Guiding Medical Devices and Associated Methods of Manufacturing

Abstract

A catheter assembly includes an inner liner made of flexible material and an outer layer having a steering mechanism. A catheter assembly is provided that includes an inner liner made of flexible material, and an outer layer having a steering mechanism that includes at least one wire and a corresponding lumen for each of the at least one wire through which the respective wire may travel. The outer layer includes a braided wire assembly that includes at least two wires braided into a wire mesh, and further includes a see-through portion positioned proximate a pull wire extraction location to facilitate extraction.

What is claimed is: 
     
         1 . A catheter assembly, comprising:
 an inner liner made of flexible material; and   an outer layer having a steering mechanism, the steering mechanism comprising:
 at least one wire; and 
 a corresponding lumen for each of the at least one wire through which the wire may travel; 
   wherein the outer layer comprises a braided wire assembly that includes at least two wires braided into a wire mesh; and   wherein the outer layer comprises a see-through portion positioned proximate a pull wire extraction location to facilitate extraction.   
     
     
         2 . The catheter assembly of  claim 1 , wherein the braided wire assembly is braided in a substantially consistent braid pattern over its length. 
     
     
         3 . The catheter assembly of  claim 1 , wherein the outer layer comprises a plurality of segments of decreasing durometer from proximal end to distal end. 
     
     
         4 . The catheter assembly of  claim 3 , wherein a distal segment of the plurality of segments is of a lower durometer PEBAX than a proximal segment of the plurality of segments. 
     
     
         5 . The catheter assembly of  claim 4 , wherein a distal segment of the plurality of segments is of a higher durometer PEBAX than a proximal segment of the plurality of segments. 
     
     
         6 . A method of manufacturing a catheter, comprising the steps of:
 providing a mandrel;   placing a lining material over the mandrel to form an inner liner;   placing a thermoplastic elastomer layer over the inner liner, at least along the mandrel at a location where one or more pull wires will be extracted;   providing at least one pull wire;   placing a flexible liner over each of the at least one pull wires to create at least one lumen;   placing a braided wire assembly over the inner liner and the at least one lumen, the braided wire assembly including at least two wires braided into a wire mesh;   providing pull wire access areas in the braided wire assembly;   covering the braided wire assembly with one or more melt processing polymers having decreasing durometers from proximal to distal end of the mandrel;   covering a portion of the braided wire assembly proximate the location where the one or more pull wires will be extracted with a melt processing polymer that is substantially see-through;   applying sufficient heat to the one or more melt processing polymers and the see-through melt processing polymer to raise the temperature of the polymer above its melting point;   cooling the assembly; and   removing the mandrel, thereby forming a catheter.   
     
     
         7 . The method of  claim 6 , wherein the braided wire assembly is placed over the inner liner and the at least one lumen in a consistent braid pattern. 
     
     
         8 . A method of manufacturing a catheter, comprising the steps of:
 providing a mandrel;   placing a lining material over the mandrel to form an inner liner;   providing at least one wire;   placing a flexible liner over each of the at least one wires to create at least one lumen;   placing a braided wire assembly over the inner liner and the at least one lumen, the braided wire assembly including at least two wires braided into a wire mesh;   covering the braided wire assembly with one or more melt processing polymers having a durometer at the proximal end that differs from the durometer at the distal end of the mandrel;   applying sufficient heat to the melt processing polymers to raise the temperature of the polymer above their melting point;   cooling the assembly; and   removing the mandrel, thereby forming a catheter.   
     
     
         9 . The method of  claim 8 , wherein the durometer at the distal end is greater than the durometer at the proximal end. 
     
     
         10 . The method of  claim 8 , wherein the durometer at the distal end is less than the durometer at the proximal end. 
     
     
         11 . The method of  claim 8  further comprising the steps of:
 covering a portion of the braided wire assembly proximate the location where the one or more pull wires will be extracted with a melt processing polymer that is substantially see-through; 
 applying sufficient heat to the one or more melt processing polymers and the see-through melt processing polymer to raise the temperature of the polymer above its melting point.