Bifurcation catheter dual balloon bond and methods

Abstract

A catheter assembly includes a main catheter branch having a catheter shaft and a distal end portion. A main balloon and a side balloon are positioned at the distal end portion of the catheter shaft. The main balloon includes a distal waist portion at a distal end thereof and a proximal waist portion at a proximal end thereof. The side balloon includes an inflatable portion, a proximal waist portion, and a distal waist portion, wherein the proximal and distal waist portions define a side inflation lumen. The proximal waist portion of the side balloon and the proximal waist portion of the main balloon are secured to the distal end portion of the catheter shaft at a single bond or connection point to create a proximal balloon joint, wherein the main inflation lumen is in fluid communication with the main balloon and the side inflation lumen.

1 . A catheter assembly, comprising:
 a main catheter branch, including:
 a catheter shaft having a proximal end portion, a distal end portion, the distal end portion defining a main inflation member, the catheter shaft having a main guidewire housing having a distal end portion, the distal end portion of the main guidewire housing extending distally beyond the distal end portion of the catheter shaft; 
 a main balloon having a distal waist at a distal end portion thereof and a proximal waist at a proximal end portion thereof, the proximal waist mounted to the catheter shaft and the distal waist mounted to the distal end portion of the main guidewire housing; and 
 a side balloon having an inflatable portion, a distal waist at a distal end portion thereof, and a proximal waist at a proximal end portion thereof, the side balloon being configured to extend in a radial direction relative to the main balloon when the side balloon is inflated, the inflatable portion positioned at a location between the proximal and distal end portions of the main balloon, wherein the proximal waist of the side balloon, the proximal waist of the main balloon, and the distal end portion of the catheter shaft are joined at a single joint such that the side balloon and the main balloon are in fluid communication with the main inflation member of the main catheter shaft, wherein a distal end point of the catheter shaft extends inside the proximal waist of the main balloon such that the distal end point of the catheter shaft resides at a distal end point of the proximal waist of the main balloon. 
   
     
     
         2 . The assembly of  claim 1 , wherein the distal waist of the side balloon is mounted to the distal end portion of the main guidewire housing. 
     
     
         3 . The assembly of  claim 1 , further comprising a stent, the stent having opposing proximal and distal open ends, and a lateral branch opening, the lateral branch opening positioned at a location between the proximal and distal open ends, wherein the stent is operably mounted to the main balloon with the side balloon inflatable portion oriented in alignment with the lateral branch opening. 
     
     
         4 . The assembly of  claim 1 , wherein the single joint is positioned proximal of the distal end point of the catheter shaft a distance in the range of about 1 mm to about 10 mm inclusive. 
     
     
         5 . The assembly of  claim 3 , further comprising a side catheter branch having a distal end portion, the side catheter branch defining a branch guidewire lumen, the distal end portion of the side catheter branch extending through the lateral branch opening of the stent prior to inflation of the main balloon and the side balloon. 
     
     
         6 . The assembly of  claim 1 , wherein the single joint is bonded together with a heat bond connection. 
     
     
         7 . The assembly of  claim 1 , wherein the single joint is bonded together with a laser bond connection. 
     
     
         8 . A catheter assembly, comprising:
 a main catheter branch having a proximal end portion and a distal end portion, the distal end portion including:
 a catheter shaft having a distal end portion with a distal end point and defining a main inflation lumen; 
 a main guidewire housing having a distal end portion extending distally beyond the distal end point of the catheter shaft, the guidewire housing defining a main guidewire lumen; 
 a main balloon having a proximal waist portion mounted to the catheter shaft and a distal waist portion mounted to the distal end portion of the main guidewire housing; 
 a side balloon having an inflatable portion, a proximal waist portion, and a distal waist portion, the proximal and distal waist portions of the side balloon defining a side inflation lumen, wherein the proximal waist portion of the side balloon, the proximal waist portion of the main balloon, and the distal end portion of the catheter shaft are joined at a single location such that the main balloon and side balloon are in fluid communication with the main inflation lumen, wherein the distal end point of the catheter shaft extends inside the proximal waist portion of the main balloon such that the distal end point of the catheter shaft resides at a distal end point of the proximal waist portion of the main balloon; 
   a side catheter branch having a distal end portion, the side catheter branch defining a side guidewire lumen; and   a stent, the stent having proximal and distal open ends, and a lateral branch opening defined in the stent at a location between the proximal and distal open ends, the distal end portion of the side catheter branch extending through the lateral branch opening prior to inflation of the main balloon and the side balloon.   
     
     
         9 . The assembly of  claim 8 , wherein the single location is positioned proximal of the distal end point of the catheter shaft a distance in the range of about 1 mm to about 10 mm inclusive. 
     
     
         10 . The assembly of  claim 8 , wherein the single proximal waist portions of the side and main balloon and the distal end portion of the catheter shaft are bonded together with a heat bond connection. 
     
     
         11 . The assembly of  claim 8 , wherein an outer surface of the proximal waist portion of the side balloon is disposed on an outer surface of the proximal waist portion of the main balloon and the distal end portion of the catheter shat is disposed inside the proximal waist portion of the main balloon at the single location.