[0001] This application claims priority to U.S. Provisional Application Serial No. 61/121 ,525 filed December 10, 2008 entitled Microcatheter, the contents of which are incorporated in their entirety herein.

FIELD OF THE INVENTION

[0002] The present invention relates generally to medical devices and methods of manufacturing the same. More particularly, this invention relates to microcatheters and methods for making microcatheters used in performing endovascular medical procedures.

BACKGROUND OF THE INVENTION

[0003] Microcatheters are used in a variety of medical procedures for the diagnosis and treatment of conditions and diseases occurring in remote, highly tortuous vascular sites. Typically, a microcatheter is introduced to the vascular system of a patient at a first location and then is advanced through the patient's vessels until the distal end of the microcatheter reaches a desired target location.

[0004] The process of advancing the microcatheter often involves applying force proximal of its distal end. Hence, as some prior art microcatheters advance deeper into the vascular system, it can become difficult to properly push and maneuver the distal end of the microcatheter. In this respect, it is desirable that a microcatheter exhibit superior pushability and trackability. Pushability is often understood as the ability to transmit force from the proximal end of the microcatheter to the distal end of the microcatheter while minimizing or eliminating kinking. Trackability is often understood as the ability to navigate the microcatheter through tortuous vasculature.

[0005] While prior art microcatheters are typically capable of performing their intended task within a patient, it is always desirable to have improved catheter performance, such as improved trackability and pushability. SUMMARY OF THE INVENTION

[0006] In one preferred embodiment according to the present invention, a microcatheter comprises a coil formed over an inner liner. The coil is covered with a series of outer jacket segments or transition segments that decrease in durometer relative to proximally adjacent segments. Preferably, these segments have angled ends that allow each segment to be inserted and bonded into the segment prior to it. The outer jacket ultimately terminates at a distal of the microcatheter with the segment having the lowest durometer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which

[0008] Figure 1 A illustrates a side cross sectional view of a microcatheter according to a preferred embodiment of the present invention;

[0009] Figure 1 B illustrates a magnified view of a distal region of the microcatheter of Figure 1 A taken from area 1 B;

[0010] Figure 1 C illustrates a cross sectional view of the microcatheter of Figure 1 A taken along lines 1 C;

[0011] Figure 2A illustrates the microcatheter of Figure 1 A having a curved distal region;

[0012] Figure 2B illustrates a distal region of the microcatheter from area 2B with the outer jacket partially removed;

[0013] Figure 3 illustrates different example segments forming the outer jacket of the microcatheter according to a preferred embodiment of the present invention; [0014] Figure 4 illustrates different example segments forming the outer jacket of the microcatheter according to a preferred embodiment of the present invention;

[0015] Figure 5A illustrates a side view of two outer jacket segments with opposing or oppositely oriented diagonal angled ends;

[0016] Figure 5B illustrates a side view of two outer jacket segments with similarly oriented diagonal angled ends; and,

[0017] Figure 5C illustrates a side perspective view of a jacket segment with a diagonal angled end region.

DESCRIPTION OF EMBODIMENTS

[0018] Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.

[0019] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0020] Figure 1 A illustrates a preferred embodiment of a microcatheter 100 comprising an elongated tubular member 101 connected to a hub member 102. The proximal end 108 of the tubular member 101 is coupled to a distal end of the hub 102 and is further covered by a strain relief member 106. At least one center lumen in the tubular member 101 is in communication with a passage within the hub 102, thereby forming catheter passage 104. In the present example embodiment, a guide wire 1 12 is positioned through passage 104, exiting at a distal end 110 of the tubular member.

[0021] The hub 102 is preferably bonded to the proximal portion 108 with DYMAX medical adhesion or a similar adhesive. The strain relief portion 106 may be installed onto the hub 102 by friction, adhesive or similar connection techniques.

[0022] As best seen in Figures 1 B and 1 C, the passage 104 is formed by an inner liner 1 14 about which is wound a coil 124. The coil 124 is covered by an outer jacket 1 16 that is formed from a plurality different section. Each section of the outer jacket 1 16 preferably has a durometer that is less that the section proximal to it. In this respect, the outer jacket 1 16 generally increases in flexibility towards the distal end 1 10 relative to the proximal end 108.

[0023] As seen in Figure 2A, the outer jacket preferably includes a hydrophilic coating along a portion of its length. Preferably, this coating is about 100-120 cm from the distal tip of the microcatheter 100.

[0024] As seen in the cross sectional view of Figure 1 B and the view of Figure 2B, the distal end 1 10 includes two radiopaque markers 1 18 and 120 that are bonded between the coil layer 124 and the outer jacket 1 16. In one example arrangement, the marker 120 is located at or near the distal tip of the catheter 100, while the marker 1 18 is located about 3 cm proximal of marker band 120. As best seen in Figure 1 B, these markers 1 18 and 120 can provide raised or elevated areas that can be used to secure an implant device such as a stent.

[0025] In one example, the microcatheter 100 is approximately 150 cm, as measured from the distal tip of the strain relief portion 106 to the distal end of the distal portion 1 10. The central lumen 104 has an inner diameter of approximately 0.0165 to 0.017 inches. The distal portion 110 preferably includes a region approximately 40 cm long that is approximately 1.9 French. The proximal portion 108 preferably includes a region of approximately 2.4 French. The outer jacket 1 16 is about .025 inches. [0026] The inner liner 1 14 is preferably composed of polytetrafluroethelyene, PTFE, or other similar material and has a wall thickness in the range of about 0.0005 and 0.007 inches. Preferably, the inner liner 1 14 is "necked" or stretched to reduce wall thickness. This stretching can also selectively orient the molecular structure of the material and thereby impart additional performance characteristics. For example, such stretching can increase burst strength and/or increase compliance or suppleness as compared with similar, non-stretched material of the same thickness.

[0027] In this respect, a smaller portion of the microcatheter 100 is used for the inner liner 1 14 while the thickness of other portions can be increased without increasing the outer diameter or reducing the inner diameter of the microcatheter 100. In other words, stretching the inner liner 1 14 allows a different thickness ratio between the inner liner 1 14 and other portions of the microcatheter, such as the outer jacket 1 16.

[0028] For example, in a 10 system microcatheter having an inner lumen diameter in the range of about 0.0165 to 0.017 inches and an outer diameter of about 0.025 inches, there is a ratio of outer jacket 1 16 thickness to inner liner 1 14 thickness greater than about 70% and more preferably about 78% while achieving desirable performance results.

[0029] Preferably, the inner liner 1 14 is stretched prior to assembly by applying heat and tension to the liner 1 14. For example, a temperature between about 250 °F and 600 °F can be applied to the liner 1 14 while a tension between about 5Og to 75Og at a speed between .5 and 12 inches per minute. In another example, the inner liner 1 14 can be stretched at room temperature with similar or stronger forces and similar or quicker speeds.

[0030] In one preferred embodiment, the inner liner 1 14 can have a uniform thickness along its length. In another preferred embodiment, the inner liner 1 14 can increase in thickness towards its proximal end, thereby imparting additional burst strength.

[0031] The coil layer 124 is preferably formed of a round wire with an outer diameter of approximately 0.001 inch filar. The pitch of coil 124 is preferably in the range of about 0.002 to 0.004 inches. In certain embodiments of the microcatheter 100, coil 124 may also be formed with a tighter pitch.

[0032] In one example, the outer jacket 116 is formed of a plurality of segments of polyether block amide, Pebax, of varying durometer bonded to one another (e.g., heat bonded or adhesive bonding). As illustrated in Figure 5C, a first jacket segment 1 16A includes a biased or angled end 116D. In other words, the segment end 1 16D is nonperpendicular to an axis 1 16E along the length of the segment 1 16A. Preferably, this angle can be within a range of about 5-75 degrees relative to the axis 1 16E.

[0033] As seen in Figure 5A, segment 116A is angle-bonded within jacket segment 1 16B. The angled cut end 1 16D is oriented such that it is in an opposite rotational position relative to the angled cut end 1 16C. In other words, the angles of ends 1 16D and 1 16C are positioned so as to form a triangular or trapezoid shape.

[0034] Preferably, segments 1 16A and 116B are bonded by first placing the angled cut end 1 16D against angled cut end 1 16C. Next, a heat shrink tube is positioned over the two segments 1 16A and 1 16B. Finally, heat is applied, causing the heat shrink tube to shrink in diameter, pushing segment 1 16A within segment 1 16B. Both the heat and the force of the heat shrink tube cause the segments 1 16A and 1 16B to bond together. Finally, the heat shrink tube can be removed from the jacket segments.

[0035] As illustrated in Figure 5B, segment 116A may also be oriented such that the angled cut end 1 16D is positioned in the same direction and orientation as angled end 1 16C. While both segments are shown having angled ends, it is also contemplated that only a single segment may include an angled or biased end. The angled bonding as described in the examples of Figures 5A and 5B can reduce kinking that may otherwise occur by providing additional axial strength while maintaining flexibility.

[0036] Preferably, the outer jacket 1 16 has seven segments, each of which having a lower durometer than the segment proximally adjacent to it. In this respect, the outer jacket 116 becomes more flexible towards the distal end 1 10.

[0037] Turning to Figure 3, an example outer jacket 116 is shown having various segments. Segment 150 represents a segment on the proximal end 108 while segment 162 represents a segment on the distal end 1 10. In one example, the segments are composed as follows:

[0038] Turning to Figure 4, an example outer jacket 116 is shown having various segments. Segment 164 represents a segment on the proximal end 108 while segment 176 represents a segment on the distal end 1 10. In one example, the segments are composed as follows:

[0039] It will be recognized that suitable alternatives to Pebax and Grilamid are known in the field and may be employed accordingly. It will further be recognized that the wall thickness of the inner liner 1 14 and the outer jacket 1 16 may be altered so as to emphasize or enhance certain characteristics, such as the trackability, pushability, internal diameter, and/or outer diameter, of the microcatheter 100 as desired in order to perform the intended procedure. [0040] Certain embodiments of the present invention provide for superior tip- shapability and enhanced tip-shape retention in the microcatheter 100. With respect to tip-shapeability, the microcatheter 100 is formed in a straight, i.e. not pre-shaped, configuration that can be steam-shaped as desired by a physician prior to use. The catheter 100 can be steam-shaped in a manner well known in the field. The tip-shape retention of the microcatheter 100 is greater that 55 percent. In a preferred embodiment the tip-shape retention is 58 percent and in another preferred embodiment the tip-shape retention is 67 percent.

[0041] Tip-shape retention is enhanced by employing a thinner inner liner 1 14 which, in turn, allows for incorporation of a thicker walled, shapeable, outer jacket 1 16. Tip- shape retention is further enhanced by incorporating the coil 124 having a tight pitch between the inner liner 1 14 and the shapeable outer jacket 1 16. The tight pitch coil 124 is disposed concentrically about the inner liner 1 14 such that the shapeable section of the microcatheter 100, i.e. the distal portion 1 10, is not significantly subjected to a straightening force by the coil 124. This is in contrast to prior art microcatheters that employ a braided or a longer pitch coil configuration that disposes wire or other filaments in the shapeable section of the microcatheter in a manner that exert a straightening force to the microcatheter tip.

[0042] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.