Device having an electroformed pleated region and method of its manufacture

Patent metadata

Field	Value
Publication number	US-2017143936-A1
Application number	US-201715403380-A
Country	US
Kind code	A1
Filing date	Jan 11, 2017
Priority date	Dec 30, 2010
Publication date	May 25, 2017
Grant date	—

Abstract

A deflectable, flexible device includes an elongate body, a convoluted tip portion at a distal end of the elongate body, and a lumen to receive one or more wires. The convoluted tip portion includes an electroformed pleated region which is formed by electrodepositing a metal on a mandrel having a pleated region. The convoluted tip portion may be hermetically sealed to permit repeated sterilization. The electroformed pleated region may include one or more fluid emission orifices. The convoluted tip portion extends or bends in response to fluid pressure manipulation, contact with tissue, manipulation with an internal spring or wire, or by a user pushing, pulling, or twisting the catheter directly or via an introducer sheath or the like. The convoluted tip portion may further include an RF ablation element or other energy-driven technique to create continuous linear lesions or a sensing element.

First claim

1 - 12 . (canceled)

13 . A method of manufacturing an elastically deformable electroformed pleated section of a device, comprising:
depositing a metal onto an electroforming mandrel having a pleated region, trimming the mandrel, dissolving or otherwise eliminating the mandrel, thereby forming an elastically deformable electroformed pleated section, wherein the elastically deformable electroformed pleated section is formed to be longitudinally extendable, and further wherein the elastically deformable electroformed pleated region is electrically conductive; and coupling the elastically deformable electroformed pleated section to the distal portion of an elongate body, wherein the proximal portion of the elongate body is coupled to a control handle.

14 . The method of 13 wherein the step of depositing a metal onto an electroforming mandrel comprises depositing any one or more of nickel, copper or gold onto the mandrel.

15 . The method of 13 , further comprising the step of over coating the elastically deformable electroformed pleated section with gold or a gold alloy.

16 . The method of 13 , further comprising the step of over coating the elastically deformable electroformed pleated section with platinum or a platinum alloy.

17 - 20 . (canceled)

21 . A method of manufacturing an elastically deformable electroformed pleated region of a catheter, comprising the steps of:
rendering the surface of a polymeric mandrel conductive, wherein the polymeric mandrel comprises at least one pleated region, and wherein the polymeric mandrel further comprises multiple interior lumens, depositing a metal onto the at least one pleated region, thereby forming an elastically deformable electroformed pleated region, wherein the elastically deformable electroformed pleated region comprises an ablation element; and coupling the elastically deformable electroformed pleated region to the distal portion of an elongate body, wherein the proximal portion of the elongate body is coupled to a control handle.

22 . The method of claim 21 , wherein the metal is selected from the group consisting of nickel, copper, and gold.

23 . The method of claim 22 , further comprising the step of over-coating the electroformed pleated region with a gold, rhodium or platinum alloy.

24 . The method of claim 21 , further comprising the step of depositing the metal onto the entire surface of the polymeric mandrel.

25 . The method of claim 21 , further comprising the step of laser drilling irrigant fluid emission orifices in the electroformed pleated region.

26 . A method of manufacturing a catheter, comprising the steps of:
forming an elastically deformable electroformed pleated region, wherein the elastically deformable electroformed pleated region comprises at least one fluid emission orifice, and further wherein the elastically deformable electroformed pleated region comprises an ablation element, coupling the elastically deformable electroformed pleated region to the distal portion of an elongate body; and coupling the proximal portion of the elongate body to a control handle, thereby forming a catheter.

27 . The method of claim 26 , wherein the step of forming an elastically deformable electroformed pleated region further comprises the steps of:
providing a polymeric mandrel comprising at least one pleated region and at least one interior lumen, rendering the surface of the polymeric mandrel conductive; and depositing a metal onto the at least one pleated region.

Assignees

• St Jude Medical Atrial Fibrillation Div Inc

Inventors

• Sliwa John W
• Morse Stephen A

Classifications

• A61M25/0141

  having flexible regions as a result of using materials with different mechanical properties · CPC title

• A61M25/0074

  Dynamic characteristics of the catheter tip, e.g. openable, closable, expandable or deformable · CPC title

• A61M25/0155

  with hydraulic or pneumatic means, e.g. balloons or inflatable compartments · CPC title

• C25D1/00

  Electroforming · CPC title

• A61M25/0133

  Tip steering devices · CPC title