Methods for manufacturing composite wires for use in medical procedures

Abstract

A composite wire, such as a guide wire, may include a principal section with a relatively large outer diameter, as well as one or more reduced sections with smaller outer diameters. The relatively small outer diameter of each reduced section may be defined by an inner element of the composite wire, while the relatively large outer diameter of the principal section may be defined by one or more outer elements that reside on, and may surround, the inner element. The inner and outer elements may be formed from materials that impart the composite wire with one or more desired characteristics, such as a stiffness, hardness and flexibility. In specific embodiments, the inner element may comprise a standard, small diameter guide wire, while the outer element comprises a polymer.

What is claimed: 
     
         1 . A method for manufacturing a composite wire for use in a medical procedure, consisting of:
 providing an inner element comprising an elongated medical device with a finish suitable for use in the medical procedure, the inner element having a first outer diameter and a first length, the first outer diameter of the inner element being uniform along an entirety of the first length of the inner element;   applying an outer element to the inner element, the outer element having an elongated structure formed from a polymer and having a second outer diameter and a second length, and including a lumen extending through an entirety of the second length, the lumen having an inner diameter receiving the first outer diameter of the inner element, the inner diameter of the lumen being about equal to the first outer diameter of the inner element, the second length being shorter than the first length, at least a portion of the inner element being exposed laterally beyond an end of the outer element to form at least one reduced section of a composite wire; and   securing the outer element to the inner element to prevent movement of the outer element along the first length of the inner element, the outer element forming at least one principal section of the composite wire.   
     
     
         2 . The method of  claim 1 , wherein the inner element is a guide wire. 
     
     
         3 . The method of  claim 2 , wherein the first outer diameter is 0.010 inch to 0.018 inch. 
     
     
         4 . The method  claim 2 , wherein the guide wire comprises a standard guide wire formed from a metal, a metal alloy or a polymer. 
     
     
         5 . The method of  claim 1 , wherein the second outer diameter of the inner element defines an outer diameter of the reduced section of the composite wire. 
     
     
         6 . The method of  claim 1 , wherein the polymer of the outer element is polyether ether ketone (PEEK). 
     
     
         7 . The method of  claim 1 , wherein the second outer diameter is 0.025 inch to 0.040 inch. 
     
     
         8 . The method of  claim 1 , wherein the second outer diameter defines a principal outer diameter of the composite wire. 
     
     
         9 . The method of  claim 1 , including a tapered region at an end of the outer element. 
     
     
         10 . A method for tailoring an outer diameter of an existing elongated medical device, comprising:
 providing an inner element comprising a finished elongated medical instrument having a first outer diameter and a first length; and   providing an outer element having an elongated structure formed from a polymer and having a second outer diameter and a second length, with a lumen extending through an entirety of the second length, the lumen having an inner diameter receiving the first outer diameter of the inner element, the inner diameter of the outer element being about the same as the first outer diameter of the inner element, the second length being shorter than the first length;   assembling the inner element and the outer element with the outer element at least a portion of the inner element exposed laterally beyond an end of the outer element to form at least one reduced section of a composite elongated medical instrument, the second outer diameter of the inner element defining an outer diameter of the at least one reduced section of the composite elongated medical instrument, the outer element forming at least one principal section of the composite elongated medical instrument; and   securing the outer element to the inner element to prevent movement of the outer element along the first length of the inner element.   
     
     
         11 . The method of  claim 10 , wherein the inner element has a non-uniform outer diameter. 
     
     
         12 . The method of  claim 10 , wherein at least one recess is formed in an outer surface of the inner element. 
     
     
         13 . The method of  claim 10 , wherein the inner element comprises a guide wire. 
     
     
         14 . The method of  claim 10 , wherein the second outer diameter is a principal outer diameter of the composite elongated medical instrument. 
     
     
         15 . The method of  claim 10 , wherein the outer element includes a tapered end. 
     
     
         16 . A method for increasing an outer diameter of a finished guide wire for use in a medical procedure, comprising:
 providing the finished guide wire having a first outer diameter and a first length;   providing an outer element comprising an elongated structure comprising a polymer and having a second outer diameter and a second length, and including a lumen extending through an entirety of the second length, the lumen having an inner diameter receiving the first outer diameter of the inner element, the inner diameter of the lumen being about equal to the first outer diameter of the inner element, the second length being shorter than the first length, the outer element having a tapered end;   assembling the inner element and the outer element with at least a portion of the inner element exposed laterally beyond an end of the outer element to form at least one reduced section of a composite wire and the outer element forming at least one principal section of the composite wire; and   securing the outer element to the inner element to prevent movement of the outer element along the first length of the inner element.   
     
     
         17 . The method of  claim 16 , wherein the inner element has a non-uniform outer diameter. 
     
     
         18 . The method of  claim 16 , wherein at least one recess is formed in an outer surface of the inner element. 
     
     
         19 . The method of  claim 16 , wherein the inner element comprises a guide wire. 
     
     
         20 . The method of  claim 16 , wherein the second outer diameter defines a principal outer diameter of the composite wire.