WO2005097471A1 - Systems and methods for laser bonding catheter components - Google Patents

Systems and methods for laser bonding catheter components Download PDF

Info

Publication number
WO2005097471A1
WO2005097471A1 PCT/US2005/009974 US2005009974W WO2005097471A1 WO 2005097471 A1 WO2005097471 A1 WO 2005097471A1 US 2005009974 W US2005009974 W US 2005009974W WO 2005097471 A1 WO2005097471 A1 WO 2005097471A1
Authority
WO
Grant status
Application
Patent type
Prior art keywords
catheter
component
laser
components
laser beam
Prior art date
Application number
PCT/US2005/009974
Other languages
French (fr)
Inventor
He Fugui
Thomas N. Trotta
Original Assignee
Cordis Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1603Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612Infrared [IR] radiation, e.g. by infrared lasers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1603Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616Near infrared radiation [NIR], e.g. by YAG lasers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1635Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1664Laser beams characterised by the way of heating the interface making use of several radiators
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1664Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1629Laser beams characterised by the way of heating the interface
    • B29C65/1674Laser beams characterised by the way of heating the interface making use of laser diodes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5324Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially annular, i.e. of finite length
    • B29C66/53241Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially annular, i.e. of finite length said articles being tubular and said substantially annular single elements being of finite length relative to the infinite length of said tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/63Internally supporting the article during joining
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1677Laser beams making use of an absorber or impact modifier
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1677Laser beams making use of an absorber or impact modifier
    • B29C65/1683Laser beams making use of an absorber or impact modifier coated on the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16Laser beams
    • B29C65/1687Laser beams making use of light guides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/65General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles with a relative motion between the article and the welding tool
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/753Medical equipment; Accessories therefor
    • B29L2031/7542Catheters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/753Medical equipment; Accessories therefor
    • B29L2031/7542Catheters
    • B29L2031/7543Balloon catheters

Abstract

Systems and methods are described for laser bonding polymer catheter components by using laser energy to create localized heat fusion bonds, specifically in the region of interfaces or contact points between two or more polymer catheter components. An example of such localized laser bonding is to form the bond from the 'inside out' at the interface where the catheter components touch each other, rather than forming the bond from the 'outside in' by using laser energy to melt the polymer components from an outer surface inward toward the interface where the components are in contact.

Description

SYSTEMS AND METHODS FOR LASER BONDING CATHETER COMPONENTS

CROSS-REFERENCE To RELATED APPLICATION

[0001] This application claims the benefit of priority of United States Provisional Patent Application number 60/556,538 filed on March 26, 2004. BACKGROUND AND SUMMARY OF THE INVENTION

[0002] 1. Technical Background:

[0003] The present invention relates generally to medical devices, and more particularly to systems and methods of laser bonding medical catheter components.

[0004] 2. Discussion:

[0005] Many different medical therapeutic treatments are conducted using catheters and catheter systems of various kinds. Examples of different type of catheter include balloon catheters, diagnostic catheters, guiding catheters, stent delivery system catheters, injection catheters, gene therapy catheters, electrophysiology catheters, therapeutic drug delivery catheters, ultrasound catheters, laser angioplasty catheters, etc.

[0006] The components of medical catheters are often made of materials including polymers or plastics. Such polymer materials may be selected to have acceptable properties, including biocompatibility, pull strength, longitudinal or column strength, and bending flexibility. Some of the polymer materials may include polyamides, polyurethanes, nylons, polyethylenes, including high-density polyethylene (HOPE), polyether block amide (PEBA) which is available as Pebax®, polyester (PET) or polyetheretherketone (PEEK). Also, any of the catheter components may be made of a coextrusion or a blend or a block copolymer of such polymer materials. [0007] Some medical catheters include polymer components that are affixed together. When polymer components are affixed together, the desirable properties of such a joint, seal or bond between components may include its strength, and its ability to hold high fluid pressures or to exhibit high pull strength. An additional desirable feature of medical component bonding techniques may include minimizing heating of the catheter components during formation of the bond, so as to minimize any adverse impact on flexibility which may occur during bonding. Another desirable feature may include creating a bond having as small a size as possible.

[0008] Previous methods for bonding polymer catheter components have included adhesives, thermal bonding techniques including the methods referred to as "hot jaws," and laser bonding.

[0009] An example of known technology involving laser bonding of catheter components is shown in the following patents: United States patent numbers 5,267,959 and 5,501,759, both entitled "Laser Bonding of Angioplasty Balloon Catheters," which issued to Forman on December 7, 1993 and March 26, 1996 respectively. These methods of laser bonding catheter components require that the wavelength of the laser be selected, and the polymer materials of the catheter components also be selected, such that all of the polymers have high absorption at the wavelength selected for the laser. In other words, the polymer materials of all catheter components to be laser bonded must be made of material having laser energy absorption curves that reach a sufficiently high absorption level at a common specific wavelength of the laser energy. According to this known method, the catheter components meeting these material requirements are placed in contact with each other, and a laser emitting energy at the common or overlapping wavelength is directed at the location where a bond is desired. [0010] This requirement of an overlapping common wavelength for high absoφtion in all of the components to be bonded necessarily limits the types and varieties of materials that can be selected for a particular catheter. In addition, the entirety of each component is heated at the location where the laser energy is directed. Also, the entire thickness of the components is heated at the region where the laser energy is directed.

[0011] In other words, since according to this known method all of the catheter component materials must be selected to have high absoφtion of the laser energy, the laser bond is formed from an initial or "outer" surface "inward."

[0012] In contrast, it would be desirable to form the laser bond at the interface or contact area between the catheter components. Because such a laser bond is not formed beginning at the first surface the laser contacts, but rather begins forming at the interface between components, it may be described as being formed from the "inside out."

[0013] It is thus desirable to form a bond between any two or more polymer catheter components at the interface or contact points between those components, and only at those interfaces or contact points. In other words, it is desirable to cause the laser energy to pass through an outer surface of a catheter component, substantially without heating the material of the catheter component, and yet causing heating at an interface or contact point between the first catheter component and a second catheter component. The absoφtion of the polymer components may be considered to be "activated" only at contact between two or more polymer components.

[0014] In the case of such a laser bond formed only at the interfaces or contact points between components, the resulting size of the laser heat or fusion bond may be smaller. Consequentially, the amount of laser energy required for a particular bond of a specific catheter construction may be less. [0015] It would also be desirable to provide systems and methods for bonding polymer catheter components, in which the bonds are at least as strong as those available with known laser bonding techniques, yet which are even smaller in size. Another desirable feature would be the freedom to choose polymer materials having desirable performance characteristics, without being limited to polymers with high laser energy absoφtion at the selected wavelength. Indeed, it would be desirable to select the polymer materials and the laser wavelength without regard to the absoφtion of the materials at that wavelength.

[0016] The terms "high absoφtion" and "low absoφtion" refer to relative absoφtion of laser energy. They may be understood in terms of the percentage transmission of laser energy through a particular material, such that "high absoφtion" may refer to less than 50% transmission, and "low absoφtion" may refer to more than 50% transmission. As a matter of preference when selecting a material, a material may be selected for "high absoφtion" if it exhibits less than 25% transmission, and a material may be selected for "low absoφtion" if it exhibits greater than 75% transmission of laser energy.

[0017] By way of example, the present invention will be described in relation to a balloon catheter and methods of bonding a balloon component to one or more catheter shaft components. However, it should be understood that the present invention relates to any catheter or methods for bonding catheter components having the features recited in any one of the following claims, and is not limited to any particular treatment or type of catheter, or catheter construction, or the particular example embodiments described below.

[0018] Additional examples of different types of catheters may include balloon catheters, diagnostic catheters, guiding catheters, stent delivery system catheters, injection catheters, gene therapy catheters, electrophysiology catheters, therapeutic drug delivery catheters, ultrasound catheters, laser angioplasty catheters, etc. The laser bonding systems and methods of the present invention may be used with or applied to any suitable type of catheter or catheter components. [0019] These and various other objects, advantages and features of the invention will become apparent from the following description and claims, when considered in conjunction with the appended drawings. The invention will be explained in greater detail below with reference to the attached drawings of a number of examples of embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a diagrammatic view of an example system for laser bonding catheter components; [0021] Figure 2 is a diagrammatic view of another example system for laser bonding catheter components; and [0022] Figure 3 is a diagrammatic view of another example system for laser bonding catheter components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The following description of the preferred embodiments of the present invention is merely illustrative in nature, and as such it does not limit in any way the present invention, its application, or uses. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention.

[0024] According to one example of the present invention, a system 10 for laser bonding two or more catheter components is depicted in Figure 1. The system 10 includes a laser generator 12, or optical fiber 14 or other element for transmitting the laser energy, and one or more emitters 16 for emitting the laser energy directed toward the catheter components to be bonded. A laser beam 18 is indicated with dashed lines. The system 10 also includes a mandrel 20 for supporting the catheter components, a mandrel holder 22 for holding one end of the mandrel 20, and a gripper 24 with a pair of jaws 26 and 28 having a pair of transparent tips 30 and 32. The gripper 24 can selectively move the jaws 26 and 28 to grip a selected portion of the catheter components. While doing so, the glass tips 26 and 28 to grip a selected portion of the catheter components.

[0025] While do so, the transparent tips 30 and 32 will allow laser energy to be transmitted to the catheter components, with very little resistance. In other words, the transparent tips 30 and 32 have very low absoφtion of the laser energy, and consequently a very high percentage transmission of laser energy. The transparent tips 30 and 32 may be made of any suitable material having such low absoφtion, such as glass for example.

[0026] As an example, some catheter components are shown in the drawings, in this case a balloon catheter having a catheter shaft that includes a tubular inner body 34, and a balloon 36 having a balloon distal leg 38. In this particular example, the laser bonding system 10 is being used to bond the balloon distal leg 38 to the inner body 34.

[0027] The transparent tips 30 and 32 may be shaped to receive the catheter components that are to be laser bonded. In the example depicted in the drawings, the inner body 34 and the balloon distal leg 38 are cylindrical, so the transparent tips 30 and 32 may also have a two semi cylinder shape to surround the catheter components and hold them in position. [0028] Of course, the systems and the methods of the present invention may be used to laser bond any two or more catheter components, and is not limited to the particular types of catheter components shown in the drawings.

[0029] One example method of laser bonding using the system shown in Figure 1 is as follows: mandrel 20 is inserted within a lumen or passage defined by the inner body 34, and the inner body34 is inserted into the balloon 36, such that balloon distal leg 38 is aligned with the portion of the inner body 34 where the bond is to be formed. The pair of transparent tips 30 and 32 affixed to the top and bottom jaw 26 and 28 respectively are clamped down on to the portion of the balloon distal leg 38 and the inner body 34. A laser system including an emitter 16 directs a laser beam 18 through the transparent tips 30 and 32, and through the balloon distal leg 38 with a minimum loss of strength and minimum absoφtion, because of the low absoφtion of both materials.

[0030] In this particular example of the present invention, the polymer material or materials of the inner body 34 include a color additive, ink or dye which is either applied to an outer surface of the tubular inner body 34 or is mixed, blended or added to the material of the inner body 34, or is co-extruded with or surrounds the inner body. The color of such a color-additive .is selected to correspond with the wavelength of the particular laser system to be used, such that, the particular color material strongly absorbs the particular laser energy.

[0031] The laser emitter 16 is activated and then moved around the contact area such, that a uniform heating occurs by the laser energy impacting the inner body 34 with the colored additive, and uniform heating is applied at the interface of the inner body 34 and balloon distal leg 38. Inward pressure caused by the transparent tips 30 and 32 helps create a desirable fusion bond. [0032] Another example of a system 40 for laser bonding polymer catheter components is illustrated in Figure 2, including a laser generator 42, a controller 44, an optical fiber 46, and one or more laser emitters 48 for selectively emitting a laser beam 50. A mandrel 52, a mandrel holder 54, a gripper 56, first and second jaws 58 and 60, and corresponding first and second transparent tips 62 and 64are included in an arrangement similar to that of the system 10 in Figure 1. In addition, a rotation servo 66, base 68, and a first and second support member or column 70 and 72 are also provided. An inner body 74 and balloon 76 with a balloon distal leg 78 are also similar to those in Figure 1.

[0033] The controller 44 is operably connected to both the laser generator 42 and the rotation servo 66, such that the laser emitters 48 can remain stationery while the controller 44 and rotation servo 66 rotate the subassembly of the balloon 76, inner body 74, and mandrel 52 by rotating the gripper 56 with its jaws 58 and 60 and transparent tips 62 and 64.

[0034] Yet another example of a laser bonding system 80 arranged according to the principles of the present invention is illustrated in Figure 3, including a first and second laser device 82 and 84, a first and second optical fiber 86 and 88, a first and second connector, a first and second distributor 90 and 92, and a first and second fiber bundle 94 and 96 connecting the first and second distributors 90 and 92 to a multitude of laser emitters 98 arranged around an emitter ring 100 in an emitter box 102. The emitters 98 are directed inwardly towards a central heating area, where the polymer catheter components to be laser welded can be held in place, perhaps by another mandrel.

[0035] The laser welding system example shown in Figure 3 shows another example of a laser bonding system for generating uniform heating of polymer components at an interface between the components, without rotating parts or rotating emitters. In the example illustrated in Figure 3, the angle between adjacent laser emitters is 22.5 degrees, such that the laser beams overlap a catheter component subassembly such that any point in the heating area may simultaneously receive laser energy from three laser emitters.

[0036] One particular type of laser which may be used with various polymers is the diode laser. Diode lasers are preferred for the laser bonding systems and methods of the present invention because their operating wavelengths are within the low energy absoφtion range (and high percentage transmission range) of most plastics and polymers.

[0037] It should be understood that an unlimited number of configuration for the present invention cold be realized. The foregoing discussion describes merely exemplary embodiments illustrating the principles of the present invention, the scope of which is recited in the following claims. Those skilled in the art will readily recognize from the description, claims and drawings that numerous changes and modifications can be made without departing from the spirit and scope of the invention.

Claims

CLA SWhat is claimed is:
1. A method for laser bonding catheter components, comprising the steps of: (a) providing a diode laser system including at least one emitter capable of selectively generating a laser beam having a specific wavelength in the infrared or near-infrared portion of the spectrum; (b) providing a first and second catheter component, each component being made of materials including at least one polymer; and placing the first and second catheter components into physical contact with each other to define a contact area; wherein the first component polymer has relatively low absoφtion of laser energy at the specific wavelength, and the second component polymer has relatively high absoφtion of laser energy at the specific wavelength; (c) providing a holder for supporting the first and second catheter component; (d) directing the emitter toward the first catheter component; (e) energizing the laser system to cause a laser beam to exit the emitter and to pass through the first catheter component with low absoφtion and without substantially generating heat, and then generating heat when the laser beam contacts a selected bonding site in the contact area; wherein heat generated by the laser beam forms a heat fusion bond of the first and second catheter components at the bonding site in the contact area between the first and second catheter components.
2. The method of Claim 1, wherein low absoφtion means energy transmission equal to or less than 30%, and wherein high absoφtion means energy transmission equal to or less than 70%.
3. The method of Claim 1, further comprising the additional step following step (e) of: moving the emitter with respect to the holder and the first and second catheter components, so as to define a larger bonding site.
4. The method of Claim 1, further comprising the additional step following step (e) of: moving or rotating the holder and the first and second catheter components with respect to the emitter, so as to define a larger bonding site.
5. The method of Claim 1, further comprising multiple emitters, each arranged to define a corresponding bonding area in the contact area, the emitters being collectively arranged so that their respective bonding areas are adjacent or overlapping.
6. The method of Claim 1, wherein in said step (b) the materials of the first and second catheter components have low absoφtion at the specific wavelength, and wherein said step (b) further comprises providing a visible colorant to the material of the second catheter component, which causes the second catheter component to have high absoφtion at the specific wavelength.
7. The method of Claim 6, wherein the visible colorant is ink applied to a surface of the second catheter component.
8. The method of Claim 6, wherein the visible colorant is added to the polymer material during compounding or extrusion.
9. The method of Claim 1, wherein the first and second catheter components are cylindrical, and at least a portion of the first component surrounds at least a portion of the second component.
10. The method of Claim 1, wherein the contact area has a complicated shape, including at least two planar and/or curved areas defined in three-dimensional space.
11. The method of Claim 1, wherein said step (b) further comprises providing a third catheter component being made of materials including at least one polymer; and placing the third catheter component into physical contact with at least one of the first and second catheter components to define a contact area.
12. A method for laser bonding catheter components, comprising the steps of: (a) providing a diode laser system including at least one emitter capable of selectively generating a laser beam having a specific wavelength in the infrared or near-infrared portions of the spectrum; (b) providing a first and second catheter component, each component being made of materials including at least one polymer; and placing the first and second catheter components into physical contact with each other to define a contact area; wherein the first and second component polymer materials have relatively low absoφtion of laser energy at the specific wavelength, and the second component polymer material has a color which causes relatively high absoφtion of laser energy at the specific wavelength; (c) providing a holder for supporting the first and second catheter component; (d) directing the emitter toward the first catheter component; (e) energizing the laser system to cause a laser beam to exit the emitter and to pass through the first catheter component with low absoφtion and without substantially generating heat, and then generating heat when the laser beam contacts a selected bonding site in the contact area; wherein heat generated by the laser beam forms a heat fusion bond of the first and second catheter components at the bonding site in the contact area between the first and second catheter components.
13. A method for laser bonding catheter components, comprising the steps of: (a) providing a diode laser system including at least one emitter capable of selectively generating a laser beam having a specific wavelength in the infrared or near-infrared portions of the spectrum; (b) providing a first and second catheter component and an intermediate component, the first and second components being made of materials including at least one polymer; and placing the intermediate component into physical contact with each of the first and second catheter components to define a contact area; the intermediate component being positioned between the first and second catheter components; wherein the first and second component polymer materials have relatively low absoφtion of laser energy at the specific wavelength, and the intermediate component material has a color which causes relatively high absoφtion of laser energy at the specific wavelength; i (c) providing a holder for supporting the first and second catheter component; (d) directing the emitter toward the first catheter component; (e) energizing the laser system to cause a laser beam to exit the emitter and to pass through the first catheter component with low absoφtion and without substantially generating heat, and then generating heat when the laser beam contacts a selected bonding site in the contact area; wherein heat generated by the laser beam forms a heat fusion bond of the first and second catheter components at the bonding site in the contact area of the intermediate component.
14. A method for laser bonding catheter components, comprising the steps of: (a) providing a laser system including at least one emitter capable of selectively generating a laser beam having a specific wavelength; (b) providing a first and second cylindrical catheter component and a mandrel; at least a portion of the first catheter component surrounding at least a portion of the second catheter component which surrounds at least a portion of the mandrel, the first and second catheter components being made of materials including at least one polymer; wherein the first and second component polymer materials have relatively low absoφtion of laser energy at the specific wavelength, and an outer surface of the mandrel has a color which causes relatively high absoφtion of laser energy at the specific wavelength; (c) providing a holder for supporting the first and second catheter component; (d) directing the emitter toward the first catheter component; (e) energizing the laser system to cause a laser beam to exit the emitter and to pass through the first catheter component with low absoφtion and without substantially generating heat, and then generating heat when the laser beam contacts a bonding site on the colored mandrel; wherein heat generated by the laser beam forms a heat fusion bond of the first and second catheter components at the bonding site of the mandrel.
15. A medical catheter having laser bonded catheter components, made by a process comprising the steps of: (a) providing a diode laser system including at least one emitter capable of selectively generating a laser beam having a specific wavelength in the infrared or near-infrared portions of the spectrum; (b) providing a first and second catheter component, each component being made of materials including at least one polymer; and placing the first and second catheter components into physical contact with each other to define a contact area; wherein the first component polymer has relatively low absoφtion of laser energy at the specific wavelength, and the second component polymer has relatively high absoφtion of laser energy at the specific wavelength; (c) providing a holder for supporting the first and second catheter component; (d) directing the emitter toward the first catheter component; (e) energizing the laser system to cause a laser beam to exit the emitter and to pass through the first catheter component with low absoφtion and without substantially generating heat, and then generating heat when the laser beam contacts a selected bonding site in the contact area; wherein heat generated by the laser beam forms a heat fusion bond of the first and second catheter components at the bonding site in the contact area between the first and second catheter components.
16. A system for laser bonding catheter components, comprising: a diode laser including at least one emitter capable of selectively generating a laser beam having a specific wavelength in the infrared or near-infrared portions of the spectrum; a first and second catheter component, each component being made of materials including at least one polymer; the first and second catheter components being in physical contact with each other and defining a contact area; wherein the first component polymer has relatively low absoφtion of laser energy at the specific wavelength, and the second component polymer has relatively high absoφtion of laser energy at the specific wavelength; a holder supporting the first and second catheter component in an initial position and orientation; wherein the emitter is directed toward a surface of the first catheter component; the laser system being energized to cause a laser beam to exit the emitter and to pass through the first catheter component with low absoφtion and without substantially generating heat, and then generating heat when the laser beam contacts a selected bonding site in the contact area, such that heat generated by the laser beam forms a heat fusion bond of the first and second catheter components at the bonding site in the contact area between the first and second catheter components.
17. The system of Claim 16, wherein the materials of the first and second catheter components have low absoφtion at the specific wavelength, and the material of the second catheter component has a visible colorant which causes the second catheter component to have high absoφtion at the specific wavelength.
18. The system of Claim 17, wherein the visible colorant is ink applied to a surface of the second catheter component.
19. The system of Claim 17, wherein the visible colorant is compounded into the polymer material of the second catheter component.
PCT/US2005/009974 2004-03-26 2005-03-24 Systems and methods for laser bonding catheter components WO2005097471A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US55653804 true 2004-03-26 2004-03-26
US60/556,538 2004-03-26

Publications (1)

Publication Number Publication Date
WO2005097471A1 true true WO2005097471A1 (en) 2005-10-20

Family

ID=35124919

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2005/009974 WO2005097471A1 (en) 2004-03-26 2005-03-24 Systems and methods for laser bonding catheter components

Country Status (1)

Country Link
WO (1) WO2005097471A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007115803A3 (en) * 2006-04-06 2007-11-22 Fresenius Medical Care De Gmbh Transmission laser welding method for joining molded plastic articles
EP2159037A1 (en) 2008-08-28 2010-03-03 Leister Process Technologies Connection or branching element for connecting with a tube end section using the laser radiation method and laser head and connection method
US20120226229A1 (en) * 2010-04-01 2012-09-06 Kimihiko Watanabe Balloon catheter, balloon catheter manufacturing device, balloon catheter manufacturing method, catheter connection device, catheter connection method, and connected catheter
WO2014138684A1 (en) * 2013-03-08 2014-09-12 Abbott Cardiovascular Systems, Inc. Methods for manufacturing a catheter using an aluminum nitride bonding apparatus

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020008089A1 (en) * 2000-04-11 2002-01-24 Grewell David A. Light guide for laser welding
US20020115963A1 (en) * 2001-02-22 2002-08-22 Gerry Clarke Through-transmission welding of catheter components
US6596217B1 (en) * 1997-07-08 2003-07-22 Advanced Cardiovascular Systems, Inc. Fusion bonding of cathether components
US6656315B2 (en) * 2000-11-10 2003-12-02 Gentex Corporation Visibly transparent dyes for through-transmission laser welding

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6596217B1 (en) * 1997-07-08 2003-07-22 Advanced Cardiovascular Systems, Inc. Fusion bonding of cathether components
US20020008089A1 (en) * 2000-04-11 2002-01-24 Grewell David A. Light guide for laser welding
US6656315B2 (en) * 2000-11-10 2003-12-02 Gentex Corporation Visibly transparent dyes for through-transmission laser welding
US20020115963A1 (en) * 2001-02-22 2002-08-22 Gerry Clarke Through-transmission welding of catheter components

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2444237A1 (en) * 2006-04-06 2012-04-25 Fresenius Medical Care Deutschland GmbH Transmission laser welding method for joining plastic moulded articles
US20090218325A1 (en) * 2006-04-06 2009-09-03 Thomas Kreischer Transmission Laser Welding Method for Connecting Shaped Plastic Bodies
JP2009532236A (en) * 2006-04-06 2009-09-10 フレゼニウス メディカル ケアー ドイチュラント ゲゼルシャフト ミット ベシュレンクテル ハフツングFresenius Medical Care Deutschland GmbH Laser transmission welding method for joining a molded plastic body
US8778120B2 (en) * 2006-04-06 2014-07-15 Fresenius Medical Care Deutschland Gmbh Transmission laser welding method for connecting shaped plastic bodies
CN101415536B (en) 2006-04-06 2012-08-22 弗雷泽纽斯医疗保健德国有限公司 Transmission laser welding method for joining molded plastic articles
WO2007115803A3 (en) * 2006-04-06 2007-11-22 Fresenius Medical Care De Gmbh Transmission laser welding method for joining molded plastic articles
WO2010022886A1 (en) * 2008-08-28 2010-03-04 Leister Process Technologies Laser head and method of connecting tubular parts by the laser transmission method
US8505604B2 (en) 2008-08-28 2013-08-13 Leister Technologies Ag Laser head and method of connecting tubular parts by the laser transmission method
EP2159037A1 (en) 2008-08-28 2010-03-03 Leister Process Technologies Connection or branching element for connecting with a tube end section using the laser radiation method and laser head and connection method
US20120226229A1 (en) * 2010-04-01 2012-09-06 Kimihiko Watanabe Balloon catheter, balloon catheter manufacturing device, balloon catheter manufacturing method, catheter connection device, catheter connection method, and connected catheter
US9795769B2 (en) * 2010-04-01 2017-10-24 Seidensha Electronics Co., Ltd. Balloon catheter, balloon catheter manufacturing device, balloon catheter manufacturing method, catheter connection device, catheter connection method, and connected catheter
WO2014138684A1 (en) * 2013-03-08 2014-09-12 Abbott Cardiovascular Systems, Inc. Methods for manufacturing a catheter using an aluminum nitride bonding apparatus
US8871136B2 (en) 2013-03-08 2014-10-28 Abbott Cardiovascular Systems, Inc. Methods for manufacturing a catheter using an aluminum nitride bonding apparatus

Similar Documents

Publication Publication Date Title
US5785685A (en) Balloon catheter with improved pressure source
US5425712A (en) Dilatation catheter having soft bumper tip
US5823995A (en) Dilatation catheter with stiffening wire anchored in the vicinity of the guide wire port
US5695468A (en) Balloon catheter with improved pressure source
EP0485903A2 (en) Catheter balloon, balloon catheter equipped with the balloon, and method of manufacturing the balloon
US6508781B1 (en) Ultrasonic ablation catheter transmission wire connector assembly
US20070016165A1 (en) Catheter having plurality of stiffening members
US5378234A (en) Coil polymer composite
US20040131808A1 (en) Medical device components and processes
US5782809A (en) Vascular catheter
US6409863B1 (en) Methods of fabricating a catheter shaft having one or more guidewire ports
US20030018318A1 (en) Irrigation and aspiration device
US20070021771A1 (en) Catheter having plurality of stiffening members
US6187130B1 (en) Method of creating a tip on a catheter
US7341571B1 (en) Balloon catheter having a multilayered distal tip
US20040267280A1 (en) Stent delivery catheter
US20060247661A1 (en) Joint for operatively coupling a contoured inner compression member and an inner guide channel member for medical device delivery systems
US20030032920A1 (en) Catheter tip
EP0608853A2 (en) Vascular dilatation instrument and catheter
US6325780B1 (en) Inflatable member formed of liquid crystal polymeric material blend
US5514128A (en) Fiber optic guide wire and support catheter therefor
US20040068240A1 (en) Covered hypotube to distal port bond
US7112357B2 (en) Medical devices comprising a multilayer construction
US5497601A (en) Packaging having discrete retainers for a medical catheter and method
US20030105453A1 (en) Porous medical catheter and methods of manufacture

Legal Events

Date Code Title Description
AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): BW GH GM KE LS MW MZ NA SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IS IT LT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SM SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW

121 Ep: the epo has been informed by wipo that ep was designated in this application
DPEN Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed from 20040101)
NENP Non-entry into the national phase in:

Ref country code: DE

WWW Wipo information: withdrawn in national office

Country of ref document: DE

122 Ep: pct application non-entry in european phase