Balloon catheter

Abstract

A method of manufacturing a balloon portion for a balloon catheter for radially expanding a vessel in the body of a mammal, which catheter comprises a tube portion with a passage therethrough and a hollow expandable balloon portion defined by a fluid impervious wall and secured to the tube portion, which balloon portion can be inflated and deflated by means of a fluid passed through the passage, such that: a. the wall of the balloon portion is formed from a flexible substantially fluid impervious material having reinforcing fibers formed integrally with the wall material; and b. the balloon portion is preformed to the desired radial diameter at its inflated state having smaller diameter end portions and a wider diameter portion intermediate the said ends and has a substantially uniform wall thickness.

Description

RELATED APPLICATIONS [0001] This application is a continuation of U.S. application Ser. No. 09 / 678,486, filed on Oct. 4, 2000, which is a continuation of U.S. application Ser. No. 09 / 241,293, filed on Feb. 1, 1999 (now U.S. Pat. No. 6,156,254), which is a continuation of International Patent Application Ser. No. PCT / IB97 / 00956, filed Aug. 1, 1997, which is herein incorporated by reference in its entirety. Foreign priority benefits are claimed under 35 U.S.C. §119(a)-(d) or 35 U.S.C. §365(b) of British application number 9616267.2, filed Aug. 2, 1996.FIELD OF THE INVENTION [0002] The present invention relates to a device, notably to a balloon catheter for locally distending a blood or other vessel in a mammal, and to a method of manufacturing a balloon for such a balloon catheter. BACKGROUND OF THE INVENTION [0003] Balloon catheters are used in surgical techniques, such as angioplasty, in which constrictions in the vascular system (usually coronary arteries) are removed by placing th...

AI Technical Summary

Benefits of technology

[0012] By preforming the balloon portion to its inflated diameter, the wall of the balloon does not thin as the balloon is inflated, nor does the axial dimension of the balloon change significantly during inflation, thus reducing the problems of wall thinning and of axial movement of the balloon where the balloon wall stretches during inflation. The reinforcing fibres are preferably in the form of braiding which limits the extent to which the balloon can be expanded radially and also provides mechanical support to the balloon portion. The balloon portion can thus be made from mechanically weaker, but physiologically more acceptable, polymers than the conventional PET polymers. For example, it is possible to use a softer but more tear resistant polymer, for example a polyurethane, as the major component of the wall of the balloon portion. Since the wall thickness does not reduce significantly during inflation, the problem of balloon puncture by the sharp edge of a stent is further reduced. Alternatives materials to a polyurethane polymer include a styrene butadiene block co-polymer or a butadiene acrylonitrile co-polymer.

[0034] The ability to use high pressures also enables the stent to be expanded to a specified diameter more consistently than hitherto.

Problems solved by technology

This technique is well established, but suffers from the disadvantage that 40% of expanded constrictions spontaneously collapse within 24 months of insertion of the balloon.

Usually, such a catheter incorporates reinforcing polymer or metal fibres or braided fibres which not only provide mechanical support to the wall material of the balloon, but also restrict the extent to which the balloon can expand radially.

However, as described in WO 87 / 00442, problems arise with such compliant catheters in that the balloon portion moves axially within the blood vessel as the balloon portion is inflated.

Such forms of catheter are complex and expensive to manufacture and require that the various plies of the structure of the balloon portion are free to move relative to one another to accommodate the changes in geometry of the wall shape as the balloon inflates.

Furthermore, as the balloon portion is expanded radially within the blood vessel, the wall thickness reduces, weakening the balloon portion.

This thinning of the wall results in a fragile balloon portion and also results in excessive thinning, and hence localised extreme weakness, at the points where the fully inflated portion of the balloon merges into the narrow end portions by which the balloon is connected to the tube of the catheter.

It is not practical to include reinforcing braiding into the wall of such a blow moulded balloon, so that the weakness of the wall cannot readily be compensated for.

As a result, such a construction cannot be used for balloon catheters where the diameter of the balloon is large compared to the tube to which it is to be attached.

Although other methods than blow moulding could be used to form the balloon portion, these are not practical in commercial scale manufacture.

Weaknesses in the wall of the balloon portion result in a risk that the balloon will burst during inflation, notably where high inflation pressures are used.

The problems due to the weaknesses in the balloon wall are accentuated when the balloon is used to expand a stent radially since the stent will typically be made from a stainless steel mesh or coil and may have sharp edges which snag the wall of the balloon.

As a result, the stent readily punctures the balloon before the stent can be properly placed.

The use of replacement balloons increases the time of the procedure during which time the arterial blood flow is restricted, thus increasing patient risk and trauma, and incurring a significant additional cost.

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