Catheter devices and methods for making them

Abstract

Tubular devices are provided that include a proximal end, a distal end sized for introduction into a patient's body, a central lumen, a conductor extending between the proximal and distal ends adjacent the central lumen, reinforcement members including windings extending helically around the central lumen, and an outer jacket. The tubular device includes a first portion in which the conductor extends helically around the central lumen, and a second portion in which the conductor extends longitudinally and either a) all of the windings surround the central lumen and the conductor remains outside the windings, b) at least some of the windings pass between the central lumen and the conductor and at least some of the windings surround both the central lumen and the conductor, and c) all of the windings surround both the central lumen and the conductor. Methods for making such tubular devices are also provided.

1 . A method for making a tubular body, comprising:
 directing a primary mandrel along a central axis of a braiding apparatus such that the primary mandrel is surrounded by a plurality of reinforcement carrying elements in a predetermined configuration relative to the central axis;   providing an elongate conductor dispenser at a first location adjacent to the reinforcement carrying elements and offset from the central axis;   with a conductor feeding from the dispenser at the first location, simultaneously wrapping reinforcement members from the reinforcement carrying elements and wrapping the conductor from the dispenser helically around a first portion of the primary mandrel;   moving the dispenser to a second location;   with the conductor feeding from the dispenser at the second location, wrapping reinforcement members from the reinforcement carrying elements helically around a second portion of the primary mandrel while the conductor extends substantially axially along the second portion;   applying an outer jacket around the primary and secondary mandrels after wrapping the one or more reinforcement members therearound; and   removing the primary mandrel to define a primary lumen within the tubular body.   
     
     
         2 - 26 . (canceled) 
     
     
         27 . A tubular device for a catheter or sheath comprising a proximal end and a distal end sized for introduction into a patient's body, the tubular device comprising:
 a central lumen extending between the proximal and distal ends, thereby defining a longitudinal axis;   an elongate conductor extending at least partially between the proximal and distal ends adjacent the central lumen;   one or more reinforcement members comprising windings extending helically around the central lumen between the proximal and distal ends; and   an outer jacket surrounding the one or more reinforcement members,   wherein the tubular device comprises a first portion in which the conductor extends helically around the central lumen, and a second portion in which the conductor extends substantially parallel to the longitudinal axis and either a) all of the windings surround the central lumen and the conductor remains outside the windings, b) at least some of the windings pass between the central lumen and the conductor and at least some of the windings surround both the central lumen and the conductor, and c) all of the windings surround both the central lumen and the conductor.   
     
     
         28 . The tubular device of  claim 27 , wherein the second portion is a distal portion adjacent the distal end, and the first portion is an intermediate portion between the proximal end and the distal portion. 
     
     
         29 . The tubular device of  claim 28 , further comprising one or more sensing elements carried on the distal portion and coupled to the conductor. 
     
     
         30 . The tubular device of  claim 28 , wherein the conductor comprises a plurality of wires, the tubular device further comprising a plurality of sensing elements carried on the distal portion and coupled to respective wires of the plurality of wires. 
     
     
         31 . The tubular device of  claim 28 , wherein the plurality of wires are braided around the central lumen in the same direction immediately adjacent one another along the first portion. 
     
     
         32 . The tubular device of  claim 28 , further comprising a steering element extending between the proximal and distal ends, the steering element extending along the distal portion within an auxiliary lumen, the auxiliary lumen extending substantially parallel to the longitudinal axis along the distal portion offset about ninety degrees around a circumference of the distal portion relative to the conductor. 
     
     
         33 . The tubular device of  claim 27 , wherein the conductor exits through the outer jacket at a location adjacent the second portion. 
     
     
         34 . The tubular device of  claim 33 , wherein the second portion comprises a proximal portion adjacent the proximal end, the tubular device further comprising a handle on the proximal end including a connector, wherein the conductor is coupled to the connector. 
     
     
         35 . The tubular device of  claim 27 , wherein the tubular device further comprises a third portion adjacent the second portion in which the conductor extends helically around the central lumen. 
     
     
         36 . The tubular device of  claim 27 , wherein the tubular device further comprises a third portion adjacent the first portion opposite the second portion in which the conductor extends substantially parallel to the longitudinal axis and either a) all of the windings surround the central lumen and the conductor remains outside the windings, b) at least some of the windings pass between the central lumen and the conductor and at least some of the windings surround both the central lumen and the conductor, and c) all of the windings surround both the central lumen and the conductor. 
     
     
         37 . The tubular device of  claim 27 , wherein the conductor comprises a plurality of wires that are braided around the central lumen in the same direction immediately adjacent one another along the first portion. 
     
     
         38 . The tubular device of  claim 27 , wherein the wires exit through the outer jacket adjacent the second portion. 
     
     
         39 - 46 . (canceled) 
     
     
         47 . A tubular device for a catheter or sheath comprising a proximal end and a distal end sized for introduction into a patient's body, the tubular device comprising:
 a central lumen extending between the proximal and distal ends, thereby defining a longitudinal axis;   one or more reinforcement members comprising windings extending helically around the central lumen between the proximal and distal ends;   an outer jacket surrounding the one or more reinforcement members; and   a plurality of conductors extending at least partially between the proximal and distal ends adjacent the central lumen;   wherein the tubular device comprises a distal portion adjacent the distal end comprising a plurality of sensing elements spaced apart from one another along the distal portion, each sensing element coupled to at least one of the conductors, and   wherein the tubular device comprises an intermediate portion proximal to the distal portion in which the conductors extend helically around the central lumen and are braided with the reinforcement members.   
     
     
         48 . The tubular device of  claim 47 , wherein the conductors exit through the outer jacket at a location adjacent the proximal end. 
     
     
         49 . The tubular device of  claim 48 , further comprising a handle on the proximal end including one or more connectors, wherein the conductors are coupled to the one or more connectors. 
     
     
         50 . The tubular device of  claim 48 , wherein the conductors exit through the outer jacket at the same axial location within the handle. 
     
     
         51 . The tubular device of  claim 47 , wherein the conductors exit through the outer jacket at different axial locations adjacent the proximal end.