BRAIDED STRUCTURE

BACKGROUND OF THE DISCLOSURE a. Field of the Disclosure

[0001] The present disclosure generally relates to apparatuses and methods for braiding ends into a desired braided structure. In particular, the present disclosure relates to methods of making braided structures having a highly consistent braided pattern. The disclosed methods utilize a novel braiding eyelet. b . B ackground Art

[0002] Many medical devices, such as occluders and stents for example, may be primarily constructed of a woven or braided body. At least some of these braided bodies are generally formed using multi-end materials, in which at least three groups of multi-end materials are utilized to form the desired structure.

SUMMARY OF THE DISCLOSURE

[0003] The present disclosure is directed to an eyelet for use in a braiding apparatus. The eyelet comprises a first side, a second side, and a flared opening extending from the first side to the second side. The flared opening has a first diameter at the first side and has a second diameter at the second side, wherein the second diameter is smaller than the first diameter. The eyelet further comprises at least a first slot and a second slot positioned at the second side of the eyelet and within the flared opening, the first slot and the second slot configured to allow passage of a first end and a second end, respectively.

[0004] The present disclosure is further directed to an apparatus for braiding multiple ends to form a braided structure. The apparatus comprises at least one carrier and a braiding eyelet positioned within the at least one carrier. The braiding eyelet comprises at least two slots, each slot configured for insertion of a single end. [0005] The present disclosure is further directed to a method of braiding multiple ends to form a braided structure. The method comprises advancing a first group of ends comprising at least a first end and a second end through a first slot and a second slot of an eyelet, respectively, and braiding the first group of ends with at least a second and a third group of ends to form the braided structure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 shows a perspective view of one embodiment of a braiding eyelet of the present disclosure.

[0007] Figure 2 shows a cross-section of the braiding eyelet of Figure 1 taken along line A-A.

[0008] Figure 3 shows a cross-section of the braiding eyelet of Figure 1 taken along line A-A and showing additional detail.

[0009] Figure 4 shows a side view of the braiding eyelet of Figure 3 to illustrate additional detail.

[0010] Figure 5 shows a side view of a braiding eyelet of another embodiment.

[0011] Figure 6 is a flow chart of one embodiment of a method of braiding multiple ends to form a braided structure.

[0012] Figure 7 shows a braiding eyelet of the present disclosure positioned within a carrier.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0013] In some cases when braided bodies are constructed, one or more of the individual wire ends within a group may "jump" and "cross" over one another, which may create undesirable inconsistencies in the resulting braided body. In some cases, these inconsistencies can add to an overall outer diameter of the resulting structure, which can be disadvantageous in some cases for medical and related devices that must have particular dimensions to function properly. Moreover, at least some of these inconsistencies may remain exposed when the body of the structure is coated (e.g., with a biocompatible polymer or the like) to prepare the final product. It is desirable to provide methods of braiding multi-end materials for use in braided structures and products, where the braids are highly uniform and consistent such that any "cross-braiding" or end "jumping" resulting from the braiding of sets of multiple ends is minimized or completely eliminated.

[0014] The present disclosure is directed to methods of braiding groups of multi-end materials including at least three groups of multi-end materials that provide a resulting braided structure where any "cross-over" or "jumping" within a group is substantially or completely eliminated. The present disclosure is further directed to braided structures and medical devices that are fabricated using groups of two or more multi-end materials and are substantially or completely free of crossed ends.

[0015] The braiding methods described herein utilize a novel braiding eyelet that may be housed in a carrier on a braiding machine. The braiding machine may include multiple braiding eyelets housed in individual carriers. The eyelet generally includes a first side, a second side, and a flared opening extending between the two sides that houses at least a first hole or slot and a second hole or slot. Both holes or slots are sized and configured to allow a single end (sometimes referred to in the art as a wire or strand) to pass there-through such that when a group of ends is used for the braiding, each individual end can pass through its own hole or slot to ensure that the individual end is locked in place and there is no space or clearance allowing them to cross over one another. In many embodiments of the present disclosure the braiding eyelet will include two or three or more holes or slots to accommodate a group of ends that includes two or three or more ends per group. Many embodiments of the present disclosure are suitable for constructing a medical device. Other embodiments are also provided herein.

[0016] Referring now to Figure 1, there is shown a perspective view of an eyelet 2 in accordance with one embodiment of the present disclosure. Eyelet 2 is suitable for use in a multi-end braiding machine or apparatus that creates a braided substrate or fabric by running three or more groups of ends through eyelet 2. The ends may be constructed of any materials suitable for use in a braiding process including, for example, metallic materials, thermoplastic materials, and the like.

Eyelet 2 may be sized and configured for use in any suitable braiding machine and may be constructed of any suitable material, and is desirably constructed of a material having a hardness value that is greater than the hardness value of any end run therethrough as further described herein. Eyelet 2 is desirably constructed to have a smooth surface that is substantially free of sharp or protruding edges. Eyelet 2 includes a first side 4 and a second side 6 with a flared opening 8 extending therebetween. In some embodiments, eyelet 2 includes a notch 10 on an outer surface thereof (see Figure 3) that may be used to position eyelet 2 in a carrier (see Figure 7) located on a multi-end braiding machine (not shown in the Figures). For example, Figure 7 shows eyelet 2 positioned in a carrier 3 such that carrier arms 5 are configured to couple notch 10 of eyelet 2 to carrier 3.

[0017] Referring now to Figure 2, there is shown a cross-section of eyelet 2 taken along line A-A in Figure 1. Figure 2 shows first side 4, second side 6 and flared opening 8 extending from first side 4 to second side 6. As shown flared opening 8 has a first diameter Dl at first side 4 and a second diameter D2 at second side 6. Second diameter D2 is smaller than first diameter Dl . Flared opening 8 additionally includes a first radius of curvature 9 at first side 4 and a second radius of curvature 11 at second side 6. First radius of curvature 9 is larger than second radius of curvature 11. In some embodiments, first radius of curvature 9 is about 0.15 inches and second radius of curvature 11 is about 0.005 inches. Other suitable radii or curvature for the first and second radius of curvature are also within the scope of the present disclosure. The flared configuration of opening 8 provides a smooth transition for ends advancing through eyelet 2 (not shown in Figure 2) during a braiding process so as to reduce the potential of the ends breaking or fraying.

[0018] Referring now to Figure 3, there is shown a cross-section of an eyelet 2 in accordance with one embodiment of the present disclosure. Eyelet 2 includes first side 4, second side 6, flared opening 8 extending from first side 4 to second side 6 and notch 10. Figure 3 additionally shows slot holder 12 (shown in more detail in Figure 4) positioned near second end 6 in flared opening 8. Slot holder 12 includes first slot 14 and second slot 16 through which first end 18 and second end 20 pass through, respectively.

[0019] Referring now to Figure 4, there is shown a side view of eyelet 2 of Figure 3 from second side 6 in order to illustrate additional detail. Second side 6 includes slot holder 12 including first slot 14 and second slot 16 through which first end 18 and second end 20 pass through, respectively. First slot 14 and second slot 16 may be suitably sized and configured (i.e., oval, circular and the like) to allow passage of a wide variety of end sizes or shapes/geometries as would be understood by one skilled in the art based on the disclosure herein. First slot 14 and second slot 16 are positioned side by side to one another or linearly with respect to one another as further discussed hereinbelow.

[0020] Further, one skilled in the art will appreciate that eyelet 2 disclosed herein may include any number of slots depending on the number of ends desired in each group of ends used in a particular braiding process so long as the slots are positioned linearly with respect to one another so as to guide the ends during the braiding process to minimize changes in the position of the ends relative to one another. In other words, the slots positioned within slot holder 12 are arranged linearly with respect to one another so as to reduce, minimize, or eliminate any "cross-over" or "jumping" of the ends in a group of ends during a braiding process. Figure 5, for example, illustrates a side view of an eyelet 102 comprising a slot holder 112 with a first slot 114, a second slot 116, and a third slot 118 arranged linearly with respect to one another. Each of first slot 114, second slot 116, and third slot 118 are sized and configured for advancement of first end 124, second end 126, and third end 128, respectively, therethrough.

[0021] The eyelets for braiding as described herein may be used in a number of braiding methods to produce braided structures or substrates useful in the manufacturing of a number of medical devices or other devices. In one specific embodiment, a method of braiding multiple ends to form a braided structure is disclosed. This method includes advancing a first group of ends that includes at least a first end and a second end (in other embodiments the group of ends may include three, four, five, six, seven, eight, nine, ten, eleven or more ends each having their own slot as described herein) through a first slot and a second slot of an eyelet, respectively. After advancing the ends through the eyelet, the ends are braided with at least two additional groups of ends to form the braided structure. The eyelet utilized in this braiding process substantially reduces or eliminates any end "cross-over" or "jumping" within the end groups such that an improved braided structure is provided. That is, the first slot and the second slot are configured to guide the first end and the second end, respectively, during the braiding process so as to minimize changes in the position of the first end relative to the second end. Figure 6 is a flow chart that further illustrates this exemplary method. Method 200 includes advancing 202 a first group of ends comprising at least a first end and a second end through a first slot and a second slot of an eyelet; and braiding 204 the first group of ends with at least a second and a third group of ends to form the braided structure. Any number of medical devices or other devices may be constructed using the braided structures of the present disclosure. Some non-limiting examples of medical devices that may be constructed using the braided structures as described herein include occluders, stents, grafts, catheters, introducers, valves, and the like.

[0022] Although a number embodiments of this disclosure have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the disclosure as defined in the claims.