Modular pre-loaded medical implants and delivery systems

Abstract

Modular pre-loaded implant subassemblies that can be packaged separately from a handle, which allows using any one of a plurality of separately packaged modular pre-loaded implants with a common handle.

Claims

1. An implant and delivery system adapted to be coupled during a medical procedure that delivers the implant, comprising: an implant subassembly including: a cartridge and an implant disposed in a collapsed state within the cartridge, the implant having an implant proximal end, an implant elongate flexible tubular member with a distal end adjacent the implant proximal end, and an implant coupling mechanism including first and second coupling members that extend through the implant flexible tubular member, the first and second coupling members coupled to the implant proximal end in a first state and positioned and configured to release the implant proximal end when in a second state; and a handle subassembly including: a handle comprising an outer housing and a handle actuator, a handle elongate tubular member in operable communication with the handle actuator, wherein actuation of the handle actuator causes axial movement of the elongate tubular member, the handle elongate tubular member having a lumen sized to receive therein the proximal end of the implant subassembly, the implant flexible tubular member, and the first and second coupling members, and the handle further comprising an implant subassembly locking mechanism that is positioned and adapted to lock a proximal end of the implant subassembly within the handle after the implant subassembly is moved proximally through the handle elongate tubular member and into the handle during a medical procedure to implant the implant.

2. The system of claim 1, wherein the handle assembly includes an implant subassembly stopper at least partially disposed within the handle, the implant subassembly stopper positioned within the handle to stop the proximal end of the implant subassembly from further proximal movement within the handle.

3. The system of claim 2, wherein the implant subassembly stopper is positioned to stop the proximal end of the implant subassembly from further proximal movement at a position that axially aligns one or more locking members of the implant subassembly locking mechanism with one or more corresponding lock features on the proximal end of the implant subassembly.

4. The system of claim 1, wherein the implant subassembly locking mechanism includes an actuator and one or more locking elements, the actuator configured to be actuated by a user to cause the one or more locking elements to interface with the proximal end of the implant subassembly and lock the proximal end of the implant subassembly in place.

5. The system of claim 4, wherein actuation of the actuator causes one of the one or more locking elements to move radially inward and interface with an outer surface of the proximal end of the implant subassembly and lock the proximal end of the implant subassembly in place.

6. The system of claim 5, wherein the outer surface is an outer surface of a detachable component of the implant subassembly.

7. The system of claim 6, wherein the detachable component is secured to the first coupling member.

8. The system of claim 6, wherein actuation of the actuator causes a second locking element to move radially inward and interface with a second outer surface of the proximal end of the implant subassembly to further lock the proximal end of the implant subassembly in place.

9. The system of claim 8, wherein the second outer surface is an outer surface of a static component of the implant subassembly.

10. The system of claim 1, wherein the handle assembly includes a second handle actuator, the second handle actuator in operable communication with the implant subassembly locking mechanism such that when the second handle actuator is actuated, a first portion of the implant subassembly locking mechanism is moved.

11. The system of claim 10, wherein the first portion includes a proximal locking member.

12. The system of claim 10, wherein a second locking member is not moved with the first locking member upon actuation of the second handle actuator.

13. The system of claim 1, wherein the handle assembly includes a second handle actuator, the second handle actuator in operable communication with the first coupling member such that when the second handle actuator is actuated, the first coupling member is moved axially to release the implant from the coupling mechanism.

14. The system of claim 1, wherein the implant subassembly is packaged in a first packaging and the handle subassembly is packaged in a second packaging different than the first packaging.

15. The system of claim 1, wherein the implant elongate flexible tubular member has a distal end and the handle elongate tubular member has a distal end, wherein the distal end of the implant elongate flexible tubular member is more flexible than the distal end of the handle elongate tubular member.

16. The system of claim 1, wherein the implant elongate tubular member comprises a helically coiled element.

17. The system of claim 1, wherein the helically coiled element is disposed at a distal end of the implant flexible tubular member, the implant flexible tubular member further comprising a flexible tube coupled to the coiled element that is disposed proximal to the helically coiled element.

18. The system of claim 1, wherein the implant flexible tubular member comprises a flexible tube.

19. The system of claim 1, wherein the implant subassembly comprises a proximal end that includes a detachable component and a static component that are coupled together in a first state when the proximal end is secured in place relative to the handle, the detachable component secured to the first coupling member, and the static component secured to the second coupling member, the detachable component adapted to be separated from the static component in a second state to release the implant from the coupling mechanism.

20. The system of claim 19, wherein the second coupling member is attached to the static component under tension.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates an exemplary system that includes a handle assembly and an implant subassembly.

(2) FIG. 2 illustrates an exemplary handle subassembly in an exemplary handle subassembly packaging.

(3) FIG. 3 illustrates an exemplary implant subassembly in an exemplary implant subassembly packaging.

(4) FIG. 4A illustrates an exemplary implant.

(5) FIG. 4B illustrates an exemplary proximal region of the exemplary implant in FIG. 4A.

(6) FIG. 5 illustrates an exemplary coupling mechanism shown coupled to an exemplary proximal end of an exemplary implant.

(7) FIG. 6 illustrates a proximal region of an exemplary implant subassembly and a portion of an exemplary handle subassembly.

(8) FIG. 7 illustrates a proximal region of an exemplary implant subassembly and a portion of an exemplary handle subassembly.

(9) FIG. 8 illustrates a proximal region of an exemplary implant subassembly disposed within a portion of an exemplary handle subassembly.

(10) FIG. 9 illustrates an exemplary system including an exemplary handle subassembly and an exemplary implant subassembly.

(11) FIG. 10 is illustrative of an exemplary system including an exemplary handle subassembly and an exemplary implant subassembly.

(12) FIG. 11 illustrates an exemplary delivery catheter.

(13) FIG. 12 illustrates an exemplary system coupled to a proximal end of an exemplary delivery catheter.

DETAILED DESCRIPTION

(14) The disclosure herein is related to medical implant packaging and delivery system solutions that can avoid having to package many complete systems that include external handles coupled to medical implants. The disclosure herein is related to modular pre-loaded implant subassemblies that can be packaged separately from a handle subassembly, which provides the ability to use any one of many separately packaged modular pre-loaded implants with a common handle. This eliminates a need to have implants pre-coupled to the delivery system and packaged therewith, thus potentially eliminating a great deal of packaging and space needed to place the packaged implants during the medical procedure.

(15) One aspect of this disclosure describes implant and delivery systems that include an implant subassembly adapted to be coupled to a handle subassembly during a medical procedure. The implant subassembly may be packaged separately from the handle subassembly.

(16) FIG. 1 illustrates an exemplary implant and delivery system 100 in an uncoupled state. System 100 includes an implant subassembly 300 that is adapted to be coupled to handle subassembly 200 during a medical procedure. FIG. 1 illustrates the two subassemblies after removal from separate packaging but before they are coupled.

(17) Implant subassembly 300 includes cartridge 310 and an implant (not visible) disposed within cartridge 310, optionally in a collapsed state within the cartridge. The implant disposed in the cartridge includes an implant proximal end, which is also not visible in FIG. 1. Implant subassembly 300 also includes an elongate flexible tubular member 320 with a distal end (not visible in FIG. 1) that is coupled to the implant proximal end. Implant subassembly includes proximal end 330. Elongate flexible tubular member 320 may be configured as a tubular member or may be configured as a helically coiled member.

(18) In this example, handle subassembly 200 includes a handle 210 and an elongate tubular member 250 extending within the handle 210 and also distally from handle 210. Handle 210 also includes an outer housing or shell 212 and a handle actuator 214. Actuator 214 is adapted to be actuated by a user and is in operable communication with the elongate tubular member 250, wherein actuation of the handle actuator 214 causes axial movement of elongate tubular member 250, which is described in more detail below. Tubular member 250 has a distal end 252 and a lumen extending therethrough that is in communication with distal end 252. Distal end 252 and the lumen within tubular member 250 are sized and configured to receive therein proximal end 330 of implant subassembly 300, implant flexible tubular member 320, as well as implant first and second coupling members, which are described below.

(19) FIG. 2 illustrates an exemplary packaging 400 for handle subassembly 200, with a recess formed therein for handle 210 and a recess formed therein to receive elongate tubular member 250 member therein. One or more sections of elongate tubular member 250 are adapted to be stored in a non-linear configuration, as shown, and are configured to revert to a linear configuration when removed from packaging 400. One or more sections of elongate tubular member 250 may also be stored in linear configurations, as shown. Elongate tubular member 250 may be stored in other configurations not shown, any of which may have some degree of non-linearity in one or more sections along its length in the packaging. Packaging elongate tubular member 250 in a configuration that is not completely straight also reduces the length dimension of the package needed for the handle subassembly.

(20) Handle elongate tubular member 250 may, in some merely exemplary embodiments, be made of a flexible tubular material that allows for some degree of bending for packaging. The material of the elongate tubular member 250 may allow for both flexibility (for packaging), as well as have the necessary stiffness for avoiding buckling and for implant actuation.

(21) FIG. 3 illustrates an exemplary packaging 500 for an individual implant subassembly. Tubular member 320 may optionally be configured in a non-linear configuration as shown to reduce the packaging size. The flexibility of tubular member 320 as shown may allow for individual modular pre-loaded implants to be disposed in much smaller packaging than if assembled to the handle and packaged together.

(22) FIGS. 4A and 4B illustrates a merely exemplary implant 600 that is shown already decoupled from a handle subassembly, and is shown in an exemplary expanded, implanted configuration. Implant 600 is an example of an implant that may be packaged as a modular pre-loaded implant according to the disclosure herein. It is understood that a wide variety of other implants may benefit from incorporating the modular pre-loaded implant concepts herein, and that implant 600 is merely an illustrative implant. FIG. 4B illustrates proximal region 610 in more detail, including proximal anchor eyelet 614 and looped element 612, which may be referred to herein as an arrowhead.

(23) FIG. 5 illustrates an exemplary coupling mechanism 332 which is shown coupled to proximal end 610 of implant 600. In this example, coupling mechanism retains implant 600 until implant 600 is ready to be fully released and implanted in a patient. The coupling mechanism in this example includes first coupling member 340 and second coupling member 350. First and second coupling members 340 and 350 are shown coupled to the implant proximal end 610 in a first state, and are also adapted to release the implant proximal end 610 when in a second state, which is described in more detail below. Generally, in the first coupled state, second coupling member 350 has a looped distal end configuration that extends into an opening created by arrowhead 612. First coupling member 340 (which may be referred to herein as a lock wire) extends through second coupling member 350 and through arrowhead 612, wherein the arrangement between the first coupling member, the second coupling member, and the implant proximal end in this state prevents the release of the implant. To release implant 600, first coupling member 340 is retracted proximally beyond arrowhead 612, which release the proximal end of the implant, and which is described in more detail below.

(24) First and second coupling members 340 and 350 extend through flexible tubular member 320 as shown in FIG. 5, and are coupled to respective implant subassembly components at the proximal end of the implant subassembly, details of which are shown in FIGS. 6-8.

(25) After one of the medical implants has been selected from the available implants, the selected modular pre-loaded implant subassembly is removed from its individual packaging, such as packaging 500 shown in FIG. 3. The handle subassembly, which may be adapted to be used with any of the implant subassemblies, is also removed from its separate packaging. The proximal end 330 of the implant subassembly 300 is then front loaded into the distal end 252 of the handle subassembly. The flexible tubular member 320, in which first and second coupling members are disposed, is advanced proximally through elongate member 250 and into handle 210.

(26) One aspect of this disclosure is a separate modular pre-loaded implant subassembly that includes a proximal end that can be advanced into and locked in place within the delivery handle during the medical procedure by medical personnel, which provides the packaging advantages set forth herein. FIG. 5 illustrates an elongate and flexible tubular member 320, as well as first and second coupling members 340 and 350, both of which extend through a lumen within tubular member 320. FIGS. 6-8 illustrate a merely exemplary implementation of proximal end 330 of the implant subassembly that is sized and configured to be advanced into a handle subassembly and locked in place during a medical procedure. In this exemplary and particular example, first coupling member 340 (an example of which is shown in FIG. 5) is coupled to detachable component 370 of the proximal end 330 of the implant subassembly 300. Second coupling member 350 (an example of which is shown in FIG. 5) is coupled to static component 360 of the proximal end 330 of the implant subassembly 300. Preferably the second coupling member 350 is secured to the static component 360 under tension. Second coupling member 350 may be secured or coupled to static component 360 in a variety of ways, such as by one or more of bonding, adhesive(s), or other common coupling techniques. In this exemplary embodiment, the second coupling member 350 serves to secure the first coupling member 340 in such a way as to lock the implant to the delivery system until the first coupling member 340 is pulled proximally to release the implant. FIG. 8 illustrates a perspective sectional view showing first coupling member 340 extending through static component 360 and through detachable component 370, and coupled to detachable component 370. First coupling member 340 is secured to detachable component 370 such that when detachable component 370 is moved proximally, first coupling member 340 is also moved proximally (and relative to static component 360 which does not move axially), which releases the implant from the delivery system.

(27) One aspect of this disclosure is a handle subassembly that includes an implant subassembly locking mechanism that is positioned and adapted to lock a proximal end of the implant subassembly within the handle after the implant subassembly is moved proximally through the handle elongate tubular member and into the handle during a medical procedure to deploy the implant. The implant subassembly locking mechanism may be adapted to be actuated by a user to lock the proximal end of the implant subassembly within the handle, an example of which is described with respect to FIGS. 6-8.

(28) In some exemplary embodiments, the handle subassembly may further include an implant subassembly stopper at least partially disposed within the handle, the implant subassembly stopper positioned within the handle to interface and stop a proximal end of the implant subassembly from further proximal movement, the stopper positioned such that the implant subassembly locking mechanism can be actuated to lock the proximal end of the implant subassembly within the handle. An implant subassembly stopper may provide the advantage of automatically stopping the implant subassembly at a particular location within the handle such that locking may be simple and successfully performed by user actuation of a lock actuator, described in more detail below. FIG. 8 illustrates an exemplary stopper 295, having a distal end positioned and configured to stop the proximal movement of the implant subassembly at a particular location. Any of the stoppers here may also function as safety release member that must be removed from the handle prior to the implant from being released. For example, the stopper and safety release can interact with the handle such that the coupling member 340 cannot physically be retracted proximally until the stopper/safety member is removed from the handle.

(29) In the exemplary embodiment in FIGS. 6-8, the implant subassembly locking mechanism of the handle subassembly includes lock actuator 280 (also see FIG. 1) that is positioned and adapted relative to handle housing 212 to be actuated by a user to lock the proximal end 330 of the implant subassembly within the handle after the implant subassembly is moved proximally through the handle elongate tubular member and into the handle during a medical procedure to implant the implant. The implant subassembly locking mechanism includes first and second locking elements 282 and 284, which are positioned and configured to be actuated radially inward toward the proximal end 330 of the implant subassembly upon actuation of lock actuator 280 (e.g., depressing a handle button). The first and second locking elements 282 and 284 are positioned and configured to, upon actuation of lock actuator 280, move radially inward and interface with static component 360 and detachable component 370, respectively, to lock the proximal end 330 in place relative to the handle.

(30) In this merely exemplary and particular embodiment, locking elements 282 and 284 are configured as clips and each have surfaces that are configured to lockingly interface with outer surfaces of axially spaced regions 362 and 372 on static and detachable components 360 and 370, respectively. In this non-limiting example, axially spaced regions 362 and 372 each have smaller outer dimensions than axially adjacent regions, the smaller outer dimension adapting the regions 362 and 372 to be locked in place relative to the handle. In this embodiment the regions 362 and 372 may be considered to have depressions therein in the outer surfaces that are configured to be locked in place relative to the handle of the handle subassembly. In an alternative embodiment, the lock actuator may not be needed by having both locking elements 282 and 284 spring loaded and configured differently so that fork 282 may slide over region 372 as the implant subassembly is being introduced into the handle subassembly and then fork 284 could then drop into region 372. Alternative arrangements are contemplated. For example, locking elements could be configured as modulated irises to close radially into regions 362 and 372, where modulation could be triggered automatically by proximal end 330 of implant subassembly passing through the handle, where no lock actuator may be necessary. In other embodiments, a boss could be provided to drop into slots provided in static component 360 and detachable component 370. The boss may be cammed or not.

(31) As set forth above, detachable component 370, to which first coupling member 340 is secured, is adapted to be moved proximally within the handle relative to static component 360 to cause first coupling member 340 to be retracted and release the implant. Detachable component 370 is coupled to region 372 such that they move proximally together. Static component 360 is coupled to region 362 such that they remain static together when detachable component is pulled proximally. Separation location 361 is shown in FIG. 6 where detachable component 370 separates from static component 360. In one embodiment, this is accomplished by actuating handle release actuator 260 (see FIG. 1), which is in operative communication with detachable component 370 via locking element 284. As shown in FIG. 8, locking element 284 is secured within threaded member 290, which is in threaded engagement with handle release actuator 260. When handle release actuator 260 (not shown in FIG. 8) is actuated (e.g., rotated), threaded member 290 is moved axially due to the threaded relationship and the handle release actuator 260 is axially fixed in place (but can rotate). Axial movement of threaded member 290 causes locking element 284 to move axially as well. Locking element 284 is locked to detachable component 370, which is coupled to first coupling member 340. This exemplary arrangement causes the proximal movement of first coupling member 340, thereby releasing the implant. Actuation of handle release actuator 260 thereby causes the release of the implant. This disclosure thereby describes a modular pre-loaded implant that can be locked in place to the handle during the medical procedure, yet an implant coupling member can be moved relative to the handle to facilitate the release of the implant when desired.

(32) Lock element 282 is not disposed within threaded member 290, and thus does not move proximally with lock element 284 when handle release actuator 260 is actuated. This configuration is thus an example of how to prevent a static member from moving when a detachable member needs to be moved to release the implant.

(33) The disclosure that follows illustrates exemplary method steps that may be performed during coupling and delivery of an implant. Some method steps that follow are described above. Not all method steps that follow need necessarily be performed, and one or more steps may in fact be illustrative and/or optional.

(34) One aspect of this disclosure is a method of assembling an implant subassembly and a handle subassembly. The method may include removing an implant subassembly (e.g., 300) from a first packaging (e.g., 500), the implant subassembly comprising a proximal end and an implant in a collapsed state within a cartridge. The method may also include removing a handle subassembly (e.g., 200) from a second packaging (e.g., 400), the handle subassembly including a handle and an elongate handle tubular member in operable communication with a handle actuator (e.g., 214), wherein actuation of the handle actuator causes axial movement of the elongate handle tubular member. The method may further include advancing the proximal end of the implant subassembly into a distal end of the elongate handle tubular member, through the elongate handle tubular member and into a handle of the handle subassembly. The method may further include locking the proximal end of the implant subassembly in place relative to the handle subassembly.

(35) Once the implant subassembly is locked in place relative to the handle, the locked system is in the configuration shown in FIG. 9, with implant elongate tubular member 320 (not visible) within handle elongate tubular member 250 and within handle 210. The distal end of handle elongate tubular member 250 is just proximal to the implant (not visible) in the cartridge. The handle elongate tubular member 250 may be much longer than is shown in FIG. 9, with the two curved lines indicating a length of the tubular member 250 that is not shown.

(36) FIG. 10 illustrates by way of example only a relative position of an implant 600 inside cartridge 310, even though FIG. 10 illustrates the implant 600 in a deployed and optionally curved configuration. Any of the implants herein may be non-expandable implants, but may still be pre-loaded within a cartridge or other elongate housing. The term cartridge herein may thus be replaced globally with a more generic term such as elongate housing with a lumen therein, and it may be rigid.

(37) In some exemplary embodiments, the distal end of the cartridge may then be coupled to a proximal end 902 of a delivery catheter 900, an example of which is shown in FIG. 11. Distal end 904 of the catheter is also shown. In some exemplary embodiments, a delivery catheter 900 may have a length from 50 cm to 90 cm, such as from 60 cm to 80 cm.

(38) FIG. 12 illustrates an exemplary luer lock connection between the cartridge and the delivery catheter (after advancement of the handle assembly and implant through the delivery catheter).

(39) After coupling the cartridge to the delivery catheter 900, the handle assembly 200, handle elongate tubular member 250, implant elongate tubular member 320, and the implant are advanced distally relative to the cartridge until the handle comes into contact with the cartridge, as shown in FIG. 12. The cartridge outer threads are configured to mate with internal threads on delivery catheter control actuator 265, such that once mated, actuation of actuator 265 controls axial movement of the cartridge and the delivery catheter, which is now coupled to the cartridge. Axial movement of the cartridge and the delivery catheter allows for unsheathing and sheathing of the implant as may be needed, with the implant now positioned at the distal end and within the delivery catheter. After the implant is deployed from the delivery catheter, which may occur by moving the delivery catheter relative to the implant, the implant may be released. Removal of a safety member (which may also be a stopper as described herein), such as is shown at the proximal end of handle in FIG. 9, may occur to allow the implant release. As is described in more detail above, the release actuator 260 may be actuated to cause locking member 284 to move proximally, which causes the proximal movement of detachable component 370 and first coupling member 340, thereby releasing the implant. The delivery system may then be removed.

(40) As set forth above, advancing the proximal end of the implant subassembly into the handle may also comprise advancing the proximal end of the implant subassembly until it engages with an implant subassembly stopper (e.g., 295) in the handle.

(41) Locking the proximal end of the implant subassembly relative to the handle subassembly may include moving a locking element (e.g., 284) into a locked position relative to the proximal end of the implant subassembly. The locking element may be moved into engagement with a detachable component (e.g., 370) of the implant subassembly, the detachable component secured to a first coupling member (e.g., 340) of the implant subassembly, the first coupling member part of a coupling mechanism that is coupled to the implant (e.g., 600) in a first state, the first coupling member moveable relative to the implant to release the implant. Locking the proximal end of the implant subassembly relative to the handle subassembly may further comprise moving a second locking element (e.g., 282) into engagement with the proximal end of the implant subassembly, and optionally into engagement with a static component (e.g., 360) of the implant subassembly. The static component may be coupled to a second coupling member (e.g., 350) of the coupling mechanism, wherein the second locking element and the second coupling member not movable axially after being locked in place relative to the handle.

(42) Locking the proximal end of the implant subassembly may comprises actuating (optionally depressing) a handle lock actuator (e.g., 280), although other types of actuators may be implemented.

(43) At a time that is subsequent to locking the proximal end of the implant subassembly, any of the methods herein may further comprise delivering the implant to a target location, and releasing the implant. The releasing step may comprise actuating a release handle actuator (e.g., 260) to cause the movement of a detachable component (e.g., 370) of the proximal end of the implant subassembly, the proximal end of the implant subassembly secured to an implant coupling member (e.g., 340).

(44) The entire delivery system may then be removed from the patient, leaving the implant implanted at the target location.