Cutting balloon catheter and method for blade mounting

Abstract

A cutting balloon catheter and methods for making and using the same. The cutting balloon catheter may include a catheter shaft having a balloon coupled thereto. One or more cutting members or blades may be coupled to the balloon. Manufacturing the cutting balloon catheter may include partially submerging or embedding a cutting member within a joining member and attaching the joining member to a balloon. The cutting member may include one or more slots along its base that can interlock with the joining member.

1 . A cutting balloon catheter, comprising:
 an elongate catheter shaft;   an inflatable balloon coupled to a distal portion of the catheter shaft;   a polymeric joining member attached to the balloon; and   a cutting member having a longitudinal axis, the cutting member including a cutting surface and a base having a lower surface, the base including an interlocking structure defined by a plurality of openings formed in the cutting member along the base such that the openings extend through the lower surface and also an imaginary plane perpendicular to the longitudinal axis which passes through one of the plurality of openings also passes through material of the base located between the opening and the lower surface of the base;   wherein the base is embedded in the polymeric joining member such that polymeric material of the joining member is disposed in the openings in the base of the cutting member.   
     
     
         2 . The cutting balloon catheter of  claim 1 , wherein the polymeric joining member includes a lower surface bonded to the balloon, wherein the lower surface of the base of the cutting member is spaced from the lower surface of the polymeric joining member. 
     
     
         3 . The cutting balloon catheter of  claim 1 , wherein the polymeric joining member is adhesively bonded to the balloon. 
     
     
         4 . The cutting balloon catheter of  claim 1 , wherein the polymeric joining member is thermally bonded to the balloon. 
     
     
         5 . The cutting balloon catheter of  claim 1 , wherein the catheter shaft includes an inner tubular member having a distal end secured to a distal end of the balloon and an outer tubular member having a distal end secured to a proximal end of the balloon. 
     
     
         6 . The cutting balloon catheter of  claim 1 , wherein the polymeric joining member secures the cutting member to the balloon while allowing the cutting member to bend or flex away from the longitudinal axis. 
     
     
         7 . The cutting balloon catheter of  claim 1 , wherein the openings define slots in the lower surface of the base, the slots having a width measured along the longitudinal axis of the cutting member which is less than a width of the openings measured along the longitudinal axis of the cutting member at a position closer to the cutting surface. 
     
     
         8 . A cutting balloon catheter, comprising:
 an elongate catheter shaft;   an inflatable balloon coupled to a distal portion of the catheter shaft such that an inflation lumen of the catheter shaft is in fluid communication with the balloon;   a polymeric joining member extending longitudinally along the balloon and attached to the balloon; and   a cutting member extending along a longitudinal axis, the cutting member having a cutting surface and a base portion embedded in the polymeric joining member, the base portion including an interlocking structure defined by a series of alternating tabs and openings disposed along the base portion, the openings opening out to a lower surface of the base portion;   wherein the openings include a wide portion and a narrow portion narrower than the wide portion wherein the narrow portion of the openings is located closer to the lower surface of the base portion than the wide portion of the openings.   
     
     
         9 . The cutting balloon catheter of  claim 8 , wherein an imaginary plane perpendicular to the longitudinal axis which passes through one of the openings also passes through material of the base portion of the cutting member located between the opening and the lower surface of the base portion. 
     
     
         10 . The cutting balloon catheter of  claim 8 , wherein the narrow portions of the openings define slots in the lower surface of the base portion, the slots having a width measured along the longitudinal axis of the cutting member which is less than a width of the openings measured along the longitudinal axis of the cutting member at a position closer to the cutting surface. 
     
     
         11 . The cutting balloon catheter of  claim 8 , wherein polymeric material of the joining member is disposed in the openings in the base portion of the cutting member. 
     
     
         12 . The cutting balloon catheter of  claim 8 , wherein the polymeric joining member includes a lower surface bonded to the balloon, wherein the lower surface of the base portion of the cutting member is spaced from the lower surface of the polymeric joining member. 
     
     
         13 . The cutting balloon catheter of  claim 8 , wherein the polymeric joining member is adhesively bonded to the balloon. 
     
     
         14 . The cutting balloon catheter of  claim 8 , wherein the polymeric joining member is thermally bonded to the balloon. 
     
     
         15 . A cutting balloon catheter, comprising:
 an elongate catheter shaft;   an inflatable balloon coupled to a distal portion of the catheter shaft;   a polymeric joining member extending longitudinally along the balloon and attached to the balloon; and   a cutting member extending along a longitudinal axis, the cutting member having a cutting surface and a base portion embedded in the polymeric joining member, the base portion including an interlocking structure defined by a series of alternating tabs and openings disposed along the base portion;   wherein the openings define slots in a lower surface of the base portion, the slots having a width measured along the longitudinal axis of the cutting member which is less than a width of the openings measured along the longitudinal axis of the cutting member at a position closer to the cutting surface.   
     
     
         16 . The cutting balloon catheter of  claim 15 , wherein the base portion is embedded in the polymeric joining member such that polymeric material of the joining member is disposed in the openings in the base portion of the cutting member.