Intravascular catheter with multiple axial fibers

Abstract

An intravascular catheter having a shaft, at least a portion of which includes a braid reinforcement with a plurality of axial members disposed between the helical members that form the braid. The axial members provide a number of advantages including: maintaining one-to-one correspondence in axial manipulation; maintaining uniform flexibility in several planes of flexure; reducing the likelihood of causing a curling effect; increasing the strength of connections between shaft segments; uniformly increasing stiffness of the catheter; and increasing the burst strength of the catheter. By positioning the axial members between the helical members, the axial members do not create a protrusion and do not become fixed to any adjacent polymer layer. Thus, the benefits of axial members are retained, without creating the undesirable effects of friction caused by an axial protrusion and without creating the undesirable effects of limited flexure caused by an adjacent polymer layer becoming fixed to the axial member.

What is claimed is:  
     
         1 . An intravascular catheter comprising an elongate shaft having a lumen extending therethrough, the shaft including an inner polymer layer, a reinforcement layer disposed about the inner layer and an outer polymer layer disposed about the reinforcement layer, the reinforcement layer comprising a tubular braid having a first helical member interwoven with a second helical member and a plurality of axial members disposed between the first helical member and the second helical member, wherein the elongate shaft has a circumference and wherein the axial members are spaced apart about the circumference of the shaft.  
     
     
         2 . An intravascular catheter as in  claim 1 , wherein the axial members are uniformly spaced about the circumference of the shaft.  
     
     
         3 . An intravascular catheter as in  claim 2 , wherein four axial members are uniformly spaced apart by 90° about the circumference of the shaft.  
     
     
         4 . An intravascular catheter as in  claim 2 , wherein eight axial members are uniformly spaced apart by 45° about the circumference of the shaft.  
     
     
         5 . An intravascular catheter as in  claim 2 , wherein the elongate shaft includes a proximal portion and a distal portion, and wherein the distal shaft portion has fewer axial members than the proximal shaft portion.  
     
     
         6 . An intravascular catheter as in  claim 5 , wherein the proximal shaft portion has the plurality of axial members and the distal shaft portion has one axial member selected from the plurality of axial members.  
     
     
         7 . An intravascular catheter as in  claim 1 , wherein the axial members are movable relative to the inner and outer layers.  
     
     
         8 . An intravascular catheter as in  claim 1 , wherein the inner and outer layers have respective inner and outer surfaces free of protrusions caused by the axial members.  
     
     
         9 . An intravascular catheter as in  claim 1 , wherein the first and second helical members each comprise polymeric material.  
     
     
         10 . An intravascular catheter as in  claim 9 , wherein the first and second helical members each comprise a plurality of monofilaments.  
     
     
         11 . An intravascular catheter as in  claim 1 , wherein the axial members each comprise a polymeric material.  
     
     
         12 . An intravascular catheter as in  claim 11 , wherein the axial members each comprise a plurality of polymeric monofilaments.  
     
     
         13 . An intravascular catheter as in  claim 12 , wherein the monofilaments are held together statically.  
     
     
         14 . An intravascular catheter as in  claim 13 , wherein the monofilaments comprise LCP.  
     
     
         15 . An intravascular catheter as in  claim 14 , wherein the monofilaments are arranged side-by-side to collectively define a flat ribbon.  
     
     
         16 . An intravascular catheter comprising an elongate shaft having a reinforcement layer comprising a tubular braid having a first helical member interwoven with a second helical member and a plurality of axial members disposed between the first helical member and the second helical member.  
     
     
         17 . An intravascular catheter as in  claim 16 , wherein the axial members are uniformly spaced about the circumference of the shaft.  
     
     
         18 . An intravascular catheter as in  claim 17 , wherein four axial members are uniformly spaced apart by 90° about the circumference of the shaft.  
     
     
         19 . An intravascular catheter as in  claim 17 , wherein eight axial members are uniformly spaced apart by 45° about the circumference of the shaft.  
     
     
         20 . An intravascular catheter as in  claim 16 , wherein the elongate shaft includes a proximal portion and a distal portion, and wherein the distal shaft portion has fewer axial members than the proximal shaft portion.  
     
     
         21 . An intravascular catheter as in  claim 20 , wherein the proximal shaft portion has the plurality of axial members and the distal shaft portion has one axial member selected from the plurality of axial members.  
     
     
         22 . An intravascular catheter as in  claim 16 , wherein the first and second helical members each comprise polymeric material.  
     
     
         23 . An intravascular catheter as in  claim 22 , wherein the first and second helical members each comprise a plurality of monofilaments.  
     
     
         24 . An intravascular catheter as in  claim 16 , wherein the axial members each comprise a polymeric material.  
     
     
         25 . An intravascular catheter as in  claim 24 , wherein the axial members each comprise a plurality of polymeric monofilaments.  
     
     
         26 . An intravascular catheter as in  claim 25 , wherein the monofilaments are held together statically.  
     
     
         27 . An intravascular catheter as in  claim 26 , wherein the monofilaments comprise LCP.  
     
     
         28 . An intravascular catheter as in  claim 27 , wherein the monofilaments are arranged side-by-side to collectively define a flat ribbon.  
     
     
         29 . A method of making a portion of a shaft of an intravascular catheter, the method comprising the steps of: 
 braiding a first helical member and a second helical member about a carrier such that a plurality of axial members are disposed between the first and second helical members.    
     
     
         30 . A method of making a portion of a shaft of an intravascular catheter as in  claim 29 , wherein the axial members are uniformly spaced about the circumference of the shaft.  
     
     
         31 . A method of making a portion of a shaft of an intravascular catheter as in  claim 30 , wherein four axial members are uniformly spaced apart by 90° about the circumference of the shaft.  
     
     
         32 . A method of making a portion of a shaft of an intravascular catheter as in  claim 30 , wherein eight axial members are uniformly spaced apart by 45° about the circumference of the shaft.