Dual Taper Stent Protector

Abstract

A dual taper stent protector having a first stent covering region configured to cover a stent without substantially engaging the stent, a second covering region, and an engagement region for engaging a product mandrel removably disposed within a catheter shaft, and first and second tapered regions connecting the first stent covering region and the second stent covering region and the second covering region and the engagement region respectively, and to methods of making and using the same.

1 . A method of making a protector, the protector comprising a first covering region having a diameter configured to cover a medical device without substantial frictional contact, a second covering region having a second diameter which is less than the first diameter, a first connecting region connecting said first covering region and said second covering region and an engagement region having a third diameter, the third diameter is less than the second diameter, the engagement region configured to engage a tubular portion of a catheter assembly, the engagement region located distally from the stent covering region and a second connecting region connecting said second covering region and said engagement region, the method comprising:
 providing an injection mold, the mold having a first region of a first diameter corresponding to said first covering region of said protector, a second region of a second diameter which is less than the first diameter corresponding to said second covering region of said protector, a first tapered region connecting said first region and said second region, a third region having a diameter that is less than that of the second region corresponding to said engagement region of said protector, and a second tapered region connecting said second region and said third region; and   forming said protector in said injection mold.   
   
   
       2 . The method of  claim 1  further comprising disposing said protector about a catheter assembly and crimping said protector onto said catheter assembly with heat and pressure. 
   
   
       3 . A mold for forming a protector for a medical device, the mold comprising:
 a first region of a first diameter for forming a first covering region of said protector;   a second region of a second diameter which is less than the first diameter for forming a second covering region of said protector;   a first tapered region connecting said first region and said second region, said first tapered region for forming a first tapered protector region;   a third region having a diameter that is less than that of the second region, the third region for forming an engagement region of said protector, said engagement region sized for disposing said protector about a catheter shaft; and   a second tapered region connecting said second region and said third region of said mold, said second tapered region for forming a second tapered protector region.   
   
   
       4 . A protector for a radially expandable medical device, the protector comprising:
 a first covering region having a proximal end and a distal end, the first covering region having a first diameter;   a second covering region having a second diameter less than the first;   a first tapered connecting region between said first covering region and said second covering region;   an engagement region for engagement with a catheter shaft, the engagement region located distally from the second covering region and the second connecting region, the engagement region having a third diameter less than the second diameter; and   a second tapered region connecting said second covering region and said engagement region.   
   
   
       5 . The protector of  claim 4  having an opening at its proximal end, the opening having a diameter substantially the same as said first diameter. 
   
   
       6 . The protector of  claim 4 , said protector disposed about an expandable medical balloon. 
   
   
       7 . The protector of  claim 5  disposed about a stent and said expandable medical balloon.