Vapor deposition coated intracorporeal device

Abstract

A method of joining two members of a medical device wherein at least one of the members has a thin layer of joinable material deposited on the surface thereof by vapor deposition, preferably, physical vapor deposition. A guidewire for advancement of intraluminal medical devices may be manufactured by depositing a thin layer of joinable material on the surface of a component which is made from a reactive alloy with a tenacious oxide layer. The thin layer of joinable material facilitates joining difficult to bond materials with other components of the guidewire. Physical vapor deposition may also be used to treat components of medical devices, such as distal guidewire segments, in order to alter their mechanical properties. Specifically, a pseudoelastic alloy segment may be made shapeable by vapor deposition of a non-pseudoelastic metal thereon.

What is claimed is:  
     
         1 . A method for joining a first member of a medical device to a second member of the medical device comprising: 
 a) depositing a thin layer of joinable material on at least a portion of the first member by vapor deposition;    b) positioning the thin layer of joinable material on the first member in proximity to a joinable portion of the second member;    c) applying a joining agent to the thin layer of joinable material on the first member and the joinable portion of the second member.    
     
     
         2 . The method of    claim 1    wherein the first member is comprised of a reactive metal having a tenacious oxide.  
     
     
         3 . The method of    claim 2    wherein the reactive metal is comprised of a titanium containing alloy.  
     
     
         4 . The method of    claim 3    wherein the titanium containing alloy is comprised of NiTi.  
     
     
         5 . The method of    claim 2    further comprising substantially removing the tenacious oxide prior to depositing the thin layer of joinable material.  
     
     
         6 . The method of    claim 5    wherein the metal substance is solder.  
     
     
         7 . The method of    claim 1    wherein the joining agent is comprised of a polymer material.  
     
     
         8 . The method of    claim 7    wherein the polymer material is comprised of a thermosetting epoxy.  
     
     
         9 . The method of    claim 7    wherein the polymer is a cyanoacrylate adhesive.  
     
     
         10 . The method of    claim 1    wherein the thin layer of joinable material is a metal.  
     
     
         11 . The method of    claim 1    wherein the thin layer of joinable material is stainless steel.  
     
     
         12 . The method of    claim 11    wherein the second member is comprised of stainless steel.  
     
     
         13 . A medical device comprising: 
 a) a first member;    b) a second member;    c) a thin layer of joinable material on at least one of the members; and    c) a joining material disposed upon the thin layer of joinable material joining the first member and the second member.    
     
     
         14 . The medical device of    claim 13    wherein the first member is made of the same metal as the second member.  
     
     
         15 . The medical device of    claim 13   , wherein the first member is a different metal than the second member.  
     
     
         16 . The medical device of    claim 13   , wherein the first member is a different metal from the second member that will not facilitate a strong solder joint together to the metal forming the second member.  
     
     
         17 . The medical device of    claim 13   , wherein the thin layer of joinable material is a metal.  
     
     
         18 . The medical device of    claim 13   , wherein the thin layer of joinable material is a non-metal.  
     
     
         19 . The medical device of    claim 13   , wherein the thin layer of joinable material is up to about  2  microns in thickness.  
     
     
         20 . The medical device of    claim 13   , wherein the thin layer of joinable material is between about  1  and  2  microns thick.  
     
     
         21 . A method of making a guidewire for intraluminal advancement of a medical device comprising: 
 a) vapor depositing a thin layer of joinable material on at least a proximal end of a distal section of an elongate core;    b) securing a distal end of a proximal section of an elongate core to the proximal end of the distal section of the elongate core; and    c) securing a flexible body member about at least a portion of the distal section of the elongate core.    
     
     
         22 . The method of    claim 21    wherein the distal section of the elongate core comprises a titanium containing alloy.  
     
     
         23 . The method of    claim 22    wherein a) includes depositing a thin layer of joinable material on at least a distal end and proximal end of the distal section of the elongate core.  
     
     
         24 . The method of    claim 23    wherein the distal end of the proximal section of the elongate core is secured to the proximal end of the distal section of the elongate core by soldering and the flexible body member is secured to the distal end of the distal section of the elongate core by soldering.  
     
     
         25 . The method of    claim 24    further comprising providing a sleeve that is positioned over at least a portion of the distal end of the proximal section of the elongate core and the proximal end of the distal section of the elongate core and soldered thereto.  
     
     
         26 . The method of    claim 22    wherein the distal section further comprises a small diameter distal segment formed into a shapeable member by vapor deposition of a sufficient layer of a non-pseudoelastic metal thereon.  
     
     
         27 . A guidewire for intraluminal advancement of a medical device within a patient, comprising: 
 a) a proximal section of an elongate core with a proximal end and a distal end;    b) a distal section of the elongate core with a proximal end and a distal end and a thin layer of joinable material on at least a portion of the distal section with the distal end of the proximal section secured to the proximal end of the distal section by a joining agent; and    c) a flexible body having a proximal end and a distal end disposed about and secured to at least a portion of the distal section with a joining agent.    
     
     
         28 . The guidewire of    claim 27   , further comprising a distal segment at the distal end of the distal section of the elongate core.  
     
     
         29 . The guidewire of    claim 28    wherein the distal section is comprised of a pseudoelastic alloy and the distal segment of the distal section has a sufficient layer of non-pseudoelastic metal on it to make it shapeable.  
     
     
         30 . The guidewire of    claim 27   , wherein the distal section has at least one tapered section.  
     
     
         31 . The guidewire of    claim 27   , wherein a distal segment of the distal section is flattened.  
     
     
         32 . The guidewire of    claim 27   , wherein the joinable material deposited is gold.  
     
     
         33 . The guidewire of    claim 27   , wherein the joinable material deposited is an alloy.  
     
     
         34 . The guidewire of    claim 33   , wherein the alloy is stainless steel.  
     
     
         35 . The guidewire of    claim 27   , wherein the joinable material deposited is a polymer.  
     
     
         36 . The guidewire of    claim 27   , wherein the distal section is completely covered with the deposited joinable material.  
     
     
         37 . The guidewire of    claim 27   , wherein the joinable material is only deposited on the distal section in areas to which other members are joined.  
     
     
         38 . The guidewire of    claim 27   , wherein the thickness of the thin layer is up to 2 microns.  
     
     
         39 . The guidewire of    claim 27   , wherein the thickness of the thin layer is between 1 and 2 microns.  
     
     
         40 . The guidewire of    claim 27   , wherein the thin coating of joinable material is sufficient to create a shapeable distal segment of the distal section.