US2010168717A1PendingUtilityA1

Multi-lumen medical devices and methods of manufacturing same

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Individually held — no corporate assignee on recordPriority: Dec 30, 2008Filed: Dec 30, 2008Published: Jul 1, 2010
Est. expiryDec 30, 2028(~2.4 yrs left)· nominal 20-yr term from priority
Inventors:Martin M. GrasseJames V. Kauphusman
B29C 49/04B29K 2027/18A61B 18/18A61M 25/0053A61L 29/041A61M 25/0147B29C 48/21A61M 2025/004B29C 48/10B29D 23/00B29C 48/022A61M 2025/0036A61M 25/0012B29C 48/0021A61B 2018/00642A61M 25/005F16L 11/22B29L 2031/7542A61B 2018/00839A61B 18/1492A61M 25/0026A61M 25/01
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Claims

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.

Claims

exact text as granted — not AI-modified
1 . A method of manufacturing a catheter assembly comprising the steps of:
 extruding an inner polymeric layer, the inner polymeric layer defining a main lumen having an inner surface and an outer surface and further defining two or more side lumens spaced about the outer surface of the main lumen, wherein a size of the side lumens is less than about ⅕ a size of the main lumen;   forming an outer polymeric layer disposed about the inner polymeric layer; and   inserting at least one elongate member through each side lumen of the inner polymeric layer.   
     
     
         2 . The method according to  claim 1 , wherein the two or more side lumens are spaced symmetrically about the outer surface of the main lumen. 
     
     
         3 . The method according to  claim 1 , wherein the inner polymeric layer comprises about 2-16 side lumens. 
     
     
         4 . The method according to  claim 1 , wherein the inner polymeric layer comprises about 6-16 side lumens. 
     
     
         5 . The method according to  claim 1 , wherein a size of the side lumens is about ⅕ to about 1/16 a size of the main lumen. 
     
     
         6 . The method according to  claim 1 , wherein the inner polymeric layer comprises polytetrafluoroethylene. 
     
     
         7 . The method according to  claim 1  further comprising a step of forming a braided layer between the inner polymeric layer and the outer polymeric layer. 
     
     
         8 . The method according to  claim 7 , further comprising heating the inner polymeric layer, the braided layer and the outer polymeric layer to bond the inner polymeric layer, the braided layer and the outer polymeric layer together. 
     
     
         9 . The method according to  claim 1 , wherein the elongate member comprises at least one of a pull wire and an electrical wire. 
     
     
         10 . A catheter assembly comprising:
 an inner extruded polymeric layer defining a main lumen having an inner surface and an outer surface and further defining two or more side lumens spaced about the outer surface of the main lumen, wherein a size of the side lumens is less than about ⅕ a size of the main lumen;   an outer polymeric layer disposed about the inner extruded polymeric layer; and   at least one elongate member extending through one of the side lumens.   
     
     
         11 . The catheter assembly according to  claim 10 , wherein the inner extruded polymeric layer comprises polytetrafluoroethylene. 
     
     
         12 . The catheter assembly according to  claim 10 , wherein the inner extruded polymeric layer comprises about 2-16 side lumens. 
     
     
         13 . The catheter assembly according to  claim 10 , wherein the inner extruded polymeric layer comprises about 6-16 side lumens. 
     
     
         14 . The catheter assembly according to  claim 10 , wherein a size of the side lumens is about ⅕ to about 1/16 a size of the main lumen. 
     
     
         15 . The catheter assembly according to  claim 10 , wherein the two or more side lumens are spaced symmetrically about the outer surface of the main lumen. 
     
     
         16 . 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. 
     
     
         17 . The catheter assembly according to  claim 10 , further comprising a braided layer disposed between the inner extruded polymeric layer and the outer polymeric layer. 
     
     
         18 . A method of manufacturing a catheter assembly comprising the steps of:
 co-extruding an inner polymeric layer and a multi-lumen layer, wherein the inner polymeric layer comprises an inner surface defining a main lumen and an outer surface, and wherein the multi-lumen layer comprises two or more side walls, each side wall defining a side lumen;   forming an outer polymeric layer about the multi-lumen layer; and   inserting at least one elongate member through each side lumen,   wherein a size of the side lumens is less than about ⅕ a size of the main lumen.   
     
     
         19 . The method according to  claim 18 , wherein the inner polymeric layer and the multi-lumen layer comprise the same material. 
     
     
         20 . The method according to  claim 18 , wherein the inner polymeric layer and the multi-lumen layer comprise polytetrafluoroethylene. 
     
     
         21 . The method according to  claim 18 , wherein the inner polymeric layer and the multi-lumen layer comprise different materials. 
     
     
         22 . The method according to  claim 18 , wherein the multi-lumen layer comprises about 2-16 side lumens. 
     
     
         23 . The method according to  claim 18 , wherein the multi-lumen layer comprises about 6-16 side lumens. 
     
     
         24 . The method according to  claim 18 , wherein a size of the side lumens is about ⅕ to about 1/16 a size of the main lumen. 
     
     
         25 . The method according to  claim 18 , wherein the side lumens are spaced symmetrically about the outer surface of the main lumen. 
     
     
         26 . The method according to  claim 18  further comprising a step of forming a braided layer between the multi-lumen layer and the outer polymeric layer. 
     
     
         27 . The method according to  claim 26  further comprising heating the inner polymeric layer, the multi-lumen layer, the braided layer and the outer polymeric layer to bond the inner polymeric layer, the multi-lumen layer, the braided layer and the outer polymeric layer together. 
     
     
         28 . The method according to  claim 18 , wherein the at least one elongate member comprises at least one of a pull wire and an electrical wire. 
     
     
         29 . A catheter assembly comprising:
 an inner polymeric layer having an inner surface defining a main lumen and an outer surface;   a multi-lumen layer disposed about the outer surface of the inner polymeric layer, the multi-lumen layer comprising two or more side walls, each side wall defining a side lumen, wherein the multi-lumen layer and the inner polymeric layer are co-extruded,   an outer polymeric layer disposed about the multi-lumen layer; and   at least one elongate member extending through one of the side lumens,   wherein a size of the side lumens is less than about ⅕ a size of the main lumen.   
     
     
         30 . The catheter assembly according to  claim 29 , wherein the side lumens are spaced symmetrically about the outer surface of the main lumen. 
     
     
         31 . The catheter assembly according to  claim 29 , wherein the multi-lumen layer comprises about 2-16 side lumens. 
     
     
         32 . The catheter assembly according to  claim 29 , wherein the multi-lumen layer comprises about 8-16 side lumens. 
     
     
         33 . The catheter assembly according to  claim 29 , wherein a size of the side lumens is about ⅕ to about 1/16 a size of the main lumen. 
     
     
         34 . The catheter assembly according to  claim 29 , wherein the at least one elongate member comprises at least one of a pull wire and an electrical wire. 
     
     
         35 . The catheter assembly according to  claim 29 , further comprising a braided layer disposed between the multi-lumen layer and the outer polymeric layer.

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