments of the subject matter disclosed herein. As shown in FIG. 1A, the circulatory support device 100 includes a motor 102 disposed within a motor housing 104. The motor 102 is configured to drive an impeller assembly 106 to provide a flow of blood through the device 100. The impeller assembly 106 is disposed within an impeller assembly housing 108, which includes a number of inlet apertures 110 and a number of outlet apertures 112 defined therein. According to embodiments, the motor housing 104 and the impeller assembly housing 108 may be integrated with one another. In other embodiments, the motor housing 104 and the impeller assembly housing 108 may be separate components configured to be coupled together, either removeably or permanently.

[0047] A controller (not shown) is operably coupled to the motor 102 and is configured to control the motor 102. The controller may be disposed outside the housing 104 (e.g., in a catheter handle, independent housing, etc.). In embodiments, the controller may include multiple components, one or more of which may be disposed within the housing 104. According to embodiments, the controller may be, include, or be included in one or more Field Programmable Gate Arrays (FPGAs), one or more Programmable Logic Devices (PLDs), one or more Complex PLDs (CPLDs), one or more custom Application Specific Integrated Circuits (ASICs), one or more dedicated processors (e.g., microprocessors), one or more central processing units (CPUs), software, hardware, firmware, or any combination of these and/or other components. Although the controller is referred to herein in the singular, the controller may be implemented in multiple instances, distributed across multiple computing devices, instantiated within multiple virtual machines, and/or the like.

[0048] As shown in FIG. 1, the impeller assembly 106 includes a drive shaft 114 and an impeller 116 coupled thereto, where the drive shaft 114 is configured to rotate with the impeller 116. As shown, the drive shaft 114 is at least partially disposed within the impeller 116. In embodiments, the drive shaft 114 may be attached to one or more ends of the impeller 116. In embodiments, the drive shaft 114 and impeller 116 may be integrated as a single piece. In embodiments, the drive shaft 114 may be made of any number of different rigid materials such as, for example, steel, titanium alloys, cobalt chromium alloys, nitinol, high-strength ceramics, and/or the like. The impeller assembly 106 further includes an impeller rotor 118 coupled to, and at least partially surrounding, the drive shaft 114. The impeller rotor 118 may be any type of magnetic rotor capable of being driven by a stator that is part of the motor 102. In this manner, as a magnetic field is applied to the impeller rotor 118 by the stator in the motor 102, the rotor 118 rotates, causing the drive shaft 114 and impeller 116 to rotate. Although various components in FIG. 1 have been illustrated as being spaced apart from one another, to facilitate clarity of description of the subject matter disclosed herein, in embodiments, the rotor 118 may be configured to extend as far as possible toward the stator without interfering with the motor housing 104 to avoid decoupling between the rotor 118 and the stator. According to embodiments, the motor 102 may include any number of additional rotors and/or stators not depicted herein.

[0049] As shown, the impeller assembly 106 is maintained in its orientation by the drive shaft 114, which is retained, at a first end 120, by a first bearing 122 and, at a second end 124, by a second bearing 126. According to embodiments, the first bearing 122 and the second bearing 126 may include different types of bearings. According to embodiments, the first bearing 122 and/or the second bearing 126 may include lubrication, while, in other embodiments, one and/or the other may not include lubrication. Various embodiments of bearing technology are contemplated herein with respect to the first and second bearings 122 and 126. In embodiments, an area around the rotor may be filled with a material that facilitates preventing water and/or blood from contacting the rotor surfaces.

[0050] According to embodiments, the rotor 118 also may include a protective coating disposed on an outer surface thereof. For example, the coating may include a corrosion-resistant coating such as an amorphous silicone, a diamond-like coating, a polymeric compound, and/or the like. In embodiments, the protective coating may be configured to cover at least a portion of the rotor 118. For example, in embodiments, the protective coating may be configured to cover the entire outer surface of the rotor 118, while in other embodiments, the protective coating may be configured to cover a portion of the outer surface of the rotor 118. In embodiments, the rotor 118 is integrated with the impeller 116 and the protective coating is at least partially disposed over an outside surface of the impeller (and, thus, the rotor 118).

[0051] The illustrative circulatory support device 100 shown in FIG. 1 is not intended to suggest any limitation as to the scope of use or functionality of embodiments of the present disclosure. The illustrative circulatory support device 100 also should not be interpreted as having any dependency or requirement related to any single component or combination of components illustrated therein. Additionally, various components depicted in FIG. 1 may be, in embodiments, integrated with various ones of the other components depicted therein (and/or components not illustrated), all of which are considered to be within the ambit of the present disclosure.

[0052] FIG. 2A depicts a cross-sectional side view of a portion of an illustrative percutaneous mechanical circulatory support device 200 (also referred to herein, interchangeably, as a blood pump), in accordance with embodiments of the subject matter disclosed herein. As shown in FIG. 2A, the circulatory support device 200 includes a motor 202 disposed within a motor housing 204. The motor 202 is configured to drive an impeller assembly 206 to provide a flow of blood through the device 200. The impeller assembly 206 is disposed within an impeller assembly housing 208, which includes a number of inlet apertures 210 and a number of outlet apertures 212 defined therein. According to embodiments, the motor housing 204 and the impeller assembly housing 208 may be integrated with one another. In other embodiments, the motor housing 204 and the impeller assembly housing 208 may be separate components configured to be coupled together, either removeably or permanently.

[0053] A controller (not shown) is operably coupled to the motor 202 and is configured to control the motor 202. The controller may be disposed outside the housing 204 (e.g., in a catheter handle, independent housing, etc.). In embodiments, the controller may include multiple components, one or more of which may be disposed within the housing 204. According to embodiments, the controller may be, include, or be included in one or more Field Programmable Gate Arrays (FPGAs), one or more Programmable Logic Devices (PLDs), one or more Complex PLDs (CPLDs), one or more custom Application Specific Integrated Circuits (ASICs), one or more dedicated processors (e.g., microprocessors), one or more central processing units (CPUs), software, hardware, firmware, or any combination of these and/or other components. Although the controller is referred to herein in the singular, the controller may be implemented in multiple instances, distributed across multiple computing devices, instantiated within multiple virtual machines, and/or the like.

[0054] As shown in FIG. 2A, the impeller assembly 206 includes a drive shaft 214 and an impeller 216 coupled thereto, where the drive shaft 214 is configured to rotate with the impeller 216. As shown, the drive shaft 214 is at least partially disposed within the impeller 216. In embodiments, the drive shaft 214 may be made of any number of different rigid materials such as, for example, steel, titanium alloys, cobalt chromium alloys, nitinol, high-strength ceramics, and/or the like. The impeller assembly 206 further includes an impeller rotor 218 coupled to, and at least partially surrounding, the drive shaft 214. The impeller rotor 218 may be any type of magnetic rotor capable of being driven by a stator (not shown) that is part of the motor 202. In this manner, as a magnetic field is applied to the impeller rotor 218 by the stator in the motor 202, the rotor 218 rotates, causing the drive shaft 214 and impeller 216 to rotate.

[0055] As shown, the impeller assembly 206 is maintained in its orientation by the drive shaft 214, which is retained, at a first end 220, by a first bearing 222 and, at a second end 224, by a second bearing 226. According to embodiments, the first bearing 222 and the second bearing 226 may include different types of bearings. According to embodiments, the first bearing 222 and/or the second bearing 226 may include lubrication, while, in other embodiments, one and/or the other may not include lubrication. Various embodiments of bearing technology are contemplated herein with respect to the first and second bearings 222 and 226.

[0056] As is shown in FIG. 2A, the circulatory support device 200 also includes a protection assembly 228 disposed adjacent the stator and configured to protect at least the rotor 218 from corrosion and/or other wear. In embodiments, the protection assembly 228 may be configured to maintain a volume of protective fluid in contact with the rotor 218. The protective fluid may be, for example, a hydrophobic lubricant. The protective fluid may be any type of hydrophobic lubricant suitable for use in a blood pump. For example, in embodiments, but without intending to limit the disclosure, the protective fluid may be a modified silicone lubricant such as, for example, a modified Polydimethylsiloxane (PDMS). In other embodiments, the protective fluid may be an oil-based lubricant, a synthetic oil, a carbon-based lubricant, and/or the like.

[0057] FIG. 2B is a close-up view of the protection assembly 228 of FIG. 2A, in accordance with embodiments of the subject matter disclosed herein. As shown in FIG. 2B, the protection assembly 228 is disposed adjacent a stator 230, which is coupled to (or integrated with) the motor 204. The protection assembly 228 is configured to receive an end 220 of the drive shaft 214 and includes a protection assembly housing 232 enclosing a protective fluid chamber 234. According to embodiments, the protective fluid chamber 234 also includes the rotor 218 (driven magnet) and at least a portion of the first bearing 222, which is configured to engage the end 220 of the drive shaft 214.

[0058] For example, the bearing 222 may include a first side 236, facing toward the impeller assembly 206, and an opposite, second side 238, facing toward the motor 204. A concave depression 240 is defined in the first side 236 of the bearing 222. The concave depression 240 is configured to receive the first end 220 of the drive shaft 214. As shown, the first end 220 of the drive shaft 214 may be at least partially rounded and, in embodiments, may include a curvature corresponding to the curvature of the concave depression 240. In this manner, the surface area of contact between the drive shaft 214 and the bearing 222 may be as small as possible, reducing the chance that any blood cells will be able to get between the drive shaft 214 and the bearing 222 at their interface.

[0059] According to embodiments, the protection assembly housing 232 includes a base 242 and peripheral wall 244 extending away from the base 242, forming a cavity 245 bounded, in part, by an inner surface 246 of the peripheral wall 244 and an inner surface 248 of the base 242. According to embodiments, for example, at least a portion of the protective fluid chamber 245 is defined between the inner surface 246 of the peripheral wall 244 and the inner surface 248 of the base 236, and at least the first side 236 of the bearing 222. In embodiments, the protection assembly housing 232 may be, or include, a cup washer.

[0060] The peripheral wall 244 may be oriented approximately orthogonal to the base 242. A shaft aperture 250 may be defined through the base 242, extending from an outer surface 252 of the base 242 to the inner surface 248 of the base 242, and may be configured to receive a portion of the drive shaft 214. As shown, the bearing 222 may be configured to be at least partially disposed within the cavity 245. Additionally, the rotor 218 is configured to be at least partially disposed within the cavity 245.

[0061] According to embodiments, the rotor 218 also may include a protective coating disposed on an outer surface thereof. For example, the coating may include an amorphous silicone, a diamond-like coating, a polymeric compound, and/or the like. In embodiments, the protective coating may be configured to cover at least a portion of the rotor 218. For example, in embodiments, the protective coating may be configured to cover the entire outer surface of the rotor 218, while in other embodiments, the protective coating may be configured to cover a portion of the outer surface of the rotor 218. In embodiments, the rotor 218 is integrated with the impeller 216 and the protective coating is at least partially disposed over an outside surface of the impeller (and, thus, the rotor 218).

[0062] The illustrative circulatory support device 200 shown in FIGS. 2A and 2B is not intended to suggest any limitation as to the scope of use or functionality of embodiments of the present disclosure. The illustrative circulatory support device 200 also should not be interpreted as having any dependency or requirement related to any single component or combination of components illustrated therein. Additionally, various components depicted in FIGS. 2A and 2B may be, in embodiments, integrated with various ones of the other components depicted therein (and/or components not illustrated), all of which are considered to be within the ambit of the present disclosure.

[0063] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described above refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present disclosure is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.