Inverted balloon neck on catheter

Abstract

A method for thermal bonding of an inverted balloon neck on a catheter, including placing an inverted balloon neck (84) on a shaft (86) of a catheter, and characterized by applying heat at an internal hollow (85) of the shaft (86) where the inverted balloon neck (84) is placed, while applying internal pressure to attach an external surface of the shaft (86) to the inverted balloon neck (84).

Claims

1. A lumen re-entry device, comprising: an elongate catheter shaft; an inflatable balloon mounted on a distal region of the elongate catheter shaft; the elongate catheter shaft including a first lumen in fluid communication with an interior of the inflatable balloon; the elongate catheter shaft including an inner surface defining a second lumen having a distal opening positioned proximal of the inflatable balloon; and an elongate member directly facing the inner surface of the second lumen with no intervening structure therebetween, the elongate member being slidably extendable through the second lumen to extend in a direction parallel to a longitudinal axis of the elongate catheter shaft as the elongate member exits out the distal opening of the second lumen and extends alongside a proximal neck of the inflatable balloon when the inflatable balloon is inflated; wherein a body portion of the inflatable balloon is configured to deflect a distal end portion of the elongate member upon inflation of the inflatable balloon.

2. The lumen re-entry device of claim 1, wherein the elongate member is a guidewire.

3. The lumen re-entry device of claim 1, wherein the elongate catheter shaft further includes a third lumen having a distal opening positioned distal of the inflatable balloon.

4. The lumen re-entry device of claim 3, wherein the third lumen is a guidewire lumen.

5. The lumen re-entry device of claim 1, wherein the elongate catheter shaft includes a first tubular member secured to the proximal neck of the inflatable balloon and a second tubular member secured to a distal neck of the inflatable balloon.

6. The lumen re-entry device of claim 5, wherein the second tubular member has a distal end located distal of a distal end of the first tubular member.

7. The lumen re-entry device of claim 5, wherein the second tubular member extends through a lumen of the first tubular member.

8. The lumen re-entry device of claim 1, wherein the body portion of the inflatable balloon extends from the proximal neck to a distal neck, wherein the body portion tapers radially outward in a distal direction in an inflated state.

9. The lumen re-entry device of claim 8, wherein the inflatable balloon is a conically-shaped balloon.

10. The lumen re-entry device of claim 1, wherein the inflatable balloon includes an inverted distal neck secured to a distal end of the elongate catheter shaft.

11. A lumen re-entry device, comprising: an elongate catheter shaft having a first lumen and a second lumen; an inflatable balloon having a proximal neck mounted on a distal region of the elongate catheter shaft; the first lumen being in fluid communication with an interior of the inflatable balloon and the second lumen having a distal opening located proximal of the inflatable balloon; and an elongate member slidable relative to the elongate catheter shaft, the elongate member configured to extend from the distal opening of the second lumen in a direction parallel to a longitudinal axis of the elongate catheter shaft alongside the proximal neck of the inflatable balloon when the inflatable balloon is inflated, the elongate member configured to be positionable exterior of and in direct contact with a proximal conical outer surface of the inflatable balloon; wherein the inflatable balloon is configured to deflect a distal end portion of the elongate member upon inflation of the inflatable balloon.

12. The lumen re-entry device of claim 11, wherein the elongate member is a guidewire advanceable in direct contact with an outer surface of the inflatable balloon.

13. The lumen re-entry device of claim 11, wherein the inflatable balloon includes a body portion extending from the proximal neck to a distal neck, wherein the body portion tapers radially outward in a distal direction in an inflated state.

14. The lumen re-entry device of claim 13, wherein the inflatable balloon is a conically-shaped balloon.

15. The lumen re-entry device of claim 11, wherein the inflatable balloon includes an inverted distal neck secured to a distal end of the elongate catheter shaft.

16. The lumen re-entry device of claim 11, wherein the elongate catheter shaft includes a tubular member extending through the inflatable balloon.

17. The lumen re-entry device of claim 16, wherein the tubular member defines a third lumen extending to a distal opening distal of the inflatable balloon.

18. The lumen re-entry device of claim 16, wherein the inflatable balloon includes an inverted distal neck secured to a distal end of the tubular member.

19. The lumen re-entry device of claim 11, wherein the elongate member is configured to extend though the second lumen and exit out the distal opening of the second lumen.

20. The lumen re-entry device of claim 11, wherein the elongate catheter shaft includes a first tubular member secured to the proximal neck of the inflatable balloon and a second tubular member secured to a distal neck of the inflatable balloon.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:

(2) FIG. 1 is a simplified illustration of a lumen reentry device, constructed and operative in accordance with an embodiment of the present invention;

(3) FIG. 2 is a simplified illustration of the lumen reentry device, alternatively or additionally, with a ring used to further increase the bonding strength of an inverted distal neck of a balloon of the lumen reentry device, in accordance with an embodiment of the present invention;

(4) FIG. 3 is a simplified illustration of a hydraulic sealing design in accordance with an embodiment of the present invention;

(5) FIGS. 4, 5, 6A and 6B are simplified illustrations of a catheter with a third lumen used for inserting a second guidewire, constructed and operative in accordance with another embodiment of the present invention;

(6) FIG. 7 is a simplified illustration of a catheter that has two lumens, a balloon lumen and a guidewire lumen, constructed and operative in accordance with another embodiment of the present invention; and

(7) FIGS. 8-11 are simplified illustrations of a method for thermal bonding of the inverted balloon neck of the catheter, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(8) The present invention describes a device for re-entry into the blood vessel's true lumen from the subintimal space between the layers of the blood vessel. The present invention provides inventive features further to those of PCT patent application PCT/IL2008/000449, the disclosure of which is incorporated herein by reference.

(9) The present invention eliminates the needs to steer a catheter rotationally with the assistance of an imaging system in order to orient a needle, guidewire, or other tool towards the true lumen for puncturing the intima layer. The catheter automatically bends its distal end in the direction of the true lumen without operator guidance and/or imaging. The device of the invention eliminates the need for curved needle, and allows direct guidewire penetration with or without the support of a straight needle.

(10) Reference is now made to FIG. 1, which illustrates a lumen reentry device 10, constructed and operative in accordance with an embodiment of the present invention. Device 10 is similar in construction to the device described in PCT patent application PCT/IL2008/000449. Device 10 includes a catheter 12 which has a balloon 14 disposed at a distal end thereof. The distal end of catheter 12 protrudes only slightly, or does not protrude at all, beyond balloon 14. Catheter 12 is formed with a first lumen 16 through balloon 14 for passing therethrough a guidewire 18, and a second lumen 20 for inflation and deflation of balloon 14.

(11) Catheter 12 may be fabricated from polyethylene, polyurethane, PEBAX (polyether block amide from Arkema), nylon or other polymers known in the art. The catheter shaft can also be made from polymers reinforced with metal wires braid or springs, as is known in the art.

(12) Balloon 14 may be fabricated from polyurethane, silicon, PET (polyethylene terephthalate), and other suitable polymers known in the art. Balloon 14 is preferably, but not necessarily, cone-shaped.

(13) In accordance with an embodiment of the present invention, catheter 12 has a weakened or softer small section 22 (bending section 22), located either inside or outside near the proximal end of the balloon 14, allowing balloon 14 to bend easily with minimal resistance from the catheter shaft. Bending section 22 can be a small section having a smaller wall thickness or a section lacking metal wire springs or braid, making it softer and easy to bend or rotate. The position of this weak or less rigid section, together with the balloon diameter, defines the catheter's distal end bend angle.

(14) In accordance with an embodiment of the invention, catheter 12 is made from two tubes, one inside the other, a softer internal tube 33 which extends distally to a harder external tube 32. This construction facilitates balloon bending, and the distal end of the harder external tube 32 defines the balloon bending point.

(15) The use of a soft internal tube 33 in catheter 12 might cause too much strain during balloon inflation due to the axial force on the internal tube from the inflated balloon. This might cause a failure of distal balloon's neck bonding as the internal tube elongates and the inverted balloon's distal neck can peel away from it.

(16) In accordance with an embodiment of the invention, a strain-reducing element is mounted in catheter 12 that reduces strain on a distal portion of balloon 14 during inflation of balloon 14, examples of which are now described.

(17) In order to prevent or significantly decrease such elongation, the internal and external tubes can be bonded one to the other close to the external tube distal end, shortening the effective length of the internal tube on which axial force is applied, preventing the above peeling effect. The bonding between the two tubes can be done with UV glue, as long as the glue does not block the balloon inflation lumen 20 between the two tubes. Alternatively a C ring 35 made from a polymer or metal, can be used to connect the distal sections of the two tubes together, by bonding the C ring to both tubes. The space in the C ring 35 prevents blockage of the balloon inflation lumen 20.

(18) Reference is now made to FIG. 2. Alternatively or additionally, a ring 34, made from plastic or from radiopaque materials, such as titanium and iridium alloy, can be used to further increase the bonding strength of the inverted distal neck 14D of balloon 14. The inverted neck 14D is exposed to peeling forces caused by both radial and axial forces due to the balloon inflation. Ring 34, mounted at the distal end of internal tube 33 and the distal end of balloon 14, prevents such peeling of the inverted distal neck 14D from the internal tube 33.

(19) Reference is now made to FIG. 3. In another embodiment of the invention, in order to increase the attachment strength of the proximal neck 14P of balloon 14 to the external tube 32, a hydraulic sealing design can be used. A short flare 36 is produced at the distal end 39 of external tube 32, such as by pushing the tube against a hot mandrel, having a slightly larger diameter and length than the balloon's proximal neck 14P. The balloon's proximal neck 14P is then inserted into flare 36 and bonded. During balloon inflation, the softer balloon proximal neck 14P abuts against the harder flare 36 of external tube 32. The higher the pressure, the more the proximal neck 14P is pushed towards flare 36.

(20) Reference is now made to FIGS. 4, 5, 6A and 6B. In accordance with another embodiment of the present invention, a catheter 40 has a third lumen 37 (FIGS. 4-5), used for inserting a second guidewire 38 (FIGS. 6A-6B). Third lumen 37 can be formed by placing an additional specially shaped tube 41 over external tube 32 (FIG. 4), wherein third lumen 37 is a bulbous protrusion of tube 41, or by making the external tube 32 into a double lumen tube 42 (FIG. 5). When using tube 41 for third lumen 37, tube 41 ends near the proximal end of balloon 14. When using double lumen tube 42, tube 42 can end near the proximal end of balloon 11, but alternatively, third lumen 37 may end near the distal end of balloon 14 by extending a portion of tube 42 over a portion of balloon 14, thereby providing better protection for balloon 14.

(21) Second guidewire 38 can be used if the distal end of the first guidewire 18, located inside balloon 14, rotates at an angle which is not sufficient for first guidewire 18 to penetrate into the true lumen. The second guidewire 38 is pushed until it is parallel or even slightly proximal to the deflated balloon 14 (FIG. 6A). When balloon 14 is inflated, second guidewire 38 bends at a bending angle, which is about twice the angle of deflection of the first guidewire 18 (FIG. 6B). The bending angle of the second guidewire 38 depends on the inflation pressure and diameter of balloon 14, and also on the location of the bending point of second guidewire 38, which is the distal end of third lumen 37. Second guidewire 38, which may be a stiff straight tip wire, is then pushed forward to penetrate the true lumen. Preferably after second guidewire 38 penetrates the true lumen, balloon 14 is deflated, to allow easy and safe further insertion of second guidewire 38 into the true lumen.

(22) Using second guidewire 38 for penetration generally requires two views of fluoroscopy radial orientation. Such orientation can be done using the two wires 18 and 38 as radiopaque markers, rotating catheter 40 until the maximum distance between the two wires is achieved, and the true lumen is beside catheter 40.

(23) Crossing the occlusion may be done as follows: 1) inserting the first guidewire into the proximal vessel's true lumen, 2) pursuing guidewire vessel dissection into the subintimal space of the blood vessel close to the occluding plaque's proximal end, 3) advancing the guidewire through the subintimal space of the blood vessel distally to the plaque, 4) using the reentry balloon catheter of the invention to crack the intimal layer or stretch the intimal layer, 5) checking if the first guidewire reentered into the true lumen, if yes, proceeding to step 13, if not proceeding to next step 6) deflating the balloon, 7) inserting the second guidewire through the catheter third lumen, until parallel to the balloon, 8) making sure the catheter is at the desired location beside (the same plane) of the distal reentry point desired, 9) rotating the catheter until the distance between the two wires is maximal, 10) inflating the balloon, 11) increasing the balloon pressure until sufficient wire rotation is achieved, 12) pushing the second guidewire forward to penetrate the true lumen, and 13) performing balloon angioplasty through the re-canalized lumen,

(24) Reference is now made to FIG. 7. In another embodiment of the present invention, a catheter 50 has two lumens, a balloon lumen 51 and a guidewire lumen 52. The balloon lumen 51 is not designed for a guidewire to pass therethrough. In this configuration the balloon lumen 51 can have a very small diameter, resulting in a very small diameter of the whole catheter 50. Catheter 50 has a groove 53 proximal and distal to the balloon 14, for free movement of a guidewire 54 that passes through groove 53. Reentering from the sub-intimal space with catheter 50 is carried out by deflecting guidewire 54 towards the true lumen by inflating balloon 14. This method requires radial orientation of guidewire 54 to be on the true lumen side and to point towards the true lumen while deflected by balloon 14. A bar or tube 55, made of metal or other hard material, can be added inside the balloon lumen 51 to add structural rigidity to the catheter distal end.

(25) Reference is now made to FIGS. 8-11, which illustrate a method for thermal bonding of the inverted balloon neck of catheter 12, in accordance with an embodiment of the present invention. As is described more in detail below, the method includes heating through the internal catheter shaft lumen, while applying internal pressure to attach the shaft external surface to the inverted balloon neck. (It is noted that the balloon in catheters 40 and 50 may have a distal tip that protrudes distally from the balloon, and thus do not need to be manufactured this way.)

(26) As seen in FIG. 8, Balloon 80 has a cylindrical or elliptical shape, and includes a proximal neck 82 and a distal inverted neck 84 which protrude from both sides of the main body of the balloon. The internal surface of inverted neck 84, which before the neck inversion was the outer neck surface, and its diameter usually change and twist during the neck inversion process, which is done by applying mechanical force on the balloon neck.

(27) As seen in FIG. 9, balloon 80 is mounted on a shaft 86. There may be some a gap 88 (space/tolerance) between the external contour of shaft 86 and the internal diameter of inverted neck 84, to allow pushing balloon 80 over shaft 86. Gap 88 is acceptable for gluing, but must be eliminated if thermal bonding is desired, because there must be good contact between the shaft and balloon inverted neck for thermal bonding.

(28) As seen in FIG. 10, a probe 90, which has a protrusion 92, is pushed into the hollow 85 of shaft 86 at the area to be bonded. Protrusion 92 has a larger diameter than the hollow 85 of shaft 86, large enough to expand the polymeric shaft material and eliminate the gap between shaft 86 and balloon inverted neck 84. Probe 90 is then heated to a desired temperature, usually in the range of 170 to 300.degree. C., for up to 60 seconds, until good thermal bonding of the two polymers is achieved. Protrusion 92 may be chamfered for easy insertion into shaft 86 of the catheter. Probe 90 may be made from metal, and preferably a good heat-conductive metal like aluminum or brass.

(29) As seen in FIG. 11, the heating machine may have two metal heating clamps 94. Each clamp 94 includes a heating element 96 and thermocouple 98, all connected to a controller 99, that controls the clamp temperature and the probe clamping time.