Micro-cutting systems for forming cuts in products and micro-fabricated devices made thereby

Abstract

Polymer catheters and guidewires for use in intravascular surgery, and more particularly polymer catheters and guidewires micro-machined with a micro-cutting machine to provide sufficient flexibility to travel through a patient's vasculature while retaining sufficient torquability to transmit torque from a proximal end to the distal end of the catheter or guidewire, and methods of producing the same.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation of U.S. patent application Ser. No. 16 / 439,894, filed Jun. 13, 2019, which is a continuation of U.S. patent application Ser. No. 12 / 753,858, filed on Apr. 2, 2010, now issued as U.S. Pat. No. 10,363,389. application Ser. No. 12 / 753,858 claims priority to and the benefit of U.S.[0002]Provisional Patent Application Ser. No. 61 / 166,480, filed on Apr. 3, 2009. application Ser. No. 12 / 753,858 is also a continuation-in-part of U.S. patent application Ser. No. 12 / 633,727, filed Dec. 8, 2009, now issued as U.S. Pat. No. 8,468,919, which claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61 / 166,480, filed on Apr. 3, 2009. Each of the foregoing are incorporated herein by this reference in their entirety.[0003]This application is also a continuation-in-part of U.S. patent application Ser. No. 16 / 212,425, filed Dec. 6, 2018, which is a continuation of U.S. patent application Ser. No. ...

AI Technical Summary

Benefits of technology

This patent is related to improving the performance of catheters and guidewalls used in intravascular surgery. Specifically, it discusses the use of elastomer laminate to stabilize the micro-machined structure of these devices to prevent deformation while under flexing strain, and to reliably transmit torque to the distal end of the device. Additionally, it describes the use of a soft tip configuration that provides a gradual stiffness transition and can be custom shaped by a surgeon for different procedures or patients. Finally, it discusses the use of micro-cut polymer guiding catheters with a shapeable soft tip that can travel through patient's vasculature while still being able to transmit torque smoothly and reliably.

Problems solved by technology

If blood in the vessels is allowed to “leak,” direct damage can be caused to any tissue outside of the normal capillary approach contacted by the blood, and / or may result in a deadly problem of exsanguination or “bleed out”.

An aneurysm is a very fragile ballooned vessel wall which can easily be punctured if the guidewire or catheter is not precisely controlled.

The guidewires and catheters produced with current technology machines (as described in published patents) have limited functionality.

Due to the single blade design and other aspects of these existing machines, the machines lack the precision necessary to control small (sub 0.002″) features on a reliable basis.

They also lack the ability to precisely control and verify larger features, which could affect the safety and / or performance of these devices.

These machines are also only capable of working with electrically conductive stock material because the machines rely on the electrical conductivity of the stock material to determine the position of the stock relative to the cutting blade.

As the cutting machine is incapable of determining the precise diameter (at the location of the cut) of the stock material being cut, each cut is made according to a preprogrammed depth regardless of that diameter.

This is a problem because stock material is not always of a uniform shape and diameter—there are often imperfections along the length of stock that can affect both the roundness of the stock material and the diameter of the stock material at any particular location.

If the diameter of the stock is thicker than anticipated at the location of the cuts, then the resultant beam will be thicker and therefore less flexible than desired.

If the diameter of the stock is thinner than anticipated at the location of the cuts, then the resultant beam will be thinner and therefore weaker than desired.

This is problematic in terms of both safety and performance of the final product, whether it is a guidewire, catheter or other device.

Existing technology is also unable to cut any kind of non-conductive material, such as plastic.

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