Multi-lumen medical devices and methods of manufacturing same

Patent metadata

Field	Value
Publication number	US-11596765-B2
Application number	US-201916288710-A
Country	US
Kind code	B2
Filing date	Feb 28, 2019
Priority date	Dec 30, 2008
Publication date	Mar 7, 2023
Grant date	Mar 7, 2023

Abstract

A method of manufacturing a catheter shaft includes extruding an inner polymeric layer having a main lumen and two or more side lumens spaced about the main lumen; forming an outer polymeric layer about the inner polymeric layer; and inserting at least one elongate member, such as a wire, through each side lumen of the inner polymeric layer. The side lumens are less than about ⅕ the size of the main lumen. The method may further include the step of forming a braided layer between the inner polymeric layer and the outer polymeric layer. In an alternate embodiment, the method includes co-extruding an inner polymeric layer and a multi-lumen layer, the multi-lumen layer having two or more side lumens; forming an outer polymeric layer about the multi-lumen layer; and inserting at least one elongate member through each side lumen. Catheter assemblies made according to the described methods are also disclosed.

First claim

What is claimed is:

1. A catheter assembly formed according to a process comprising:
co-extruding an inner polymeric layer of a first polymeric material and a multi-lumen layer of a second polymeric material different from the first polymeric material, wherein the inner polymeric layer defines a main lumen and the multi-lumen layer defines two or more side lumens spaced about the main lumen, and wherein a size of the two or more side lumens is less than a size of the main lumen;
forming an outer polymeric layer about the co-extruded inner polymeric layer and multi-lumen layer; and
inserting at least one elongate member through each of the two or more side lumens.

2. The catheter assembly according to claim 1 , wherein the two or more side lumens are spaced symmetrically about the main lumen.

3. The catheter assembly according to claim 1 , wherein the multi-lumen layer defines between two and sixteen side lumens.

4. The catheter assembly according to claim 3 , wherein the multi-lumen layer defines between six and sixteen side lumens.

5. The catheter assembly according to claim 1 , wherein the size of the two or more side lumens is between ⅕ and 1/16 the size of the main lumen.

6. The catheter assembly according to claim 1 , wherein the first polymeric material comprises polytetrafluoroethylene.

7. The catheter assembly according to claim 1 , wherein the process further comprises forming a braided layer between the outer polymeric layer on one side and the co-extruded inner polymeric layer and multi-lumen layer on another side.

8. The catheter assembly according to claim 1 , wherein the process further comprises heating the co-extruded inner polymeric layer and multi-lumen layer and the outer polymeric layer to bond the co-extruded inner polymer layer and multi-lumen layer to the outer polymeric layer.

9. The catheter assembly according to claim 1 , wherein the at least one elongate member comprises at least one of a pull wire and an electrical wire.

10. A catheter assembly, comprising:
a co-extrusion of an inner polymeric layer of a first polymeric material that defines a main lumen and a multi-lumen layer of a second polymeric material different from the first polymeric material that defines two or more side lumens spaced about the main lumen, wherein a size of the two or more side lumens is less than a size of the main lumen;
an outer polymeric layer disposed about the co-extrusion of the inner polymeric layer and the multi-lumen layer; and
at least one elongate member extending through each of the two or more side lumens.

11. The catheter assembly according to claim 10 , wherein the two or more side lumens are spaced symmetrically about the main lumen.

12. The catheter assembly according to claim 10 , wherein the multi-lumen layer defines between two and sixteen side lumens.

13. The catheter assembly according to claim 12 , wherein the multi-lumen layer defines between six and sixteen side lumens.

14. The catheter assembly according to claim 10 , wherein the size of the two or more side lumens is between ⅕ and 1/16 the size of the main lumen.

15. The catheter assembly according to claim 10 , wherein the first polymeric material comprises polytetrafluoroethylene.

16. The catheter assembly according to claim 10 , further comprising a braided layer disposed between the outer polymeric layer on one side and the co-extrusion of the inner polymeric layer and the multi-lumen layer on another side.

17. The catheter assembly according to claim 10 , wherein the at least one elongate member comprises at least one of a pull wire and an electrical wire.

Assignees

• St Jude Medical Atrial Fibrillation Div Inc

Inventors

• Grasse Martin Maitre
• Kauphusman James V

Classifications

• B29C49/04

  Extrusion blow-moulding · CPC title

• A61M25/0147

  with movable mechanical means, e.g. pull wires · CPC title

• B29L2031/7542

  Catheters · CPC title

• A61B18/1492

  having a flexible, catheter-like structure, e.g. for heart ablation (A61B18/1477 takes precedence) · CPC title

• F16L11/22

  Multi-channel hoses · CPC title