Catheter having hypotube connected by connecting member and method for manufacturing same

Abstract

A catheter (10) comprising: a first tubular structure; a second tubular structure wherein the first tubular structure (202) and the second tubular structure (204) are arranged in series relative to each other along a longitudinal axis of the catheter; and a polymeric connection (220) between (1) a portion of the first tubular structure at an end of the first tubular structure and (2) a portion of the second tubular structure at an end of the second tubular structure; wherein the polymeric connector is configured to couple the first tubular structure and the second tubular structure to each other and / or to prevent the first tubular structure and the second tubular structure from being separated from each other.

Description

Technical Field

[0001] The present disclosure relates generally to medical devices and, more particularly, to catheters and methods of making catheters. Background Art

[0002] The use of catheters, such as intravascular catheters, to access and treat various types of diseases is well known. For example, a suitable intravascular catheter can be inserted into the vascular system of a patient. Common vascular applications for accessing a target site in a patient involve inserting a guidewire through an incision in the femoral artery near the groin and advancing the guidewire until it reaches the target site. The catheter is then advanced over the guidewire until the open distal end of the catheter is disposed at the target site. While or after the distal end of the catheter is disposed at the target site, the intravascular implant is advanced through the catheter via a delivery wire.

[0003] In certain applications, such as neurovascular treatments, catheters are required to traverse tortuous and complex vasculature. By using appropriately sized catheters with the necessary performance characteristics (such as "pusherability," "steerability," "torqueability," and most importantly, distal tip flexibility), almost any target site in the vascular system can be approached, including target sites within the tortuous brain and peripheral vasculature. In addition, the forces applied at the proximal ends of these catheters should be transmitted to the distal ends to obtain appropriate pushability (axial stiffness) and torsion (rotation). Achieving a balance between these features is highly desirable, but difficult. For example, the catheter may include a variable stiffness segment (e.g., achieved by changing the proportions of materials, including selective enhancements) that is suitable for providing sufficient flexibility, kink resistance, pushability, and torsionability to enable traversal of the vascular system.

[0004] In some cases, the catheter may include grooves along its elongated body or selected portions thereof. Integrating grooves into these elongated medical devices can modify or customize the flexibility / rigidity of these devices. For example, the distal end portion of a catheter, guidewire, or other delivery member may have a groove pattern that increases its flexibility (e.g., more grooves, longer grooves, and / or wider grooves per unit area). When used as a component of a delivery system, the elongated tubular device with grooves is preferably substantially sealed (e.g., using a housing, sheath, coating, etc.) to prevent fluid exchange (entry or exit) with the lumen of the tube, and also to enhance lubricity. Exemplary medical devices with grooves and coatings are disclosed in U.S. Patents Nos. 5,095,915, 5,443,455, 6,488,637, and 9,162,040, the entire disclosures of which are incorporated herein by reference. Summary of the invention

[0005] A catheter comprises: a first tubular structure; a second tubular structure, wherein the first tubular structure and the second tubular structure are arranged in series relative to each other along a longitudinal axis of the catheter; and a polymer connector, which is located between (1) a portion of the first tubular structure at an end of the first tubular structure and (2) a portion of the second tubular structure at an end of the second tubular structure; wherein the polymer connector is configured to connect the first tubular structure and the second tubular structure to each other and / or prevent the first tubular structure and the second tubular structure from being separated from each other.

[0006] Optionally, the first tubular structure includes a first opening located at the end of the first tubular structure; the second tubular structure includes a first opening located at the end of the second tubular structure; and the polymer connector includes: a first connector portion, arranged in the first opening at the end of the first tubular structure; and a second connector portion, arranged in the first opening at the end of the second tubular structure.

[0007] Optionally, the first opening at the end of the first tubular structure is a laser cut opening.

[0008] Optionally, the first tubular structure includes a protrusion located at an end of the first tubular structure; the second tubular structure includes an opening located at the end of the second tubular structure, the size of the opening being designed to accommodate at least a portion of the protrusion; and the polymer connector is located in a portion of the opening to prevent the protrusion of the first tubular structure from moving within the opening.

[0009] Optionally, the first tubular structure is a first hypotube made of a metal, an alloy or a polymer, and wherein the second tubular structure is a second hypotube made of the metal, the alloy, the polymer, another metal, another alloy or another polymer.

[0010] Optionally, the catheter further comprises a liner, wherein the liner is located on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and wherein the polymeric connector is connected to the liner.

[0011] Optionally, the catheter further comprises a sheath, wherein the sheath is located on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, and wherein the polymer connector is connected to the sheath.

[0012] Optionally, at least a portion of the polymeric connector and the sheath are made of the same material.

[0013] Optionally, at least a portion of the polymeric connector and the liner are made of the same material.

[0014] Optionally, the first tubular structure and the second tubular structure are made of different respective materials.

[0015] Optionally, the first tubular structure and the second tubular structure have different respective inner diameters and / or different respective outer diameters.

[0016] Optionally, the first tubular structure and the second tubular structure have the same inner diameter and / or the same outer diameter.

[0017] Optionally, the polymer connector is configured to transfer one or more forces between the first tubular structure and the second tubular structure, and wherein the one or more forces include compression, tension, shear, torsional forces, or any combination of the foregoing.

[0018] Optionally, the end of the first tubular structure and the end of the second tubular structure are connected to each other without welding, without brazing and without using any adhesive.

[0019] Optionally, the polymer connector has a first enlarged portion at a first end of the polymer connector and a second enlarged portion at a second end of the polymer connector.

[0020] Optionally, the polymer connector has a dumbbell shape or an I-shape.

[0021] Optionally, the catheter further comprises an additional polymer connector, wherein the additional polymer connector is configured to couple the first tubular structure and the second tubular structure to each other and / or prevent the first tubular structure and the second tubular structure from being separated from each other.

[0022] Optionally, the polymer connector and the additional polymer connector are arranged circumferentially around the longitudinal axis of the catheter and lie in a plane perpendicular to the longitudinal axis of the catheter.

[0023] Optionally, the polymer connector and the additional polymer connector are located in different respective planes that are perpendicular to the longitudinal axis of the catheter.

[0024] Optionally, the polymer connector and the second polymer connector are portions of the filling structure having a tubular or annular configuration.

[0025] Optionally, each of the first tubular structure and the second tubular structure comprises a structural component, wherein the structural component of the first tubular structure is configured to abut and mate with a structural component of the second tubular structure, and wherein the structural components are configured to transmit shear forces.

[0026] A method for manufacturing a portion of a catheter, the method comprising: providing a first tubular structure; providing a second tubular structure; arranging the first tubular structure and the second tubular structure in series relative to each other; and forming a polymer connector in a space between an end of the first tubular structure and an end of the second tubular structure, wherein the formed polymer connector connects the first tubular structure and the second tubular structure to each other and / or prevents the first tubular structure and the second tubular structure from separating from each other.

[0027] Optionally, in the method, the first tubular structure includes a first opening located at the end of the first tubular structure; the second tubular structure includes a first opening located at the end of the second tubular structure; and the formed polymer connector includes: a first connector portion, which is arranged in the first opening at the end of the first tubular structure; and a second connector portion, which is arranged in the first opening at the end of the second tubular structure.

[0028] Optionally, in the method, the first opening at the end of the first tubular structure is a laser cut opening.

[0029] Optionally, in the method, the first tubular structure includes a protrusion located at the end of the first tubular structure; the second tubular structure includes an opening located at the end of the second tubular structure, the size of the opening being designed to accommodate at least a portion of the protrusion; and the formed polymer connector is located in a portion of the opening to prevent the protrusion of the first tubular structure from moving within the opening.

[0030] Optionally, in the method, the first tubular structure is a first hypotube made of a metal, an alloy or a polymer, and wherein the second tubular structure is a second hypotube made of the metal, the alloy, the polymer, another metal, another alloy or another polymer.

[0031] Optionally, in the method, the thickness of the first tubular structure is equal to the thickness of the second tubular structure.

[0032] Optionally, in the method, a thickness of the first tubular structure is different from a thickness of the second tubular structure.

[0033] Optionally, in the method, the material of the first tubular structure is the same as the material of the second tubular structure.

[0034] Optionally, in the method, the material of the first tubular structure is different from the material of the second tubular structure.

[0035] Optionally, in the method, the formed polymer connector has a first enlarged portion at a first end of the polymer connector and a second enlarged portion at a second end of the polymer connector.

[0036] Optionally, in the method, the polymer connector has a dumbbell shape or an I-shape.

[0037] Optionally, the method further comprises providing a liner, wherein the liner is located on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and wherein the polymeric connector is connected to the liner.

[0038] Optionally, the method further comprises providing a sheath, wherein the sheath is located on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, and wherein the polymer connector is connected to the sheath.

[0039] Optionally, the step of providing a liner, the step of providing a sheath, and the step of forming a polymer connector include: arranging the liner within the first tubular structure and the second tubular structure; arranging the material of the polymer connector in the space between the end of the first tubular structure and the end of the second tubular structure; arranging the sheath around the first tubular structure and the second tubular structure; and curing the material of the polymer connector to form the polymer connector.

[0040] Optionally, in the method, the liner is made of a liner material and the step of forming the polymer connector includes flowing some of the liner material into a space between the end of the first tubular structure and the end of the second tubular structure.

[0041] Optionally, in the method, the sheath is made of a sheath material and the step of forming the polymeric connector comprises flowing some of the sheath material into a space between the end of the first tubular structure and the end of the second tubular structure.

[0042] Optionally, in the method, the lining material flows from the lining side to the jacket side. Optionally, in the method, the jacket material flows from the jacket side to the lining side.

[0043] Optionally, in the method, the lining material flows out from the lining side, the jacket material flows out from the jacket side, and the lining material and the jacket material meet at a certain position in the space.

[0044] Optionally, the step of providing a liner, the step of providing a jacket, and the step of forming a polymer connector include: immersing the first tubular structure and the second tubular structure in a material to coat the first tubular structure and the second tubular structure with the material; and curing the material to form the liner, the jacket, and the polymer connector.

[0045] Optionally, the step of providing a liner, the step of providing a jacket, and the step of forming a polymer connector include: spraying the first tubular structure and the second tubular structure with a material to coat the first tubular structure and the second tubular structure with the material; and curing the material to form the liner, the jacket, and the polymer connector.

[0046] Optionally, the step of forming the polymer connector includes laminating a portion of the liner and a portion of the jacket in the space to form the polymer connector.

[0047] Optionally, in the method, at least a portion of the polymer connector and the sheath are made of the same material.

[0048] Optionally, in the method, at least a portion of the polymeric connector and the liner are made of the same material.

[0049] Optionally, in the method, the first tubular structure and the second tubular structure have different respective inner diameters and / or different respective outer diameters.

[0050] Optionally, in the method, the first tubular structure and the second tubular structure have the same inner diameter and / or the same outer diameter.

[0051] Optionally, in the method, the formed polymer connector is configured to transfer one or more forces between the first tubular structure and the second tubular structure, and wherein the one or more forces include compression, tension, shear, torsional forces, or any combination of the foregoing.

[0052] Optionally, in the method, the end of the first tubular structure and the end of the second tubular structure are connected to each other without welding, without brazing and without using any adhesive.

[0053] Optionally, the method further comprises: forming an additional polymer connector, wherein the additional polymer connector is configured to couple the first tubular structure and the second tubular structure to each other and / or prevent the first tubular structure and the second tubular structure from being separated from each other.

[0054] Optionally, in the method, the polymer connector and the additional polymer connector are arranged circumferentially around the longitudinal axis of the catheter and lie in a plane perpendicular to the longitudinal axis of the catheter.

[0055] Optionally, in the method, the polymer connector and the additional polymer connector are located in different respective planes that are perpendicular to the longitudinal axis of the catheter.

[0056] Optionally, in the method, the polymer connector and the second polymer connector are portions of the filling structure having a tubular or annular configuration.

[0057] Optionally, in the method, each of the first tubular structure and the second tubular structure comprises a structural component, wherein the structural component of the first tubular structure is configured to abut and mate with the structural component of the second tubular structure, and wherein the structural components are configured to transmit shear forces.

[0058] Other and further aspects and features of the embodiments will become apparent from the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1 A catheter is shown;

[0060] Figure 2 Shows Figure 1 A portion of a catheter in FIG. 1 , specifically showing a portion where two tubular structures are connected to each other;

[0061] Figure 3A An example of a tubular structure prior to connection is shown;

[0062] Figure 3B Shows the connection Figure 3A Tubular structures in

[0063] FIG. 4A to FIG. 4C An example of a polymer connector for connecting two tubular structures is shown;

[0064] Figure 5 shows exemplary forces transmitted by a polymer connector connecting two tubular structures;

[0065] Figure 6 Shows Figure 1 A side view of a portion of a catheter in , specifically showing a polymer connector integrally formed with a liner and a sheath;

[0066] Figure 7 Shows Figure 1 A side view of a portion of a catheter in FIG. 1 , specifically showing a polymer connector formed from two connector portions;

[0067] Figure 8 Another example of a catheter having a polymer connector connecting two tubular structures is shown;

[0068] Fig. 9 Another example of a catheter having a polymer connector connecting two tubular structures is shown;

[0069] Fig.10 A method of manufacturing a portion of a catheter is shown. DETAILED DESCRIPTION

[0070] The various embodiments will be described below with reference to the accompanying drawings. It should be noted that the drawings are not drawn to scale, and in all the drawings, elements of similar structure or function are represented by the same reference numerals. It should also be noted that the drawings are intended only to facilitate the description of the embodiments. They are not intended to be an exhaustive description of the invention or to limit the scope of the invention. In addition, the illustrated embodiments do not need to have all the aspects or advantages shown. The aspects or advantages described in conjunction with a specific embodiment are not necessarily limited to that embodiment, and may be implemented in any other embodiment, even if not shown or not so explicitly described.

[0071] A new catheter and a new technology for manufacturing a catheter are described herein. An exemplary catheter includes at least two tubular structures arranged in series along the longitudinal axis of the catheter. The two tubular structures are aligned circumferentially relative to each other and are connected to each other via one or more polymer connectors. It is advantageous to use a polymer connector to connect two tubular structures because they make it possible for the two tubular structures to be made of the same material or made of different materials (e.g., nitinol+stainless steel, nitinol+platinum-iridium, different polymers, etc.), and / or whether the two tubular structures have the same inner diameter, different inner diameters, the same outer diameter or different inner diameters, to connect the two tubular structures. This is advantageous compared to the pipe connection using welding (when the tubular structure is made of different materials, welding may not work) or glue (implementation may be cumbersome and may not provide ideal structural and / or dimensional characteristics). The polymer connectors described herein also have the advantage that they can be configured to have compliance in one or more degrees of freedom.

[0072] In one exemplary technique described herein, a cutting pattern is formed at the end of a first tubular structure (e.g., a first hypotube), and a cutting pattern is formed at the end of a second tubular structure (e.g., a second hypotube). The two ends of the respective tubular structures are aligned so that the cutting patterns at the respective ends of the respective tubular structures are ready for connection. A polymer jacket is arranged on the two tubular structures, and a polymer liner is arranged within the two tubular structures, thereby forming a structure in which the two tubular structures are sandwiched between the polymer jacket and the polymer liner. The polymer jacket and / or the polymer liner are then heated so that some polymer material (of the jacket and / or the liner) flows into the cutting pattern at the end of the tubular structure and / or into the space between the ends of the tubular structure. After the polymer material cools / solidifies, the polymer connector is then formed.

[0073] Figure 1A catheter 10 is depicted according to some embodiments. The catheter 10 is configured for insertion into a blood vessel. The catheter 10 can be: a delivery catheter configured to deliver items (e.g., implants (such as coils, stents, etc.), drugs, diagnostic agents, etc.) into the human body and / or remove items (e.g., blood, biopsy tissue, etc.) from the human body for delivery outside the human body; a treatment catheter including an energy delivery device configured to provide treatment; a diagnostic catheter configured to image an internal portion of the human body; or any other type of catheter (e.g., a balloon catheter).

[0074] The catheter 10 includes an elongated member 11 having a proximal end 15, a distal end 16, and a body 13 extending between the proximal end 15 and the distal end 16. The elongated member 11 includes a tubular member 14. The tubular member 14 is configured to provide certain structural features along the longitudinal axis of the elongated member 11. The tubular member 14 can be any elongated device or component with a lumen, which can be made of any material, such as any suitable biocompatible metal, polymer, or combination thereof. In some embodiments, the tubular member 14 can have a circular cross-section. In other embodiments, the tubular member 14 of the elongated member 11 can have any cross-sectional shape, such as an elliptical shape or any custom designed shape. Similarly, in some embodiments, the tubular member 14 can have different cross-sectional shapes and / or cross-sectional sizes along the longitudinal axis of the tubular member 14.

[0075] The wall thickness of tubular member 14 can be any value between 0.001 inch and 0.01 inch, or any value between 0.001 inch and 0.006 inch, or any value between 0.002 inch and 0.004 inch. In other embodiments, tubular member 14 can have a wall thickness greater than 0.01 inch or less than 0.001 inch. In some examples, the outer diameter of tubular member 14 can be any value from 0.01 inch to 0.11 inch, or any value from 0.08 inch to 0.11 inch, or any value from 0.01 inch to 0.03 inch (e.g., 0.024 inch + / - 0.002 inch), or any value from 0.01 inch to 0.02 inch. In other examples, tubular member 14 can have an outer diameter greater than 0.11 inch. In some further examples, tubular member 14 can have an outer diameter less than 0.01 inch.

[0076] like Figure 2As shown in , the tubular member 14 of the catheter 10 includes a first tubular structure 202 and a second tubular structure 204, wherein the first tubular structure 202 and the second tubular structure 204 are arranged in series relative to each other along a longitudinal axis 208 of the catheter 10. The tubular member 14 of the catheter 10 also includes a polymer connector 220, which is located between (1) a portion of the first tubular structure 202 at an end 222 of the first tubular structure 202 and (2) a portion of the second tubular structure 204 at an end 224 of the second tubular structure 204. The polymer connector 220 is configured to couple the first tubular structure 202 and the second tubular structure 204 to each other and / or prevent the first tubular structure 202 and the second tubular structure 204 from being separated from each other.

[0077] like Figure 2 As shown in , in some embodiments, the first tubular structure 202 includes a first opening 242 located at the end 222 of the first tubular structure 202, and the second tubular structure 204 includes a first opening 244 located at the end 224 of the second tubular structure 204. The polymer connector 220 includes: a first connector portion 252, which is arranged in the first opening 242 at the end 222 of the first tubular structure 202; and a second connector portion 254, which is arranged in the first opening 244 at the end 224 of the second tubular structure 204.

[0078] In some embodiments, the first opening 242 at the end 222 of the first tubular structure 202 is a laser cut opening. Similarly, in some embodiments, the first opening 244 at the end 224 of the second tubular structure 204 is a laser cut opening. In other embodiments, one or both of the openings 242, 244 can be formed by mechanical cutting, punching, or chemical etching.

[0079] In some embodiments, the first tubular structure 202 can be a first hypotube made of a metal, an alloy, or a polymer, and the second tubular structure 204 can be a second hypotube made of the metal, the alloy, the polymer, another metal, another alloy, or another polymer.

[0080] Furthermore, in some embodiments, the first tubular structure 202 can have a plurality of slots, openings, etc. to form a porous wall of the first tubular structure 202. Similarly, in some embodiments, the second tubular structure 204 can have a plurality of slots, openings, etc. to form a porous wall of the second tubular structure 204. By way of non-limiting example, each of the first tubular structure 202 and the second tubular structure 204 can be a tube with laser cut openings, a braided tubular structure, a wire mesh, a coil, a tube with slots / gaps formed by laser cutting or machine cutting, etc.

[0081] In some embodiments, the opening / slot / gap in each of the first and second tubular structures 202, 204 can be formed by sawing the tubular structure 202 / 204 with a circular blade, micromachining, laser cutting, electrical discharge machining, plasma arc cutting, grinding, milling, casting, molding, chemical etching, or other known suitable methods, etc. In other embodiments, the tubular structure 202 / 204 with the opening / slot / gap can be produced using "additive" manufacturing (e.g., 3D printing) rather than the various "subtractive" techniques described.

[0082] In some examples, the first tubular structure 202 can have a plurality of first openings 242 at the end 222 of the first tubular structure 202, and the second tubular structure 204 can have a plurality of first openings 244 at the end 224 of the second tubular structure 204. The first openings 242 of the first tubular structure 202 are configured to be aligned with the first openings 244 of the second tubular structure 204, respectively, wherein each pair of aligned first openings 242 forms a space for accommodating a corresponding polymer connector 220.

[0083] Figure 3A An example of a first tubular structure 202 is shown, specifically a first tubular structure 202 having a plurality of annular elements 302 arranged in series along the longitudinal axis of the first tubular structure 202. Adjacent annular elements 302 are connected by a plurality of structural members 312. The annular elements 302 and the structural members 312 cooperate together to transmit one or more forces during use of the catheter 10. By way of non-limiting example, the one or more forces may be axial compression, axial tension, bending, shear, torsional, or any combination of the foregoing.

[0084] Similarly, the second tubular structure 204 has a plurality of annular elements 304 arranged in series along the longitudinal axis of the second tubular structure 204. Adjacent annular elements 304 are connected by a plurality of structural members 314. The annular elements 304 and the structural members 314 cooperate together to transmit one or more forces during use of the catheter 10. By way of non-limiting example, the one or more forces may be axial compression, axial tension, bending, shear, torsional, or any combination of the foregoing.

[0085] The openings defined by the annular elements and structural members of the tubular structures 202, 204 are advantageous because they enhance the flexibility of the tubular member 14 of the catheter 10, while the structural members (e.g., beams) and annular elements (annular segments) provide relatively high torsional stiffness while maintaining a desired level of lateral bending flexibility.

[0086] It should be noted that the tubular structure 202 / 204 is not limited to having the configurations and features described in the above examples, and in other embodiments, the tubular structure 202 / 204 may have other configurations and features. For example, in other embodiments, each of the tubular structures 202, 204 may have annular elements and structural members that are arranged and configured differently. In some embodiments, at least some of the structural members or all of the structural members are arranged so that their respective longitudinal axes form the same angle or a similar angle (e.g., 0 degrees + / - 10 degrees) with the longitudinal axis of the catheter 10. In other embodiments, the structural members are arranged so that their respective longitudinal axes form different angles with the longitudinal axis of the catheter 10. It should be understood that the distribution and / or configuration of the annular elements and structural members may have any suitable variations and combinations of these variations.

[0087] Furthermore, in some examples, the tubular structures 202, 204 having the cut patterns may provide one or more mechanical requirements (eg, axial stiffness, hoop strength, bending stiffness, bending radius, torsional stiffness, etc. or any combination of the foregoing).

[0088] Additionally, in some examples, it may be desirable to provide greater stiffness to the proximal portion of the catheter 10. This may be accomplished by using tubular structures 202, 204 having different geometric, mechanical, and / or material properties (e.g., different thicknesses, different materials, different tube opening patterns, etc.).

[0089] like Figure 3A As shown in the drawings, the first tubular structure 202 has a plurality of first openings 242 at the end of the first tubular structure 202, and the second tubular structure 204 has a plurality of first openings 244 at the end of the second tubular structure 204. In addition, as shown in the drawings, the first tubular structure 202 also has such a structural component 332 (e.g., a tube portion having an opening) that is configured to abut and mate with a corresponding structural component 334 (e.g., a protrusion) at the end of the second tubular structure 204. The structural components 332, 334 form a guide element that is configured to align the pairs of openings 242, 244 along the circumferential direction. In some embodiments, the structural components 332, 334 are configured to transmit shear forces between the first and second tubular structures 202, 204 after the first and second tubular structures 202, 204 are coupled to each other.

[0090] Figure 3A The first and second tubular structures 202, 204 are shown before they are coupled to one another. Figure 3BThe first and second tubular structures 202, 204 are shown adjacent to each other and guide elements (pairs of mating structural components 332, 334) circumferentially aligning a set of first openings 242 at the end of the first tubular structure 202 with a set of first openings 244 at the end of the second tubular structure 204. Each pair of first openings 242, 244 forms a space in which a polymer connector 220 will be formed.

[0091] Figure 4A An example of a polymer connector 220 is shown. As shown in the drawings, the shape of the polymer connector 220 corresponds to the shape of the space formed by a pair of first openings 242, 244. In the illustrated embodiment, the polymer connector 220 has a dumbbell shape. Specifically, the polymer connector 220 has a first enlarged portion 402 located at a first end of the polymer connector, a second enlarged portion 404 located at a second end of the polymer connector, and a relatively small central portion 406. In other embodiments, the polymer connector 220 may have other shapes. For example, in other embodiments, the polymer connector 220 may have two enlarged portions 402, 404 at opposite ends of the polymer connector 220, and also have an enlarged central portion 406 ( Figure 4B ). The enlarged central portion 406 can be used as a guide element configured to align the first tubular structure 202 and the second tubular structure 204 relative to each other and / or transfer forces between the first tubular structure and the second tubular structure 202, 204. In yet other embodiments, the polymer connector 220 can have an I-shaped shape ( Figure 4C ).

[0092] In some embodiments, the polymer connector 220 can be made of one or more polymer materials, such as polyurethane, cellulose acetate, mixed ester cellulose, PTFE / polyester, acrylic copolymer, any other biocompatible polymer, or any combination of the foregoing materials. Other examples of materials that can be used to make the polymer connector 220 include: polyether block amide or PEBA (TPE: trade name PEBAX® and VESTAMID® E), polyamide (PA: trade name Nylon), thermoplastic polyurethane (TPU), polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyolefin elastomer (POE), styrene-ethylene-butylene-styrene (SEBS), polyethylene terephthalate (PET or PETE), polylactic acid (PLA), fluorinated ethylene propylene (FEP) polymer or other polymers. In some examples, the polymer connector 220 may also include one or more non-polymer materials. Therefore, the term "polymer connector" is not limited to components made of only polymer materials, and may refer to components made of one or more polymer materials and optionally include one or more non-polymer materials.

[0093] In some examples, the polymer connector 220 can be made of a material having an elastic modulus of any value between 2 MPa and 2000 MPa. This makes the polymer connector 220 significantly more elastic than the material of the tubular structures 202, 204. Likewise, in some examples, the polymer connector 220 makes the tubular member 14 more flexible (compared to a solution where the tubular structures are connected by welding). As a result, the tubular member 14 can pass through relatively tight bends during use of the catheter 10.

[0094] In some examples, the length of the polymer connector 220 enables the tubular member 14 to achieve a desired radius of curvature, which is formed by the bending of the tubular member 14. The desired radius of curvature of the tubular member 14 can be any value from 0.02 inches to 0.16 inches, or any value from 0.03 inches to 0.10 inches, or any value from 0.035 inches to 0.08 inches, or any value from 0.04 inches to 0.06 inches, or any value from 0.055 inches to 0.06 inches, or any value of 0.039 inches + / - 0.01 inches. In some examples, the total longitudinal length of the polymer connector 220 (measured in a direction parallel to the longitudinal axis of the tubular member 14) can be any value from 0.2 mm to 2 mm, and more preferably any value from 0.2 mm to 1 mm, and even more preferably any value from 0.4 mm to 0.8 mm. The longitudinal length of each of the two anchoring portions of the polymer connector 220 opposite to each other (measured in a direction parallel to the longitudinal axis of the tubular member 14) can be any value from 0.05 mm to 0.15 mm, such as 0.1 mm. In other examples, the two anchoring portions of the polymer connector 220 opposite to each other can each have a longitudinal length greater than 0.15 mm. Similarly, the longitudinal length of the central portion of the polymer connector 220 extending between the two anchoring portions opposite to each other (measured in a direction parallel to the longitudinal axis of the tubular member 14) can be any value from 0 mm to 5.5 mm, or any value from 0 mm to 4 mm, or any value from 0 mm to 3 mm, or any value from 0 mm to 2 mm, or any value from 0.4 mm to 1.5 mm, or any value from 0.4 mm to 1.0 mm, or any value from 0.4 mm to 0.9 mm, or any value from 0.5 mm to 0.9 mm. In some examples, when polymer connector 220 is implemented more distally (eg, closer to the distal end of tubular member 14), polymer connector 220 may have a shorter longitudinal length (compared to when polymer connector 220 is implemented more proximally).

[0095] Furthermore, in some examples, a plurality of polymer connectors 220 may be arranged circumferentially (at one longitudinal position) between the first and second tubular structures 202, 204. In these examples, the total shear strength V provided by the polymer connectors 220 is T = Vc = 2 ... T It can be higher than the shear strength of each tubular structure 202 , 204 .

[0096] In some examples, polymer connector 220 can be configured to achieve a stiffness curve and / or a force-displacement curve to meet clinical requirements for a particular application.

[0097] In some embodiments, each polymer connector 220 has an uncompressed (intermediate) volume, and each polymer connector 220 is compressible to achieve a compressed volume of less than 50%, less than 40%, less than 30%, less than 20%, less than 10%, or less than 5% of the intermediate volume. Similarly, in some embodiments, each polymer connector 220 has an unstretched (intermediate) volume, and each polymer connector 220 is stretchable to achieve a stretched volume of greater than 105%, greater than 110%, greater than 120%, greater than 130%, greater than 140%, or greater than 150% of the intermediate volume. In other embodiments, each polymer connector 220 can be compressible and / or stretchable to achieve a strain (compressive strain or tensile strain) of at least 0.1, at least 0.2, at least 0.3, at least 0.4, at least 0.5, where "strain" is defined as the change in length of the polymer connector 220 divided by the original length of the polymer connector 220 (e.g., strain = change in length / original length). In yet other embodiments, each polymer connector 220 may be compressible and / or stretchable to achieve a strain (compressive strain or tensile strain) of less than 0.1.

[0098] Additionally, in some examples, the polymer connector 220 can be configured to have a stretch limit that is shorter than the longitudinal length of a guide element (e.g., a guide element described with respect to structural components 332, 334). This allows the guide element to continue to transfer forces (e.g., shear forces) between the tubular structures 202, 204 even when the polymer connector 220 is stretched. In other examples, the polymer connector 220 can be configured to have a stretch limit that is longer than the longitudinal length of the guide element.

[0099] It should be noted that the polymer connector 220 is not limited to having the configuration shown in the above examples, and in other embodiments, the polymer connector 220 may have other configurations.

[0100] like Figure 5As shown in, in some embodiments, the polymer connector 220 is configured to transmit one or more forces between the first tubular structure 202 and the second tubular structure 204. The one or more forces may include compressive forces, tensile forces, shear forces, torsional forces, or any combination of the foregoing forces. In some examples, the first and second tubular structures 202, 204 may include guiding elements, such as the structural components 332, 334 described herein. In these examples, the guiding element may serve to transmit one or more forces (such as axial tensile forces, axial compressive forces, shear forces, torsional forces, etc.). In other examples, the catheter 10 may not include any guiding elements at the tubular structures 202, 204. In these examples, the polymer connector 220 may serve to transmit one or more forces, as described herein.

[0101] Reference now Figure 6 , the catheter 10 may optionally further include a liner 600. The liner 600 is located on a first inner surface 602 of the first tubular structure 202 and on a second inner surface 604 of the second tubular structure 204. The catheter 10 may optionally further include a sheath 610. The sheath 610 is located on a first outer surface 612 of the first tubular structure 202 and on a second outer surface 614 of the second tubular structure 204. The polymer connector 220 may be connected to the liner 600 and / or the sheath 610.

[0102] In some examples, at least a portion of polymer connector 220 and jacket 610 can be made of the same material. Likewise, in some examples, at least a portion of polymer connector 220 and liner 600 can be made of the same material. In other examples, polymer connector 220 can be made of a material different from the material of jacket 610 and / or the material of liner 600.

[0103] The polymer connector 220 may be connected to the liner 600 by being integrally formed with the liner 600 or by forming the polymer connector 220 on the liner 600. In other examples, the polymer connector 220 may be connected to the liner 600 via an adhesive (e.g., glue). Similarly, the polymer connector 220 may be connected to the liner jacket 610 by being integrally formed with the jacket 610 or by forming the polymer connector 220 on the jacket 610. In other examples, the polymer connector 220 may be connected to the jacket 610 via an adhesive (e.g., glue). Figure 6As shown in , in some examples, the polymer connector 220 can be integrally formed with both the liner 600 and the jacket 610. This can be achieved by attaching the first and second tubular structures 202, 204 to the liner 600, or vice versa. Then, the material of the polymer connector 220, which is uncured and / or in liquid form, is arranged in the space between the first and second tubular structures 202, 204. Then, the jacket 610 is arranged on the first and second tubular structures 202, 204 to cover the material of the polymer connector 220. Alternatively, the material of the jacket 610, which is uncured or in liquid form, can be arranged on the outer surfaces 612, 614 of the respective first and second tubular structures 202, 204. After the material of the polymer connector 220 (and the material of the jacket 610, if it is applied in liquid form) is cured or hardened, the polymer connector 220 is then formed and integrally formed with the liner 600 and the jacket 610.

[0104] In other examples, the liner 600 is first coupled to the first and second tubular structures 202, 204. Then, the polymer connector 220 in solid form can be arranged in the space between the first and second tubular structures 202, 204. Then, the sheath 610 is arranged around the first and second tubular structures 202, 204. The liner 600, the polymer connector 220, and the sheath 610 can then be heated so that the opposite ends of the polymer connector 220 are fused with the liner 600 and the sheath 610, respectively. In some examples, the opposite ends of the polymer connector 220 may include a heat-activated adhesive. In other examples, the polymer connector 220 may be made of a material having a melting point lower than the melting point of the liner 600 material and the melting point of the sheath 610 material. This allows the material of the polymer connector 220 to melt while being contained between the liner 600 and the sheath 610. After the material of the polymer connector 220 cures or hardens, the polymer connector 220 is then integrally formed with the liner 600 and the jacket 610 .

[0105] In some examples, the liner 600 can be provided as a tube, and the first and second tubular structures 202, 204 can be arranged above the tube. The surface of the liner 600 having a layer of material can be configured to be bonded to the surfaces of the first and second tubular structures 202, 204. For example, the layer of material can be an adhesive or a heat-activated adhesive. After the tube (liner 600) is heated, the first and second tubular structures 202, 204 are then attached to the liner 600.

[0106] Similarly, the sheath 610 can be provided as a tube, and the tube can be arranged above the first and second tubular structures 202, 204. The surface of the sheath 610 having a layer of material can be configured to be bonded to the surfaces of the first and second tubular structures 202, 204. For example, the layer of material can be an adhesive or a heat-activated adhesive. After the tube (sheath 610) is heated, the first and second tubular structures 202, 204 are then attached to the sheath 610.

[0107] In some examples, the material of the polymer connector 220 (in liquid or solid form) can be disposed in the space between the first and second tubular structures 202, 204 before the jacket 610 is disposed over the first and second tubular structures 202, 204. After the material of the polymer connector 220 is disposed, and after the jacket 610 is disposed over the first and second tubular structures 202, 204, heat can then be applied to heat the liner 600 and the jacket 610. The heated liner 600 causes the liner 600 to bond to the inner surfaces of the first and second tubular structures 202, 204, and also to the material of the polymer connector 220. Similarly, the heated jacket 610 causes the jacket 610 to bond to the outer surfaces of the first and second tubular structures 202, 204, and also to the material of the polymer connector 220.

[0108] In some other examples, the first and second tubular structures 202, 204 can be immersed in a solution (material). When the solution solidifies, it forms a liner 600 on the inner surfaces 602, 604 of the respective first and second tubular structures 202, 204, forms a polymer connector 220 between the first and second tubular structures 202, 204, and forms a jacket 610 on the outer surfaces 612, 614 of the respective first and second tubular structures 202, 204.

[0109] In other examples, the first and second tubular structures 202, 204 may be sprayed with a solution (material). When the solution solidifies, it forms a liner 600 on the inner surfaces 602, 604 of the respective first and second tubular structures 202, 204, forms a polymer connector 220 between the first and second tubular structures 202, 204, and forms a jacket 610 on the outer surfaces 612, 614 of the respective first and second tubular structures 202, 204.

[0110] In other examples, the step of forming the polymer connector 220 may include laminating a portion of the liner 600 and a portion of the jacket 610 in the space to form the polymer connector 220 .

[0111] In other examples, the polymer connector 220 may have a first connector portion 220a and a second connector portion 220b ( Figure 7 ). As shown in the figures, the first connector portion 220a and the second connector portion 220b are different respective layers that form the polymer connector 220. The first connector portion 220a and the second connector portion 220b can be made of the same material, or alternatively, the first connector portion and the second connector portion can be made of different respective materials. The first connector portion 220a can be closer to the sheath 610 than the liner 600, and / or the first connector portion can be directly connected to the sheath 610. The second connector portion 220b can be closer to the liner 600 than the sheath 610, and / or the second connector portion can be directly connected to the liner 600. The seam between the first connector portion 220a and the second connector portion 220b is located in the middle, so that the thickness of the first connector portion 220a (measured in a direction perpendicular to the longitudinal axis 208 of the catheter 10) is equal to the thickness of the second connector portion 220b. In other examples, the thickness of the first connector portion 220a and the thickness of the second connector portion 220b can be different from each other. For example, the thickness of the first connector portion 220a may be greater than the thickness of the second connector portion 220b, or the thickness of the first connector portion 220a may be less than the thickness of the second connector portion 220b.

[0112] Figure 7 The configuration of the polymer connector 220 shown in FIG. 2 can be achieved by causing some of the material of the liner 600 to flow into the space between the first and second tubular structures 202, 204 when the material is in liquid form; and causing some of the material of the sheath 610 to flow into the space between the first and second tubular structures 202, 204 when the material is in liquid form. The material of the liner 600 and the material of the sheath 610 flow into the space between the first and second tubular structures 202, 204 from opposite ends of the space. Therefore, the material of the liner 600 disposed in the space between the first and second tubular structures 202, 204 only occupies a portion of the space. Similarly, the material of the sheath 610 disposed in the space between the first and second tubular structures 202, 204 only occupies a portion of the space.

[0113] In other examples, the catheter 10 may not include the liner 600 and / or the sheath 610. For example, in other examples, the polymer connector 220 may not extend beyond the lateral boundaries of the space between the tubular structures 202, 204 (e.g., the inner surface of the tubular structures 202, 204 and / or the outer surface of the tubular structures 202, 204). In still other examples, the polymer connector 220 may extend beyond the inner surface of the tubular structures 202, 204 and / or extend beyond the outer surface of the tubular structures 202, 204. For example, in other examples, the catheter 10 may include a sheath 610 and a polymer connector 220 attached to the sheath 610, wherein the polymer connector 220 may extend through the inner surface of the wall of the tubular structure 202 and / or the inner surface of the wall of the tubular structure 204 to enter the lumen of the tubular member 14. In another example, the catheter 10 may include a liner 600 and a polymer connector 220 attached to the liner 600, wherein the polymer connector 220 may extend through the outer surface of the wall of the tubular structure 202 and / or the outer surface of the wall of the tubular structure 204. In some examples, the portion of the polymer connector 220 that extends beyond the lateral boundary of the space between the tubular structures 202, 204 may be a bump, an elongated protrusion, a block, or may have any shape (e.g., a shape formed due to a manufacturing defect). In still other embodiments, the portion of the polymer connector 220 that extends through the inner surface of the tubular structure 202 / 204 may extend to an inner layer (e.g., the liner 600) disposed on the inner surface of the tubular structure 202 / 204, wherein the portion of the polymer connector 220 may be separately attached to the inner layer, or may be integrally formed with the inner layer. In yet other embodiments, the portion of the polymer connector 220 that extends through the outer surface of the tubular structure 202 / 204 can extend to an outer layer (e.g., a sheath 600) disposed on the outer surface of the tubular structure 202 / 204, wherein the portion of the polymer connector 220 can be separately attached to the outer layer or can be integrally formed with the outer layer. In other embodiments, the polymer connector 220 can have a first portion that extends through the outer surface of the tubular structure 202 / 204 and a second portion that extends through the inner surface of the tubular structure 202 / 204. In these examples, the first portion of the polymer connector 220 can be separately attached to the outer layer (e.g., a sheath 610) disposed on the outer surface of the tubular structure 202 / 204, and the second portion of the polymer connector 220 can be separately attached to the inner layer (e.g., a liner 600) disposed on the inner surface of the tubular structure 202 / 204.

[0114] As shown in the above examples, the catheter 10 may have a plurality of polymer connectors 220 (eg, Figure 23 ), these polymer connectors are connected to each other via a liner 600 and / or a sheath 610. In some examples, the liner and / or sheath together with the polymer connector 220 constitute a filling structure having a tubular or annular structure. The filling structure may include one or more filling portions that fill one or more spaces between two adjacent tubular structures.

[0115] like Figure 6 to Figure 7 As shown in , the first tubular structure 202 and the second tubular structure 204 have the same inner diameter and / or the same outer diameter. In other examples, the first tubular structure 202 and the second tubular structure 204 have different corresponding inner diameters and / or different corresponding outer diameters.

[0116] Furthermore, in some examples, the first tubular structure 202 and the second tubular structure 204 can be made of the same material. In other examples, the first tubular structure 202 and the second tubular structure 204 can be made of different respective materials.

[0117] In the above examples, the catheter 10 is described as having a plurality of polymer connectors 220 (e.g., a polymer connector and an additional polymer connector). Each of the polymer connectors (e.g., the polymer connector, the additional polymer connector) is configured to couple the first tubular structure 202 and the second tubular structure 204 to each other and / or prevent the first tubular structure 202 and the second tubular structure 204 from being separated from each other. In other examples, the catheter 10 may have only a single polymer connector 220 to connect each pair of adjacent tubular structures.

[0118] Furthermore, in other examples, the catheter 10 may have more than two tubular structures (eg, three tubular structures, four tubular structures, etc.) In these examples, each pair of adjacent tubular structures may be connected by one or more polymer connectors 220 .

[0119] exist Figure 2 In the example of FIG. 3 , the polymer connectors 220 are arranged circumferentially around the longitudinal axis 208 of the catheter 10 and are located in a plane (e.g., a common plane) perpendicular to the longitudinal axis 208 of the catheter 10. The polymer connectors 220 are evenly distributed along the circumference. This facilitates forming a catheter body with the same connection strength on different sides of the catheter. Alternatively or additionally, the polymer connectors 220 can be located in different corresponding planes perpendicular to the longitudinal axis 208 of the catheter 10. For example, as Figure 8As shown in FIG, the catheter 10 has two groups 700, 702 of polymer connectors 220. The polymer connectors 220 in the first group 700 are arranged circumferentially around the longitudinal axis 208 of the catheter 10 and are located in a first common plane perpendicular to the longitudinal axis 208 of the catheter 10. The polymer connectors 220 in the second group 702 are arranged circumferentially around the longitudinal axis 208 of the catheter 10 and are located in a second common plane perpendicular to the longitudinal axis 208 of the catheter 10, wherein the second common plane is different from the first common plane.

[0120] In the above examples, the polymer connector 220 has enlarged portions at opposite ends that serve as anchors to mechanically connect the first and second tubular structures 202, 204 to each other. In other examples, the polymer connector 220 may have a different configuration. For example, in other examples, the polymer connector 220 may have only one enlarged portion to serve as an anchor, or may have multiple enlarged portions. In addition, the polymer connector 220 does not need to "actively" connect the first and second tubular structures 202, 204 to each other, and in some examples, the polymer connector may be a "passive" connector. For example, Fig. 9As shown in , the first tubular structure 202 can have a protrusion 902 located at the end of the first tubular structure 202, wherein the protrusion 902 is configured to be arranged in an opening 904 at the end of the second tubular structure 204. In the example shown, the protrusion 902 is in the form of a hook, the size and shape of which are designed to be inserted into the opening 904. The opening 904 has a hook shape corresponding to the hook configuration of the protrusion 902. The size of the opening 904 is designed to accommodate at least a portion of the protrusion 902. During manufacturing, the first tubular structure 202 is positioned toward the second tubular structure 204, or vice versa, to insert the protrusion 902 into the opening 904. After the protrusion 902 is inserted into the opening 904, the first tubular structure 202 is then rotated relative to the second tubular structure 204 about the longitudinal axis, or vice versa, to move the protrusion 902 from one position in the opening 904 to another position in the opening 904, thereby locking the protrusion 902 longitudinally relative to the opening 904. As shown in the drawings, the polymer connector 220 is located in a portion of the opening 904 to prevent the protrusion 902 of the first tubular structure 202 from moving within the opening 904 after the protrusion 902 is inserted into the opening 904. Therefore, the protrusion 902 cannot move out of the opening 904 in the circumferential direction, thereby keeping the first and second tubular structures 202, 204 connected to each other. Therefore, as used in this specification, the term "connector" is not limited to a mechanical component for "connection", and may include a mechanical component (such as a lock, a stopper, a filler, a stopper, etc.) that prevents two items (e.g., two tubular structures) from being separated.

[0121] Fig.10 A method 1100 of manufacturing a portion of a catheter is shown. The method 1100 includes providing a first tubular structure (step 1102); providing a second tubular structure (step 104); arranging the first tubular structure and the second tubular structure in series relative to each other (step 1106); and forming a polymer connector in a space between an end of the first tubular structure and an end of the second tubular structure, wherein the formed polymer connector couples the first tubular structure and the second tubular structure to each other and / or prevents the first tubular structure and the second tubular structure from being separated from each other (step 1108).

[0122] Optionally, in method 1100, the first tubular structure includes a first opening located at the end of the first tubular structure; the second tubular structure includes a first opening located at the end of the second tubular structure; and the formed polymer connector includes a first connector portion arranged in the first opening at the end of the first tubular structure, and a second connector portion arranged in the first opening at the end of the second tubular structure.

[0123] Optionally, in method 1100, the first opening at the end of the first tubular structure is a laser cut opening.

[0124] Optionally, in method 1100, the first tubular structure includes a protrusion at the end of the first tubular structure; the second tubular structure includes an opening at the end of the second tubular structure, the opening being sized to accommodate at least a portion of the protrusion; and the formed polymer connector is located in a portion of the opening to prevent the protrusion of the first tubular structure from moving within the opening.

[0125] Optionally, in method 1100, the first tubular structure is a first hypotube made of a metal, an alloy, or a polymer, and wherein the second tubular structure is a second hypotube made of the metal, the alloy, the polymer, another metal, another alloy, or another polymer.

[0126] Optionally, in method 1100, the thickness of the first tubular structure is equal to the thickness of the second tubular structure.

[0127] Optionally, in method 1100, a thickness of the first tubular structure is different than a thickness of the second tubular structure.

[0128] Optionally, in method 1100, the material of the first tubular structure is the same as the material of the second tubular structure.

[0129] Optionally, in method 1100, the material of the first tubular structure is different from the material of the second tubular structure.

[0130] Optionally, in method 1100, the formed polymer connector has a first enlarged portion at a first end of the polymer connector and a second enlarged portion at a second end of the polymer connector.

[0131] Optionally, in method 1100, the polymer connector has a dumbbell shape or an I-shape.

[0132] Optionally, method 1100 further includes providing a liner, wherein the liner is located on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and wherein the polymer connector is connected to the liner.

[0133] Optionally, method 1100 further includes providing a sheath, wherein the sheath is located on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, and wherein the polymer connector is connected to the sheath.

[0134] Optionally, the step of providing a liner, the step of providing a sheath, and the step of forming a polymer connector include: arranging the liner within the first tubular structure and the second tubular structure; arranging the material of the polymer connector in the space between the end of the first tubular structure and the end of the second tubular structure; arranging the sheath around the first tubular structure and the second tubular structure; and curing the material of the polymer connector to form the polymer connector.

[0135] Optionally, in method 1100, the liner is made of a liner material, and the step of forming the polymer connector includes flowing some of the liner material into a space between an end of the first tubular structure and an end of the second tubular structure.

[0136] Optionally, in method 1100, the sheath is made of a sheath material, and the step of forming the polymer connector includes flowing some of the sheath material into a space between an end of the first tubular structure and an end of the second tubular structure.

[0137] Optionally, in method 1100, the liner material flows from the liner side to the jacket side.

[0138] Optionally, in method 1100, the jacket material flows from the jacket side to the liner side.

[0139] Optionally, in method 1100, the liner material flows out from the liner side, the jacket material flows out from the jacket side, and the liner material and the jacket material meet at a certain position in the space.

[0140] Optionally, the step of providing a liner, the step of providing a jacket, and the step of forming a polymer connector include: immersing the first tubular structure and the second tubular structure in a material to coat the first tubular structure and the second tubular structure with the material; and curing the material to form the liner, the jacket, and the polymer connector.

[0141] Optionally, the step of providing a liner, the step of providing a jacket, and the step of forming a polymer connector include: spraying the first tubular structure and the second tubular structure with a material to coat the first tubular structure and the second tubular structure with the material; and curing the material to form the liner, the jacket, and the polymer connector.

[0142] Optionally, the step of forming the polymer connector includes laminating a portion of the liner and a portion of the jacket in the space to form the polymer connector.

[0143] Optionally, in method 1100, at least a portion of the polymer connector and the jacket are made of the same material.

[0144] Optionally, in method 1100, at least a portion of the polymer connector and the liner are made of the same material.

[0145] Optionally, in method 1100, the first tubular structure and the second tubular structure have different respective inner diameters and / or different respective outer diameters.

[0146] Optionally, in method 1100, the first tubular structure and the second tubular structure have the same inner diameter and / or the same outer diameter.

[0147] Optionally, in method 1100, the formed polymer connector is configured to transfer one or more forces between the first tubular structure and the second tubular structure, and wherein the one or more forces include compression, tension, shear, torsional force, or any combination of the foregoing.

[0148] Optionally, in method 1100, the end of the first tubular structure and the end of the second tubular structure are connected to each other without welding, without brazing, and without using any adhesive.

[0149] Optionally, the method 1100 further includes: forming an additional polymer connector, wherein the additional polymer connector is configured to couple the first tubular structure and the second tubular structure to each other and / or prevent the first tubular structure and the second tubular structure from being separated from each other.

[0150] Optionally, in method 1100, the polymer connector and the additional polymer connector are arranged circumferentially around the longitudinal axis of the catheter and lie in a plane perpendicular to the longitudinal axis of the catheter.

[0151] Optionally, in method 1100, the polymer connector and the additional polymer connector are located in different respective planes that are perpendicular to the longitudinal axis of the catheter.

[0152] Optionally, in method 1100, the polymer connector and the second polymer connector are portions of the filling structure having a tubular or annular configuration.

[0153] Optionally, in method 1100, each of the first tubular structure and the second tubular structure comprises structural components, wherein the structural components of the first tubular structure are configured to abut and mate with structural components of the second tubular structure, and wherein the structural components are configured to transmit shear forces.

[0154] The polymer connectors 220 described herein are advantageous because they connect two adjacent tubular structures without welding, brazing, or any adhesive. Therefore, the tubular structures 202, 204 are not affected by the heat generated by welding or brazing. In addition, in some examples, the connection of the two tubular structures 202, 204 can be assembled while the sheath 610 / liner 600 of the catheter is formed. This provides manufacturing flexibility, that is, a series of catheters can be assembled by only changing the discrete sections of the catheter design. In addition, the polymer connector 220 allows the two tubular structures (e.g., hypotubes) to be assembled regardless of their materials and / or geometries, for example, the two tubular structures can be made of the same material or made of different corresponding materials, the two tubular structures can have the same thickness or different corresponding thicknesses, the two tubular structures can have the same inner diameter or have different corresponding inner diameters (ID), and / or the two tubular structures can have the same outer diameter or have different corresponding outer diameters (OD). In some examples, one or more polymer connectors 220 can withstand higher compressive, tensile, shear, and / or torsional forces than a butt joint without the use of welding or glue.

[0155] In the above examples, the polymer connector 220 is described as being located in the space between the tubular structures 202, 204. Figure 2 As shown in , the space between the tubular structures 202, 204 for accommodating the polymer connector 220 includes an opening 242 defined by a portion of the tubular structure 202 at the end of the tubular structure 202 and an opening 244 defined by a portion of the tubular structure 204 at the end of the tubular structure 204. Alternatively or additionally, the space between the tubular structures 202, 204 may include an area between the end of the tubular structure 202 and the end of the tubular structure 204.

[0156] In addition, the "end" of a member / structure (e.g., tubular structure 202, tubular structure 204, etc.) can be a section of the member / structure that is 1 / 10, 1 / 20, 1 / 30, 1 / 40, or 1 / 50 of the entire length of the member / structure measured from the end of the member / structure. In some examples, the "end" of a member / structure can have a longitudinal length of 1 inch, 0.5 inch, 0.4 inch, 0.3 inch, 0.2 inch, 0.1 inch, or less than 0.1 inch.

[0157] Whether or not explicitly stated, it is assumed herein that all numerical values ​​are modified by the term "about". The term "about" generally refers to a numerical range that one skilled in the art considers to be equivalent to the listed value (i.e., having the same function or result). In many cases, the term "about" may include numbers rounded to the nearest significant figure. In some cases, the term "about" may refer to a range of values ​​within + / -10% of a value. For example, a value of 2 or about 2 may refer to any value within the range of 2+ / -10% (= 2+ / -0.2 = 1.8 to 2.2).

[0158] The recitation of numerical ranges by endpoints includes all numbers within that range (eg, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

[0159] As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural references unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term "or" is generally used in its meaning and includes "and / or" unless the content clearly dictates otherwise.

[0160] Although specific embodiments have been shown and described, it should be understood that it is not intended to limit the claimed invention to these preferred embodiments, and it is obvious to those skilled in the art that various changes and modifications (e.g., the size and / or shape of the various components) may be made without departing from the spirit and scope of the claimed invention. Therefore, the description and drawings are to be regarded as illustrative rather than restrictive. The claimed invention is intended to cover alternatives, modifications, and equivalents.

Claims

1. A catheter, comprising: a first tubular structure; a second tubular structure, wherein the first tubular structure and the second tubular structure are arranged in series relative to each other along a longitudinal axis of the catheter; and a polymer connector located between (1) a portion of the first tubular structure at an end of the first tubular structure and (2) a portion of the second tubular structure at an end of the second tubular structure; Wherein, the polymer connector is configured to connect the first tubular structure and the second tubular structure to each other and / or prevent the first tubular structure and the second tubular structure from being separated from each other.

2. The catheter according to claim 1, wherein: The first tubular structure includes a first opening at an end of the first tubular structure; the second tubular structure comprising a first opening at an end of the second tubular structure; and The polymer connector includes: a first connector portion disposed in a first opening at an end of the first tubular structure; and a second connector portion disposed in the first opening at the end of the second tubular structure.

3. The catheter according to claim 2, wherein: The first opening at the end of the first tubular structure is a laser cut opening.

4. The catheter of claim 1, wherein: The first tubular structure includes a protrusion at an end of the first tubular structure; the second tubular structure comprising an opening at an end of the second tubular structure, the opening being sized to receive at least a portion of the protrusion; and The polymer connector is located in a portion of the opening to prevent the protrusion of the first tubular structure from moving within the opening.

5. The catheter according to any one of claims 1 to 4, wherein: The first tubular structure is a first hypotube made of a metal, an alloy or a polymer, and wherein the second tubular structure is a second hypotube made of the metal, the alloy, the polymer, another metal, another alloy or another polymer.

6. The catheter according to any one of claims 1 to 5, further comprising an inner liner, wherein: The liner is located on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and wherein the polymeric connector is connected to the liner.

7. The catheter according to claim 6, further comprising a sheath, wherein The sheath is located on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, and wherein the polymeric connector is connected to the sheath.

8. The catheter according to claim 7, wherein At least a portion of the polymer connector and the sheath are made of the same material.

9. The catheter according to any one of claims 1 to 8, wherein: The first tubular structure and the second tubular structure are made of different respective materials.

10. The catheter according to any one of claims 1 to 9, wherein: The first tubular structure and the second tubular structure have different respective inner diameters and / or different respective outer diameters.

11. The catheter according to any one of claims 1 to 9, wherein: The first tubular structure and the second tubular structure have the same inner diameter and / or the same outer diameter.

12. The catheter according to any one of claims 1 to 11, wherein The polymer connector is configured to transfer one or more forces between the first tubular structure and the second tubular structure, and wherein the one or more forces include compressive forces, tensile forces, shear forces, torsional forces, or any combination of the foregoing.

13. The catheter according to any one of claims 1 to 12, wherein: The end of the first tubular structure and the end of the second tubular structure are connected to each other without welding, without brazing, and without adhesive.

14. The catheter according to any one of claims 1 to 13, wherein: The polymer connector has a first enlarged portion at a first end of the polymer connector and a second enlarged portion at a second end of the polymer connector.

15. The catheter according to any one of claims 1 to 14, further comprising an additional polymer connector, wherein: The additional polymer connector is configured to couple the first tubular structure and the second tubular structure to each other and / or prevent the first tubular structure and the second tubular structure from being separated from each other.

16. The catheter of claim 15, wherein: The polymer connector and the additional polymer connector are arranged circumferentially around the longitudinal axis of the catheter and lie in a plane perpendicular to the longitudinal axis of the catheter.

17. The catheter of claim 15, wherein: The polymer connector and the additional polymer connector are located in different respective planes that are perpendicular to the longitudinal axis of the catheter.

18. The catheter of claim 15, wherein: The polymer connector and the additional polymer connector are portions of the filling structure having a tubular or annular configuration.

19. The catheter of claim 1, wherein: Each of the first tubular structure and the second tubular structure includes a structural component, wherein the structural component of the first tubular structure is configured to abut and mate with a structural component of the second tubular structure, and wherein the structural component is configured to transmit shear forces.

20. A method of manufacturing a portion of a catheter, the method comprising: providing a first tubular structure; providing a second tubular structure; placing the first tubular structure and the second tubular structure in series relative to each other; as well as A polymer connector is formed in a space between an end of the first tubular structure and an end of the second tubular structure, wherein the formed polymer connector connects the first tubular structure and the second tubular structure to each other and / or prevents the first tubular structure and the second tubular structure from being separated from each other.

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