Introducer needle, catheter insertion assembly and method of manufacture

Abstract

The introducer needle may include a needle shaft (144), a sheath (142) covering the needle shaft, and a needle hub (146) around a proximal portion of each of the needle shaft and sheath. The needle shaft may include a needle slot (150) extending from the proximal portion of the needle shaft to the distal needle tip, and the needle tip may include a bevel having a tip bevel (152) and a heel (154). The needle shaft may include opposing needle slot walls (230) that a) face each other and are parallel or oblique to each other, or b) face toward or away from the bottom of the needle slot. Additionally or alternatively, the opposing needle shaft walls may be parallel to each other. The sheath covering the needle shaft may seal the needle slot below it, except for a sheath opening at the proximal portion of the sheath.

Description

[Technical field]

[0001] The present disclosure relates to introducer needles, catheter insertion assemblies, and methods of manufacture thereof. [Background technology]

[0002] Central venous catheters ("CVCs") are typically introduced into a patient and advanced through the patient's vascular system via the Seldinger technique. The Seldinger technique utilizes many steps and medical devices (e.g., needles, scalpels, guidewires, introducer sheaths, dilators, CVCs, etc.). Although the Seldinger technique is effective, many steps are time consuming and many medical devices are cumbersome to handle, which can lead to trauma to the patient. In addition, there is a relatively high chance of contact contamination due to the large number of medical devices that need to be replaced during the Seldinger technique. Thus, there is a need to reduce the number of steps and medical devices involved in introducing a catheter, such as a CVC, into a patient and advancing the catheter through the patient's vascular system.

[0003] Disclosed herein is an introducer needle for a rapidly insertable central catheter ("RICC") insertion assembly and method that addresses the above. Summary of the Invention

[0004] Disclosed herein, in some embodiments, is an introducer needle that includes a needle shaft, a sheath covering the needle shaft, and a needle hub around both a proximal portion of the needle shaft and a proximal portion of the sheath. The needle shaft includes a needle slot extending from the proximal portion of the needle shaft to a distal needle tip, the needle tip including a bevel having a tip bevel and a heel. The needle shaft includes one or more features selected from the group of features consisting of: a) opposing needle slot walls face each other and are parallel to each other consistent with a needle slot cut into the needle shaft, b) opposing needle slot walls face each other but are angled to each other consistent with a needle shaft that is stamped or rolled to form the needle slot, c) opposing needle slot walls face away from the bottom of the needle slot consistent with a needle slot that is ground into the needle shaft, d) opposing needle slot walls face toward the bottom of the needle slot consistent with opposing needle slot walls that are bent toward the bottom of the needle slot, and e) opposing needle shaft walls are parallel to each other consistent with a needle shaft that is stamped or rolled to form the needle slot. A sheath covering the needle shaft seals the needle slot below it except for a sheath opening at a proximal portion of the sheath.

[0005] In some embodiments, the needle slot extends along at least a portion of the upper portion of the needle shaft. The upper portion of the needle shaft includes a beveled heel. In some embodiments, the needle slot extends along at least a portion of the bottom of the needle shaft, the bottom of the needle shaft including a beveled tip.

[0006] In some embodiments, the needle slot extends along at least a portion of a side of the needle shaft, the side of the needle shaft being between the heel of the bevel and the tip bevel. In some embodiments, the needle slot bisects the heel of the bevel.

[0007] In some embodiments, the needle slot bisects the distal bevel of the bevel. In some embodiments, the needle slot intersects the heel, tip bevel, or both the heel and tip bevel of the bevel without bisecting the heel or tip bevel of the bevel.

[0008] In some embodiments, the needle slot is linear from the proximal portion of the needle shaft to the needle tip. In some embodiments, the needle slot is non-linear from the proximal portion of the needle shaft to the needle tip.

[0009] In some embodiments, the needle slot is at least partially helical. The needle slot forms at least a portion of a helix between a proximal portion of the needle shaft and the needle tip. In some embodiments, the needle slot has a constant needle slot width.

[0010] In some embodiments, the needle slot has a non-constant needle slot width. In some embodiments, the needle slot includes one or more needle slot openings that are wider than the remainder of the needle slot.

[0011] In some embodiments, the needle slot comprises a taper, reverse taper, or a gradual change in needle slot width from the proximal portion of the needle shaft to the needle tip. In some embodiments, the needle slot is located short of the proximal end of the needle shaft.

[0012] In some embodiments, the needle slot extends through the proximal end of the needle shaft. In some embodiments, the edges of the needle slot walls are finished to minimize or eliminate sharp access guidewire fraying edges in the needle slot.

[0013] Also disclosed herein, in some embodiments, is a RICC insertion assembly including a RICC, an introducer needle, an access guidewire disposed within the RICC and introducer needle, and a coupler coupling the RICC and introducer needle to one another. The RICC includes a catheter tube and a primary lumen therethrough. The introducer needle includes a needle shaft, a sheath covering the needle shaft, and a needle hub around both a proximal portion of the needle shaft and a proximal portion of the sheath. The needle shaft includes a needle slot extending from a proximal portion of the needle shaft to a distal needle tip, and the needle tip includes a bevel having a tip bevel and a heel. The needle shaft includes one or more features selected from the group of features consisting of: a) the opposing needle slot walls face each other and are parallel to each other consistent with a needle slot cut into the needle shaft, b) the opposing needle slot walls face each other but are oblique to each other consistent with a needle shaft that is stamped or rolled to form the needle slot, c) the opposing needle slot walls face away from the bottom of the needle slot consistent with a needle slot that is ground into the needle shaft, d) the opposing needle slot walls face toward the bottom of the needle slot consistent with opposing needle slot walls that are bent toward the bottom of the needle slot, and e) the opposing needle shaft walls are parallel to each other consistent with a needle shaft that is stamped or rolled to form the needle slot. A sheath covering the needle shaft seals the needle slot below it except for a sheath opening at a proximal portion of the sheath. The access guidewire includes a proximal portion disposed within the primary lumen of the RICC and a distal portion disposed within the needle shaft through both the sheath opening and the needle slot.

[0014] In some embodiments, the needle slot extends along at least a portion of the upper portion of the needle shaft. The upper portion of the needle shaft includes a beveled heel. In some embodiments, the needle slot extends along at least a portion of the bottom of the needle shaft, the bottom of the needle shaft including a beveled tip.

[0015] In some embodiments, the needle slot extends along at least a portion of a side of the needle shaft, the side of the needle shaft being between the heel of the bevel and the tip bevel. In some embodiments, the needle slot bisects the heel of the bevel.

[0016] In some embodiments, the needle slot bisects the distal bevel of the bevel. In some embodiments, the needle slot intersects the heel, tip bevel, or both the heel and tip bevel of the bevel without bisecting the heel or tip bevel of the bevel.

[0017] In some embodiments, the needle slot is linear from the proximal portion of the needle shaft to the needle tip. In some embodiments, the needle slot is non-linear from the proximal portion of the needle shaft to the needle tip.

[0018] In some embodiments, the needle slot is at least partially helical. The needle slot forms at least a portion of a helix between the proximal portion of the needle shaft and the needle tip. In some embodiments, the needle slot has a constant needle slot width.

[0019] In some embodiments, the needle slot has a non-constant needle slot width. In some embodiments, the needle slot includes one or more needle slot openings that are wider than the remainder of the needle slot.

[0020] In some embodiments, the needle slot comprises a taper, reverse taper, or a gradual change in needle slot width from the proximal portion of the needle shaft to the needle tip. In some embodiments, the needle slot is located short of the proximal end of the needle shaft.

[0021] In some embodiments, the needle slot extends through the proximal end of the needle shaft. In some embodiments, the edges of the needle slot walls are finished to minimize or eliminate sharp access guidewire fraying edges in the needle slot.

[0022] In some embodiments, the coupler includes a coupler housing including a sealing module cavity and a sealing module insert disposed within the sealing module cavity. The sealing module cavity and the sealing module insert form a sealing module of the RICC insertion assembly. The sealing module is configured to separately seal around a proximal portion of the introducer needle including the sheath opening and a distal portion of the access guidewire when compressed within the sealing module cavity.

[0023] In some embodiments, the coupler housing includes a longitudinal coupler housing slot configured to allow the access guidewire to exit the coupler housing after the distal portion of the sealing module insert is removed from the sealing module cavity by withdrawal of the introducer needle from the coupler.

[0024] In some embodiments, the coupler includes a blade extending into the sealing module to be disposed in the needle slot beneath the distal end of the sheath opening, the blade including a distally facing blade edge configured to decouple the sheath from the needle shaft when the introducer needle is withdrawn from the coupler, thereby allowing the access guidewire to exit the needle shaft through the needle slot.

[0025] Also disclosed herein is a method of making an introducer needle. The method, in some embodiments, includes a needle slot creation step, a sheath placement step, and a needle hub securing step. The needle slot creation step includes creating a needle slot in the needle shaft. The needle slot extends from a proximal portion of the needle shaft to a distal needle tip, the needle tip including a bevel having a tip bevel and a heel. The sheath placement step includes placing a sheath over the needle shaft. The sheath seals the needle slot therebelow. The needle hub securing step includes securing a needle hub around both the proximal portion of the needle shaft and the proximal portion of the sheath, thereby forming an introducer needle.

[0026] In some embodiments, the needle slot creating step comprises cutting the needle slot into the needle shaft by machining or laser cutting. In some embodiments, the opposing needle slot walls face each other and are parallel to each other after cutting. In addition, the needle slot walls face the bottom of the needle slot.

[0027] In some embodiments, the needle slot creating step comprises grinding the needle slot into the needle shaft. In some embodiments, the opposing needle slot walls face away from the bottom of the needle slot after grinding.

[0028] In some embodiments, the method further comprises a wall bending step, the wall bending step comprising bending the needle slot wall towards a bottom of the needle slot, thereby increasing bending strength of the needle shaft.

[0029] In some embodiments, the method further comprises an edge finishing step, which comprises finishing the edges of the needle slot walls to thereby minimize or eliminate sharp access guidewire frayed edges in the needle slot.

[0030] In some embodiments, the sheath positioning step includes inserting the needle shaft into the sheath. In some embodiments, the sheath positioning step further comprises heat shrinking the sheath over the needle shaft.

[0031] In some embodiments, the method further comprises a sheath opening creating step, the sheath opening creating step comprising creating a sheath opening in the sheath, the sheath sealing the needle slot thereunder except for the sheath opening in a proximal portion of the sheath.

[0032] In some embodiments, the sheath opening creating step comprises cutting a sheath opening into the needle shaft by laser cutting after placing the sheath over the needle shaft in the sheath placing step.

[0033] In some embodiments, the needle hub securing step includes bonding the needle hub to both the proximal portion of the needle shaft and the proximal portion of the sheath. In some embodiments, the needle hub securing step includes forcing both the proximal portion of the needle shaft and the proximal portion of the sheath into the needle hub with an engineered fit selected from a transition fit and an interference fit.

[0034] In some embodiments, the method further includes a metal strip rolling step, a seam welding step, a cold working step, and a grinding step. The metal strip rolling step includes rolling the metal strip into a metal tube. The metal tube includes a longitudinal seam formed between longitudinal side edges of the metal strip. The seam welding step includes welding the seam. The cold working step includes forcing the metal tube through one or more dies, thereby simultaneously reducing an outer diameter of the metal tube and increasing a metal tube wall thickness of the metal tube. The grinding step includes grinding an end of the metal tube at multiple angles to form a needle shaft having a needle tip with a beveled end.

[0035] These and other features of the concepts provided herein will become more apparent to those of ordinary skill in the art upon consideration of the following description and accompanying drawings, which describe in more detail certain embodiments of such concepts. [Brief description of the drawings]

[0036] [Figure 1] 1 illustrates a RICC insertion assembly, according to some embodiments. [Diagram 2] 1 illustrates a perspective view of a coupler of a RICC insertion assembly, according to some embodiments. [Diagram 3] 1 illustrates a longitudinal cross section of a coupler and its splittable sealing module according to some embodiments. [Figure 4] 1 illustrates a longitudinal cross-section of a needle hub and proximal and distal portions of a sealing module insert according to some embodiments. [Diagram 5] FIG. 1 illustrates a top view of an introducer needle, according to some embodiments. [Figure 6] 1 illustrates a sheath for an introducer needle, according to some embodiments. [Figure 7A] 1 illustrates a needle shaft of an introducer needle having a needle slot extending along at least a portion of the top of the needle shaft, according to some embodiments. [Figure 7B] 13A-13C show a needle shaft having a needle slot opening at a proximal portion of the needle shaft, according to some embodiments. [Figure 7C] 1 illustrates a needle shaft having a needle slot opening at a distal portion of the needle shaft, according to some embodiments. [Figure 7D] 1 illustrates a needle shaft having a needle slot extending along at least a portion of a side of the needle shaft, according to some embodiments. [Figure 7E] 1 illustrates a needle shaft having a partially helical needle slot extending along the needle shaft, according to some embodiments. [Figure 7F] 13A-13C show a needle shaft having another partially helical needle slot extending along the needle shaft, according to some embodiments. [Figure 8A] 14A shows a detailed view of the distal portion of the needle shaft, where the needle slot bisects the heel of the bevel of the needle tip, according to some embodiments. [Figure 8B] 13A-13C show detailed views of a distal portion of a needle shaft in which the needle slot intersects both the heel and tip bevel of the bevel without bisecting the heel or tip bevel, according to some embodiments. [Figure 9A] 14A-14C show cross-sectional views of needle shafts with opposing needle slot walls facing each other and parallel to each other, according to some embodiments. [Figure 9B] 14A-14C show cross-sectional views of needle shafts with opposing needle slot walls facing each other and angled relative to each other, according to some embodiments. [Figure 9C] 14A-14C show cross-sectional views of a needle shaft with opposing needle slot walls facing away from the bottom of the needle slot, according to some embodiments. [Figure 9D] 14A-14C show cross-sectional views of a needle shaft with opposing needle slot walls facing away from the bottom of the needle slot, according to some embodiments. [Figure 9E] FIG. 13 shows a cross-sectional view of a needle shaft with opposing needle shaft walls parallel, according to some embodiments. [Figure 10] 1 illustrates a RICC of a RICC insertion assembly, according to some embodiments. [Figure 11] 1 shows a detailed view of a distal portion of a catheter tube of a RICC, according to some embodiments. [Figure 12] FIG. 1 shows a cross-sectional view of a distal portion of a catheter tube according to some embodiments. [Figure 13] 13 shows another cross-sectional view of a distal portion of a catheter tube according to some embodiments. [Figure 14] 1 shows a longitudinal cross-sectional view of a distal portion of a catheter tube according to some embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] Before some specific embodiments are disclosed in more detail, it should be understood that the specific embodiments disclosed herein do not limit the scope of the concepts provided herein. It should also be understood that the specific embodiments disclosed herein can have features that can be easily separated from the specific embodiment and, optionally, combined with or substituted for features of any of the other numerous embodiments disclosed herein.

[0038] With regard to the terms used herein, it should also be understood that the terms are intended to describe certain embodiments, and that the terms do not limit the scope of the concepts provided herein. Ordinal numbers (e.g., first, second, third, etc.) are generally used to distinguish or identify different features or steps within a group of features or steps, and do not provide sequential or numerical limitations. For example, the "first", "second", and "third" features or steps do not necessarily have to appear in that order, and a particular embodiment including such features or steps is not necessarily limited to three features or steps. In addition, any of the aforementioned features or steps may further include one or more features or steps, unless otherwise indicated. Designations such as "left", "right", "up", "down", "front", "rear", etc. are used for convenience and do not imply, for example, a particular fixed position, orientation, or direction. Instead, such designations are used to reflect, for example, a relative position, orientation, or direction. The singular forms "one", "one", and "the" also include plural references unless the context clearly dictates otherwise.

[0039] With respect to "proximal," for example, a "proximal portion" or "proximal end portion" of a catheter includes a portion of the catheter that is intended to be near a clinician when the catheter is used with a patient. Similarly, for example, a "proximal length" of a catheter includes a length of the catheter that is intended to be near a clinician when the catheter is used with a patient. For example, a "proximal end" of a catheter includes an end of the catheter that is intended to be near a clinician when the catheter is used with a patient. Although a proximal portion, proximal end portion, or proximal length of a catheter can include the proximal end of the catheter, a proximal portion, proximal end portion, or proximal length of a catheter need not include the proximal end of the catheter. That is, unless otherwise indicated by context, a proximal portion, proximal end portion, or proximal length of a catheter is not a terminal portion or terminal length of a catheter.

[0040] With respect to "distal," for example, a "distal portion" or "distal end portion" of a catheter includes a portion of a catheter that is intended to be near or within a patient when the catheter is used with a patient. Similarly, for example, a "distal length" of a catheter includes a length of a catheter that is intended to be near or within a patient when the catheter is used with a patient. For example, a "distal end" of a catheter includes an end of a catheter that is intended to be near or within a patient when the catheter is used with a patient. Although a distal portion, distal end portion, or distal length of a catheter can include the distal end of the catheter, a distal portion, distal end portion, or distal length of a catheter need not include the distal end of the catheter. That is, unless otherwise suggested by context, a distal portion, distal end portion, or distal length of a catheter is not a terminal portion or terminal length of a catheter.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. As described above with respect to the Seldinger procedure, many steps are time consuming and many medical devices are cumbersome to handle, which can lead to trauma to the patient. In addition, due to the large number of medical devices that need to be replaced during the Seldinger procedure, the potential for contact contamination is relatively high. Thus, there is a need to reduce the number of steps and medical devices involved in introducing a catheter, such as a CVC, into a patient and advancing the catheter through the patient's vascular system.

[0042] Disclosed herein is an introducer needle for an insertion assembly and method of RICC that addresses the above. For example, the introducer needle can include a needle shaft, a sheath covering the needle shaft, and a needle hub around the proximal portion of each of the needle shaft and the sheath. The needle shaft includes a needle slot extending from the proximal portion of the needle shaft to a distal needle tip, and the needle tip includes a beveled end having a tip bevel and a heel. The needle shaft includes opposing needle slot walls that a) face each other and are parallel or oblique to each other, or b) face toward or point away from the bottom of the needle slot. Additionally or alternatively, the opposing needle shaft walls can be parallel to each other. The sheath covering the needle shaft seals the needle slot below it, except for a sheath opening at the proximal portion of the sheath.

[0043] The foregoing and other features of the introducer needle, RICC insertion assembly, and method disclosed herein will become more apparent to those skilled in the art upon consideration of the accompanying drawings and the following description, which describe in more detail certain embodiments of the introducer needle, RICC insertion assembly, and method, beginning with the RICC insertion assembly. However, it should be understood that the RICC of the RICC insertion assembly is only one type of catheter that may be incorporated into a catheter insertion assembly such as that disclosed herein. Indeed, peripherally inserted central catheters ("PICCs"), dialysis catheters, and the like, may also be incorporated into a catheter insertion assembly and method such as that disclosed herein.

[0044] RICC Insertion Assembly FIG. 1 illustrates a RICC insertion assembly 100 according to some embodiments. As shown, the RICC insertion assembly 100 includes a RICC 102, an introducer needle 104, an access guidewire 106, and a coupler 108 that couples the RICC 102, the introducer needle 104, and the access guidewire 106 together in a ready-to-operate state of the RICC insertion assembly 100. As described in more detail below, in a ready-to-operate state of the RICC insertion assembly 100, a proximal end of the access guidewire 106 is coupled to the coupler 108 and a distal end of the access guidewire 106 is disposed within a needle lumen 158 of the introducer needle 104. This allows for a loop 110 of the access guidewire 106 with the RICC 102 disposed over the loop 110 in the ready-to-operate state of the RICC insertion assembly 100, keeping the RICC insertion assembly 100 in a relatively compact configuration.

[0045] The RICC insertion assembly 100 may further include a syringe 112 fluidly coupled to the introducer needle 104 in a ready-to-operate state of the RICC insertion assembly 100. As described below, the splittable sealing module 196 seals around a proximal portion of the introducer needle 104 and a distal portion of the access guidewire 106 when the sealing module insert 198 is compressed within the sealing module cavity 178 in one or more states of the RICC insertion assembly 100. In particular, the splittable sealing module 196 covers and seals a sheath opening 162 of the sheath 142 that opens to a needle slot 150 of the needle shaft 144. Outside of the splittable sealing module 196, the sheath 142 seals the needle slot 150 of the needle shaft 144. Such a seal allows the syringe 112 to aspirate blood in accordance with a blood aspirating step of the method described below.

[0046] FIG. 10 illustrates a RICC 102 of a RICC insertion assembly 100, according to some embodiments. As shown, the RICC 102 includes a catheter tube 114 , a catheter hub 116 , one or more extension legs 118 , and one or more extension leg connectors 120 .

[0047] 11-14 show various views of the catheter tube 114 of the RICC 102, according to some embodiments. The catheter tube 114 includes a first section 122 at a distal portion of the catheter tube 114, a second section 124 at a distal portion of the catheter tube 114 proximal to the first section 122, and a tapered junction 126 between the first section 122 and the second section 124 of the catheter tube 114.

[0048] The first section 122 of the catheter tube 114 includes a catheter tip 128 having a relatively short taper from an outer diameter of the distal portion of the first section 122 distal to the junction 126 to an outer diameter of the distal end of the first section 122. The taper of the catheter tip 128 is configured to immediately dilate tissue around the needle tract established by the introducer needle 104 to the outer diameter of the distal portion of the first section 122 of the catheter tube 114. As best shown in FIG. 14, the first section 122 of the catheter tube 114 also includes a proximal portion that is disposed within a bore in the distal portion of the junction 126 and is fixedly attached thereto, such as by solvent bonding, adhesive bonding, or heat welding.

[0049] The second section 124 of the catheter tube 114 includes a constant outer diameter along its length from the distal end of the second section 124 to the proximal end of the second section 124. The constant diameter of the second section 124 of the catheter tube 114 is configured for smooth insertion into the needle tract and target vasculature after any expansion by the first section 122 and junction 126 of the catheter tube 114. The distal end of the second section 124 of the catheter tube 114 has a flat surface that is flush with and fixedly bonded to the flat surface proximal end of junction 126, such as by solvent bonding, adhesive bonding, or heat welding.

[0050] The junction 126 includes a taper over its length from the proximal end of the junction 126 to the distal end of the junction 126. The taper of the junction 126 is configured to instantly expand the tissue around the needle tract from the outer diameter of the proximal portion of the first section 122 of the catheter tube 114 to the outer diameter of the second section 124 of the catheter tube 114. The abluminal surface of the junction 126 provides a smooth transition from the abluminal surface of the first section 122 of the catheter tube 114 to the abluminal surface of the second section 124 of the catheter tube 114 without creating an edge that can catch on the skin when the catheter tube 114 is inserted into the needle tract. In addition to having minimal to negligible edges, the edges may include solvent interdiffusion polymeric material of the polymeric material forming the catheter tube 114, which provides a smooth transition from the first section 122 of the catheter tube 114 to the junction 126, and from the junction 126 to the second section 124 of the catheter tube 114. In particular, the junction 126 has a length that is approximately equal to the length of the exposed portion of the first section 122 of the catheter tube 114, or a length between the lengths of the exposed portions of the first section 122 and the second section 124 of the catheter tube 114. Thus, the length of the exposed portion of the first section 122 of the catheter tube 114 is less than the length of the junction 126, and at most approximately equal to the length of the junction 126.

[0051] The first section 122 of the catheter tube 114 is formed from a first polymeric material (e.g., polytetrafluoroethylene, polypropylene, or polyurethane) having a first durometer. The second section 124 of the catheter tube 114 is formed from a second polymeric material (e.g., polyvinyl chloride, polyethylene, another polyurethane, or silicone) having a second durometer less than the first durometer. For example, the first section 122 of the catheter tube 114 can be formed from a first polyurethane having a first durometer, and the second section 124 of the catheter tube 114 can be formed from a second, different polyurethane (e.g., the same or different diisocyanates or triisocyanates reacted with different diols or triols, different diisocyanates or triisocyanates reacted with the same or different diols or triols, the same diisocyanates or triisocyanates reacted with the same diols or triols under different conditions or with different additives, etc.) having a second durometer that is less than the first durometer. Indeed, polyurethanes are advantageous for the catheter tube 114 in that they are relatively stiff at room temperature, but can become more flexible in vivo at body temperature, thereby reducing irritation to the vessel wall and phlebitis. Polyurethanes are also advantageous in that they can be less thrombogenic than some other polymers. The joint 126 is formed from a second polymeric material or a third polymeric material (e.g., yet another polyurethane) having a third durometer less than the first durometer and greater than, approximately equal to, or less than the second durometer.

[0052] It should be understood that the first durometer of the first polymeric material, the second durometer of the second polymeric material, and the third durometer of the third polymeric material may be on different scales (e.g., Type A or Type D). With this understanding, the second durometer of the second polymeric material or the third durometer of the third polymeric material may not be numerically less than the first durometer of the first polymeric material when the second durometer or the third durometer is less than the first durometer. In fact, the hardness of the second polymeric material or the third polymeric material may be even less than the hardness of the first polymeric material because the different scales, each ranging from 0 to 100, are designed to characterize different materials in a group of materials having similar hardness.

[0053] With the first section 122 of the catheter tube 114, the second section 124 of the catheter tube 114, and the junction 126 between the first section 122 and the second section 124 of the catheter tube 114 described above, the catheter tube 114 has sufficient column strength to prevent buckling of the catheter tube 114 when inserted into a needle tract established by an introducer needle 104, described below. The column strength of the catheter tube 114 is also sufficient to prevent buckling of the catheter tube 114 when advanced through a patient's vasculature without pre-dilating the tissue around the needle tract or any of the vessels of the vasculature with a separate dilator.

[0054] The catheter tube 114 includes one or more catheter tube lumens extending therethrough. However, typically in a multi-lumen RICC (e.g., a two-lumen RICC, a three-lumen RICC, a four-lumen RICC, a five-lumen RICC, a six-lumen RICC, etc.), there is only one catheter tube lumen extending from the proximal end of the catheter tube 114 to the distal end of the catheter tube 114. (See FIGS. 11-14.) In fact, the first section 122 of the catheter tube 114 typically has a single lumen passing therethrough, as shown in FIGS. 12 and 14.

[0055] A catheter hub 116 is coupled to a proximal portion of the catheter tube 114. The catheter hub 116 includes one or more catheter hub lumens corresponding in number to the one or more catheter tube lumens. The one or more catheter hub lumens extend entirely through the catheter hub 116 from the proximal end of the catheter hub 116 to the distal end of the catheter hub 116.

[0056] Each of the one or more extension legs 118 is coupled by its distal portion to the catheter hub 116. Each of the one or more extension legs 118 includes one or more extension leg lumens, the number of which corresponds to the number of the one or more catheter hub lumens. Each of the one or more extension leg lumens extends entirely through the extension leg from a proximal end of the extension leg to a distal end of the extension leg.

[0057] Each of the one or more extension leg connectors 120 is on a proximal portion of the extension leg of one or more extension legs 118. For example, each of the one or more extension leg connectors 120 can be a luer connector on a proximal portion of the extension leg of one or more extension legs 118. Through such extension leg connector, the corresponding extension leg and its extension leg lumen can be connected to another medical device and its lumen. However, in the ready-to-operate state of the RICC insertion assembly 100, at least one extension leg connector (e.g., an extension leg connector including a portion of the primary lumen 130 of the RICC 102) is indirectly connected to the access guidewire connection side arm 174 of the coupler 108 via the intervening access guidewire hub 218 to realize the loop 110 of the access guidewire 106 and the RICC 102 thereon.

[0058] As shown, the RICC 102 is a tri-lumen RICC including a set of three lumens. However, the RICC 102 is not limited to the set of three lumens as described above. The set of three lumens includes a primary lumen 130, a secondary lumen 132, and a tertiary lumen 134 formed from fluidly connected portions of three catheter tube lumens, three catheter hub lumens, and three extension leg lumens. The primary lumen 130 has a primary lumen aperture 136 at the distal end of the first section 122 of the catheter tube 114, which corresponds to the distal end of the catheter tube 114 and the distal end of the RICC 102. The secondary lumen 132 has a secondary lumen aperture 138 on the side of the distal portion of the catheter tube 114. The tertiary lumen 134 has a tertiary lumen aperture 140 on the side of the distal portion of the catheter tube 114 proximal to the secondary lumen aperture 138 .

[0059] Figure 5 shows a top view of the introducer needle 104 of the RICC insertion assembly 100, according to some embodiments. Figure 6 shows the sheath 142 of the introducer needle 104, according to some embodiments. Figures 7A-7F, 8A, 8B, and 9A-9E show various views of the needle shaft 144 of the introducer needle 104, according to some embodiments.

[0060] As shown, the introducer needle 104 includes a needle shaft 144, a sheath 142 that covers the needle shaft 144, and a needle hub 146 within a proximal portion of the introducer needle 104 that covers both the proximal end portion of the needle shaft 144 and the proximal end portion of the sheath 142. In addition, the introducer needle 104 can be considered to include a proximal portion 200 of the sealing module insert 198 coupled to a distal portion of the needle hub 146, particularly if the proximal portion 200 of the sealing module insert 198 is fixedly rather than removably coupled to the needle hub 146. At least in the ready-to-operate state of the RICC insertion assembly 100, the needle shaft 144 and sheath 142 extend from the needle hub 146, through the splittable sealing module 196, and out the distal end of the coupler housing 172.

[0061] The needle shaft 144 includes a needle tip 148 at a distal portion of the needle shaft 144 and a longitudinal needle slot 150 that extends from a proximal portion of the needle shaft 144 to the needle tip 148 . The needle tip 148 includes a bevel having a distal or secondary bevel 152 and a primary bevel 154 proximal to the distal bevel 152, the primary bevel 154 terminating in a proximal heel. The distal bevel angle of the distal bevel 152 is greater than the primary bevel angle of the primary bevel 154 (e.g., 7°-21°, e.g., 14°) such that the bevel provides a smooth transition across the needle tip 148. Such a needle tip is thus configured to establish a needle path from an area of ​​skin into a vascular lumen of a patient in accordance with the needle path establishment steps of the method described below. In particular, the top of the needle shaft 144 includes the bevel heel, the bottom of the needle shaft 144 includes the bevel distal bevel 152, and the side of the needle shaft 144 is between the bevel heel and the distal bevel 152.

[0062] The needle slot 150 extends from the proximal portion of the needle shaft 144 to the needle tip 148, thereby forming a needle channel 156 along most of the length of the needle shaft 144 (e.g., about 3 to 5 inches, e.g., about 3.4 inches or 4.3 inches), as opposed to a needle lumen through the needle shaft 144.

[0063] The needle slot 150 may extend along at least a portion of the top of the needle shaft 144, for example, from a small portion of the top of the needle shaft 144 to most of the top of the needle shaft 144, but only short of the proximal end of the needle shaft 144 (e.g., about 0.2 to 0.3 inches). The needle slot 150 may even extend along the entire top of the needle shaft 144, including the proximal end of the needle shaft 144, as suggested in FIG. 7A. As shown in FIGS. 7A-7C, for example, the needle slot 150 is linear, extending along most of the top of the needle shaft 144 from the proximal portion of the needle shaft 144 to the needle tip 148, and from just short of the proximal end of the needle shaft 144, bisecting the heel of the bevel as shown in FIG. 8A. However, the needle slot 150 may also be non-linear, such as at least partially helical, as described below.

[0064] The needle slot 150 may extend along at least a portion of the bottom of the needle shaft 144, for example, from a small portion of the bottom of the needle shaft 144 to most of the bottom of the needle shaft 144, but only short of the proximal end of the needle shaft 144 (e.g., about 0.2 to 0.3 inches). The needle slot 150 may even extend along the entire bottom of the needle shaft 144, including the proximal end of the needle shaft 144. Although not shown, the needle slot 150 may be linear and may extend along most of the bottom of the needle shaft 144 from the proximal portion of the needle shaft 144 to the needle tip 148, bisecting the beveled tip 152 just short of the proximal end of the needle shaft 144. However, the needle slot 150 may also be non-linear, such as at least partially helical, as described below.

[0065] The needle slot 150 may extend along at least a portion of the side of the needle shaft 144, for example, from a small portion of the side of the needle shaft 144 to a majority of the side of the needle shaft 144, but only short of the proximal end of the needle shaft 144 (e.g., about 0.2 to 0.3 inches). The needle slot 150 may even extend along the entire side of the needle shaft 144, including the proximal end of the needle shaft 144. As shown in FIG. 7D, for example, the needle slot 150 may be linear and extend along a majority of the top of the needle shaft 144 from the proximal portion of the needle shaft 144 to the needle tip 148, but only short of the proximal end of the needle shaft 144, intersecting the heel of the bevel, the tip bevel 152, or both the heel and the tip bevel 152, without bisecting the heel of the bevel or the tip bevel 152, as shown in FIG. 8B. However, needle slot 150 may also be non-linear, such as at least partially helical, as described below.

[0066] The needle slot 150, in view of the above, may extend along at least a portion of the top, bottom, or side of the needle shaft 144, for example, from a small portion of the top, bottom, or side of the needle shaft 144 to a majority of the top, bottom, or side of the needle shaft 144 (but not to the proximal end of the needle shaft 144). Also, such needle slots are not limited to being linear. In fact, the needle slot 150 may be non-linear, such as at least partially helical, as described below. By varying the implementation of the needle slot 150, the bending strength of the needle shaft 144 can be varied as desired. For example, when the needle slot 150 bisects the heel of the bevel, as shown at least in Figures 7A-7C, 7E, 7F, and 8A, the bending strength of the needle shaft 144 is greater along the top and bottom of the needle shaft 144 around at least a distal portion of the needle shaft 144 compared to the needle slot 150 at the side of the needle shaft 144. This can be important because the introducer needle 104 is typically bent around a distal portion of the needle shaft 144 into the top or bottom of the needle shaft 144 during venipuncture. Also, by varying the implementation of the needle slot 150 in combination with the coupler housing slot 182 of the coupler housing 172, the access guidewire 106 can be easily inserted into the needle shaft 144 during assembly of the RICC insertion assembly 100 and removed from the coupler housing slot 182 after the introducer needle withdrawal step, such as during the introducer needle withdrawal step of the method described below, or during the access guidewire withdrawal step.

[0067] 7E and 7F , for example, the needle slot 150 can form at least a portion of a spiral (e.g., a ¼ spiral, a ½ spiral, a ¾ spiral, etc.) from the proximal portion of the needle shaft 144 to the needle tip 148, between the proximal end of the needle shaft 144 (e.g., about 0.2-0.3 inches) and the portion that bisects the heel of the bevel. The needle slot 150 configured as such a spiral allows the access guidewire 106 to be easily inserted into the side of the needle shaft 144 during assembly of the RICC insertion assembly 100 and removed from the top or bottom of the needle shaft 144 after an introducer needle withdrawal step, such as during an introducer needle withdrawal step of the method described below, or during an access guidewire withdrawal step. In particular, the needle slot 150 in FIG. 7E illustrates a gentler quarter helix than that in FIG. 7F, where the needle slot 150 in FIG. 7E turns more gradually from the side of the needle shaft 144 at its midsection to the top of the needle shaft 144 where it bisects the heel of the bevel. The needle slot 150 in FIG. 7F turns more rapidly from the side of the needle shaft 144 at its distal section to the top of the needle shaft 144 where it bisects the heel of the bevel. Although the needle slot 150 in FIG. 7E and the needle slot 150 in FIG. 7F turn from the side of the needle shaft 144 to the top of the needle shaft 144, the needle slot 150 can alternatively turn from the side of the needle shaft 144 to the bottom of the needle shaft 144 where it bisects the tip bevel 152 of the bevel. The needle slot 150 can alternatively be turned from the top or bottom of the needle shaft 144 to the side of the needle shaft 144 such that the needle slot 150 intersects the heel of the bevel, the tip bevel 152, or both the heel and the tip bevel 152 without bisecting the heel of the bevel or the tip bevel 152. Additionally, the helix can have a handedness selected from a right-handed helix and a left-handed helix for a handheld RICC insertion assembly.

[0068] The needle slot 150 has a needle slot width dimensioned at least according to the outer diameter of the access guidewire 106, which allows the access guidewire 106 to pass from the proximal portion of the needle shaft 144 to the needle tip 148 when the introducer needle withdrawal step of the method described below is performed. In practice, the needle slot 150 can have a constant needle slot width dimensioned at least according to the outer diameter of the access guidewire 106, such as being slightly larger than the outer diameter of the access guidewire 106. For example, the slot width can be in the range of about 0.018 inches to about 0.035 inches (e.g., 0.02 inches). However, the needle slot 150 can alternatively have a non-constant needle slot width dimensioned at least according to the outer diameter of the access guidewire 106. For example, the needle slot 150 may include a taper, a reverse taper, or one or more step changes in needle slot width from the proximal portion of the needle shaft 144 to the needle tip 148. If the needle slot 150 is tapered or includes one or more step changes in the same direction as the taper, the slot width may vary from the proximal portion of the needle shaft 144 to the distal portion of the needle shaft 144 to the needle tip 148. For example, the slot width may vary from approximately 0.025 inches at the proximal portion of the needle shaft 144 to approximately 0.018 inches at the distal portion of the needle shaft 144 to the needle tip 148. Advantageously, such a slot width facilitates insertion of the access guidewire 106 into the needle slot 150 during assembly of the RICC insertion assembly 100. Additionally, such slot width guides the blades 212 of the splittable sealing module 196 during severing the sheath 142 from the needle shaft 144 during the introducer needle withdrawal step of the method described below. Alternatively or additionally, the needle slot 150 can include one or more needle slot openings 228 that are wider than the remainder of the needle slot 150 (e.g., about 0.020 inches for a needle slot width of 0.018 inches).In one example, the needle slot 150 can include a distal needle slot opening 228 that can interact with a safety mechanism sealed about the distal needle slot opening 228 to prevent at least proximal movement of the introducer needle 104 until desired, such as during an introducer needle withdrawal step of the method described below. In another example, the needle slot 150 can include a proximal needle slot opening 228 that facilitates insertion of the access guidewire 106 into the needle slot 150 during assembly of the RICC insertion assembly 100.

[0069] As shown in FIG. 9A, the opposing needle slot walls 230 can face each other and be parallel to each other, which corresponds to the needle slot 150 cut into the needle shaft 144, such as by a laser or machining (e.g., EDM). As shown in FIG. 9B, the opposing needle slot walls 230 can face each other but at an angle to each other, which corresponds to the needle shaft 144 being stamped or rolled to form the needle slot 150, such as by a milling machine. As shown in FIG. 9C, the opposing needle slot walls 230 can face away from the bottom of the needle slot 150, which corresponds to the needle slot 150 being ground into the needle shaft 144. As shown in FIG. 9D, the opposing needle slot walls 230 can face toward the bottom of the needle slot 150, which corresponds to the opposing needle slot walls 230 being bent toward the bottom of the needle slot 150. Advantageously, bending the opposing needle slot walls 230 toward the bottom of the needle slot 150 increases the bending strength of the needle shaft 144. As shown in FIG. 9E, the opposing needle shaft walls 230 may be parallel to one another for a "U" shape, which corresponds to the needle shaft 144 being stamped or rolled to form the needle slot 150. In particular, the edges of the needle slot walls 230 may be finished (e.g., ground, polished, etc.). The finished edges of the needle slot walls 230 minimize or eliminate sharp access guidewire fraying edges of the needle slot 150.

[0070] In particular, the needle shaft 144 includes a needle channel 156, while the introducer needle 104 includes a needle lumen 158. This is because the needle lumen 158 results from the combination of the needle shaft 144 and the sheath 142 that covers the needle shaft 144. In effect, the sheath 142 that covers the needle shaft 144 seals off the needle channel 156, forming the needle lumen 158 of the introducer needle 104 and allowing the syringe 112 to aspirate blood in accordance with the blood aspirating steps of the method described below.

[0071] The sheath 142 includes a sheath tip 160 at a distal portion of the sheath 142 and a sheath opening 162 at a side of a proximal portion of the sheath 142 . The sheath tip 160 includes a relatively short taper from the outer diameter of the distal portion of the sheath 142 to the outer diameter of the distal end of the sheath 142, which is comparable to the outer diameter of the distal portion of the needle shaft 144. The taper has a taper angle that is less than the primary bevel angle of the primary bevel 154 of the needle tip 148, which in turn is less than the tip bevel angle of the tip bevel 152 of the needle tip 148. The sheath tip 160, including such a taper, is configured to provide a smooth transition from the needle tip 148 to the sheath body for the needle path establishment step of the method described below.

[0072] The sheath opening 162 is open to the needle slot 150 of the needle shaft 144 and allows the access guidewire 106 to pass therethrough and into the needle slot 150 in the ready-to-operate state of the RICC insertion assembly 100. Thus, the sheath opening 162 has a width approximately corresponding to the width of the needle slot 150 below it, which is sized according to the diameter of the access guidewire 106. The sheath opening 162 also has a length sufficient to accommodate the blade 212 of the splittable sealing module 196 below the distal end of the sheath opening 162 while allowing the access guidewire 106 to pass therethrough and into the needle slot 150. In particular, the sheath 142 covering the needle shaft 144 seals the needle slot 150 below it, except where it is below the sheath opening 162. However, the splittable sealing module 196 covers and seals the needle slot 150 exposed by the sheath opening 162 by sealing the needle shaft 144 and the proximal portion of the sheath 142 therein, thereby enabling the syringe 112 to aspirate blood in accordance with the blood aspirating steps of the method described below.

[0073] The sheath 142 may be a cuttable or splittable sheath configured to separate or split the sheath 142, respectively, from the needle shaft 144 to allow the access guidewire 106 to exit the needle shaft 144 via the needle slot 150. If configured to separate from the needle shaft 144, the sheath 142 may be formed from a polymeric material such as polyurethane that facilitates separating the sheath 142 from the needle shaft 144. If configured to split away from the needle shaft 144, the sheath 142 may include one or more weakened portions of the sheath 142 (e.g., a longitudinal perforation pattern, longitudinal grooves, etc.) that facilitate separating the sheath 142 from the needle shaft 144.

[0074] The sheath 142 or sheath body of the sheath 142 is formed from a polymeric material configured to facilitate smooth and consistent insertion of the introducer needle 104 from an area of ​​skin into the patient's vascular lumen in accordance with the needle path establishment step of the method described below. In addition, the polymeric material has sufficient mechanical properties at the thickness of the sheath 142 to withstand collapse of the sheath 142 into the needle slot 150 of the needle shaft 144 when the blood aspiration step of the method described below is performed, while also facilitating severing or splitting the sheath 142 from the needle shaft 144, particularly in accordance with at least the introducer needle withdrawal step of the method described below for severing the sheath 142 from the needle shaft 144. Such polymeric materials may include, but are not limited to, polyethylene, polypropylene, polyurethane, or polytetrafluoroethylene ("PTFE"). In one example, in an embodiment of the RICC insertion assembly 100 in which the sheath 142 is separated from the needle shaft 144 by a blade 212, the sheath 142 may be polyurethane. As another example, in embodiments of the RICC insertion assembly 100 in which the sheath 142 splits away from the needle shaft 144, the sheath 142 can be PTFE or even expanded PTFE ("ePTFE"). If the sheath 142 is ePTFE, for example, the sheath 142 does not need to include one or more weakened portions of the sheath 142 to split the sheath 142 away from the needle shaft 144 because the ePTFE itself facilitates separation of the sheath 142 from the needle shaft 144 due to the longitudinal arrangement of the polymer chains within the ePTFE.

[0075] The needle hub 146 includes an access guidewire channel 164 at a distal portion of the needle hub 146 and a needle hub connector 166 at a proximal portion of the needle hub 146 . The access guidewire channel 164 in the needle hub 146 is configured to allow the access guidewire 106 to pass over the needle hub 146 and guide the access guidewire 106 into the access guidewire passage 206 of the splittable seal module 196. The access guidewire channel 164 is open such that the access guidewire 106 is located within the access guidewire channel 164, at least in the ready-to-operate state of the RICC insertion assembly 100. Advantageously, the open access guidewire channel 164 allows the access guidewire 106 to remain in place when the introducer needle 104 is withdrawn from the RICC insertion assembly 100 in accordance with the introducer needle withdrawal step of the method described below.

[0076] In particular, the access guidewire channel 164 of the needle hub 146 transitions into the access guidewire channel 168 of the proximal portion 200 of the sealing module insert 198 coupled to the distal portion of the needle hub 146. When the proximal portion 200 of the sealing module insert 198 is mated with the distal portion 202 of the sealing module insert 198, the access guidewire channel 168 of the proximal portion 200 of the sealing module insert 198 combines with the access guidewire channel of the distal portion 202 of the sealing module insert 198 to form an access guidewire passageway 206 of the splittable sealing module 196. The needle hub 146 includes the proximal portion 200 of the sealing module insert 198 coupled to the needle hub 146 and is configured to be removably positioned within the needle hub receptacle 180 and the sealing module cavity 178 of the coupler housing 172, respectively. As described below, the distal portion of the needle hub 146 axially compresses the proximal portion 200 of the sealing module insert 198 within the sealing module cavity 178 when the needle hub 146 is disposed within the needle hub receptacle 180 and the proximal portion 200 of the sealing module insert 198 is disposed within the sealing module cavity 178. The axial compression of the proximal portion 200 of the sealing module insert 198 within the sealing module cavity 178 in turn radially compresses both the proximal portion 200 and the distal portion 202 of the sealing module insert 198 within the sealing module cavity 178.

[0077] The needle hub connector 166 includes a needle hub bore 170 and an optional needle hub flange (not shown) around the needle hub connector 166 . The needle hub bore 170 of the needle hub connector 166 is configured to receive the syringe tip of the syringe 112 therein to fluidly connect the introducer needle 104 to the syringe 112. Indeed, the needle hub bore 170 can have a luer taper (e.g., a 6% taper) configured to receive the syringe tip therein, and the syringe tip can be complementarily configured with a luer taper.

[0078] The needle hub flange of the needle hub connector 166 is configured to threadably mate with the female threads of a threaded collar about the syringe tip of the syringe 112. While the threaded collar of the syringe 112 is optional, the needle hub flange advantageously provides a so-called luer lock type connection with the female threads of the threaded collar, if both are present, thereby providing additional security against inadvertent separation of the introducer needle 104 and the syringe 112 in addition to the security provided by a luer slip type connection.

[0079] 1-3 show various views of a coupler 108 of a RICC insertion assembly 100, according to some embodiments. As shown, the coupler 108 includes a coupler housing 172, an access guidewire connection side arm 174, and, optionally, if the RICC insertion assembly 100 also includes a keeper 220, a splittable casing retaining side arm 176.

[0080] The coupler housing 172 includes a sealing module cavity 178, a needle hub receptacle 180 proximal to the sealing module cavity 178, and a longitudinal coupler housing slot 182 formed along the length of the coupler housing 172. (See FIG. 3. FIG. 4 includes a proximal portion 200 and a distal portion 202 of a sealing module insert 198 disposed within the sealing module cavity 178. FIG. 3 also includes the needle hub 146 of the introducer needle 104 disposed within the needle hub receptacle 180.) In particular, the coupler housing 172 may be formed into a bullet-shaped body configured to be comfortably held underhand (e.g., cradle-style) or overhand with the RICC insertion assembly 100 in the left hand for left-handed venipuncture or in the right hand for right-handed venipuncture. To further facilitate such venipuncture, the exterior of coupler housing 172 may be textured with grip-enhancing ridges (eg, lateral or circumferential ridges), protrusions, or the like.

[0081] The sealing module cavity 178 is configured to hold a proximal portion 200 and a distal portion 202 of the sealing module insert 198 therein. In practice, the sealing module cavity 178 includes at least the distal portion 202 of the sealing module insert 198 disposed so as to be captured therein in each of the one or more states of the RICC insert assembly 100. For example, the sealing module cavity 178 can include a catch 184 in its distal portion, the catch 184 configured to receive a protrusion 186 of the distal portion 202 of the sealing module insert 198 therein for a captured placement of the distal portion 202 of the sealing module insert 198 in the sealing module cavity. The sealing module cavity 178 also includes the proximal portion 200 of the sealing module insert 198 disposed therein in at least some of the one or more states of the RICC insert assembly 100, such as a ready-for-operation state or one or more operational states of the RICC insert assembly 100.

[0082] The needle hub receptacle 180 is configured to hold the needle hub 146 of the introducer needle 104 therein. In fact, the needle hub receptacle 180 includes the needle hub 146 inserted therein in the ready-to-operate state of the RICC insertion assembly 100. Although not shown, the coupler 108 may include a needle hub lock around the needle hub receptacle 180 configured to lock the needle hub 146 within the needle hub receptacle 180. In fact, a pair of locking buttons (e.g., spring-loaded locking buttons) of the needle hub lock may be distributed between opposite sides of the coupler housing 172, such that each of the locking buttons extends through the coupler housing 172 on a respective side of the coupler 108. Such locking buttons may be configured to unlock the needle hub 146 when the locking buttons are pressed into the coupler housing 172 to withdraw the introducer needle 104 from the coupler 108. Releasing the lock button immediately releases the axial compression from the distal portion of the needle hub 146 compressing the proximal portion 200 of the sealing module insert 198 within the sealing module cavity 178. This allows the proximal and distal portions 200, 202 of the sealing module insert 198 to relax for withdrawal of the introducer needle 104 from the coupler 108. This also allows the proximal and distal portions of the sealing module insert 198 to be separated for escape of the access guidewire 106 when the introducer needle 104 is withdrawn from the coupler 108 during the introducer needle withdrawal step of the method described below.

[0083] The coupler housing slots 182 formed along the length of the coupler housing 172 are configured to allow the access guidewire 106 to exit the coupler housing 172 after the introducer needle 104 is withdrawn from the coupler 108 in an introducer needle withdrawal step of the method described below. Indeed, when the introducer needle 104 is withdrawn from the coupler 108 in the introducer needle withdrawal step, the proximal portion 200 of the sealing module insert 198 is also withdrawn from the sealing module cavity 178, allowing the access guidewire 106 to exit the coupler housing 172 once the proximal portion 200 of the sealing module insert 198 is removed from the sealing module cavity 178.

[0084] An access guidewire connection side arm 174 extends from the coupler 108 or its coupler housing 172. The access guidewire connection side arm 174 includes a connector 188 configured to connect around a proximal end portion of the access guidewire 106 to an access guidewire hub 218 that extends from a proximal end of the RICC 102, at least in the ready-to-operate state of the RICC insertion assembly 100. During the ready-to-operate state of the RICC insertion assembly 100, a distal portion of the access guidewire 106 is disposed within the needle shaft 144 and the access guidewire hub 218 is connected to the connector 188 of the access guidewire connection side arm 174, thereby achieving a loop 110 of the access guidewire 106 with the RICC 102 disposed over the loop 110. When both the keeper 220 and the splittable casing retaining side arm 176 are present in the RICC insertion assembly 100, the distal portion of the splittable casing 222 is also retained within the primary channel 190 of the splittable casing retaining side arm 176, thereby further achieving a loop 110 of the access guidewire 106 with the RICC 102 positioned over the loop 110.

[0085] When present, the splittable casing retaining side arm 176 extends from the coupler 108 or its coupler housing 172 opposite the access guidewire connecting side arm 174. The splittable casing retaining side arm 176 includes a primary channel 190 and a secondary channel 192. The primary channel 190 is configured to slidably retain the splittable casing 222, or the splittable casing 222 and at least the longitudinal composite of the access guidewire 106 therein. The secondary channel 192 is configured to guide the access guidewire 106 split off of the splittable casing 222 into the coupler 108, into its splittable sealing module 196, and into the needle shaft 144 sealed therein via the needle slot 150. The branch point 194 of the splittable casing retaining side arm 176 between the primary channel 190 and the secondary channel 192 is configured to split and separate the access guidewire 106 from the splittable casing 222 when the splittable casing 222 and at least the longitudinal composite of the access guidewire 106 therein are pushed therein.

[0086] FIG. 4 shows a longitudinal cross section of a splittable sealing module 196 according to some embodiments. The splittable sealing module 196 of the RICC insertion assembly 100 includes a sealing module cavity 178 of the coupler housing 172 and an elastomeric sealing module insert 198 disposed therein, the sealing module insert 198 being split between a captured proximal portion 200 and a removable distal portion 202, referred to herein as a proximal portion 200 of the sealing module insert 198 and a distal portion 202 of the sealing module insert 198, respectively. (Notably, the proximal portion 200 and the distal portion 202 of the sealing module insert 198 may be formed from the same elastomer (e.g., silicone) or different elastomers.) The proximal portion 200 of the sealing module insert 198 is configured to be disposed or otherwise inserted within the sealing module cavity 178 of the coupler housing 172, and the proximal portion 200 of the sealing module insert 198 mates with the distal portion 202 of the sealing module insert 198 to complete a pair of passages through the splittable sealing module 196. By virtue of the aforementioned passages, the splittable sealing module 196 is configured to separately seal around the introducer needle 104 and the access guidewire 106 when the proximal and distal portions 200, 202 of the sealing module insert 198 are compressed within the sealing module cavity 178 in one or more states of the RICC insertion assembly 100 (e.g., in a ready-to-operate state or one or more operational states of the RICC insertion assembly 100), thereby enabling the syringe 112 to aspirate blood in accordance with the blood aspirating step of the method described below.

[0087] A pair of passageways completed when the proximal and distal portions 200, 202 of the sealing module insert 198 are combined within the sealing module cavity 178 of the coupler housing 172 includes an introducer needle passageway 204 and an access guidewire passageway 206. As shown in FIG. 4, a proximal portion of the introducer needle passageway 204 can reside within the proximal portion 200 of the sealing module insert 198, while a distal portion of the introducer needle passageway 204 is completed by the proximal and distal portions 200, 202 of the sealing module insert 198 when combined within the sealing module cavity 178 of the coupler housing 172. As further shown in FIG. 4, the entirety of the access guidewire passageway 206 can be completed by the proximal and distal portions 200, 202 of the sealing module insert 198 when combined within the sealing module cavity 178 of the coupler housing 172. To provide the aforementioned passageways, other configurations of the sealing module insert 198 are possible, with the splittable sealing module 196 configured to separately seal around the proximal portion of the introducer needle 104 and the distal portion of the access guidewire 106 via the introducer needle passageway 204 and the access guidewire passageway 206, respectively, when the proximal and distal portions 200, 202 of the sealing module insert 198 are compressed within the sealing module cavity 178 in one or more states of the RICC insertion assembly 100. Notably, in contrast to the introducer needle passageway 204, which passes through both the proximal and distal ends of the sealing module insert 198, the distal end of the access guidewire passageway 206 connects to an inner portion of the introducer needle passageway 204, thereby allowing the distal portion of the access guidewire 106 to be disposed within the needle shaft 144 while the distal portion of the access guidewire 106 is disposed within the splittable sealing module 196.In fact, the access guidewire passage 206 is configured to guide the access guidewire 106 from the access guidewire channel 164 in the needle hub 146 into both the sheath opening 162 of the sheath 142 and the needle slot 150 of the needle shaft 144 below, such that when the RICC insertion assembly 100 is in a ready-to-operate state, the access guidewire 106 can be positioned within the needle shaft 144 with the distal end of the access guidewire 106 just proximal to the needle tip 148.

[0088] The splittable sealing module 196 is configured to separately seal around the proximal portion of the introducer needle 104 and the distal portion of the access guidewire 106 when the sealing module insert 198 is compressed within the sealing module cavity 178. In practice, the proximal and distal portions 200, 202 of the sealing module insert 198 may be radially compressed within the sealing module cavity 178, or may be both axially and radially compressed within the sealing module cavity 178 to seal around the introducer needle 104 and the access guidewire 106. With the seal around the introducer needle 104 and the access guidewire 106 as described above, the syringe 112 may aspirate blood in accordance with the blood aspirating step of the method described below.

[0089] In an example of radial compression of the sealing module insert 198 within the sealing module cavity 178, the proximal and distal portions 200, 202 of the sealing module insert 198 may be radially compressed within the sealing module cavity 178 by the coupler housing 172 itself. Without limiting such an embodiment, the two halves of the coupler housing 172 may be clamshell-like coupled together by hinges on opposite sides of a coupler housing slot 182 formed between the two halves of the coupler housing 172. One or more clamps across the coupler housing slot 182 may be clamped at least in the ready-to-operate state of the RICC insertion assembly 100 to hold the two halves of the coupler housing 172 together and apply sufficient pressure to radially compress the proximal and distal portions 200, 202 of the sealing module insert 198 within the sealing module cavity 178, sealing the sealing module insert 198 around the introducer needle 104 and the access guidewire 106. One or more clamps may be unclamped in one or more operating states of the RICC insertion assembly 100 to release radial compression and then allow the introducer needle 104 to be withdrawn from the coupler 108 so that the access guidewire 106 can exit through the coupler housing slot 182.

[0090] In an example of both radial and axial compression of the seal module insert 198 within the seal module cavity 178, the proximal and distal portions 200, 202 of the seal module insert 198 may be both axially and radially compressed within the seal module cavity 178 by the distal portion of the needle hub 146. The distal portion of the needle hub 146 axially compresses the proximal and distal portions 200, 202 of the seal module insert 198 within the seal module cavity 178 when the needle hub 146 is disposed within the needle hub receptacle 180, such as in the ready-to-operate state of the RICC insertion assembly 100. The axial compression of the proximal and distal portions 200, 202 of the sealing module insert 198 within the sealing module cavity 178 then radially compresses the proximal and distal portions 200, 202 of the sealing module insert 198 within the sealing module cavity 178, thereby sealing the sealing module insert 198 around the introducer needle 104 and the access guidewire 106. The needle hub 146 may be removed from the needle hub receptacle in one or more operational states of the RICC insertion assembly 100 to release both the axial and radial compression and then allow the introducer needle 104 to be withdrawn from the coupler 108 for the access guidewire 106 to exit through the coupler housing slot 182.

[0091] The coupler housing 172 of the coupler 108 may further include a blade 212 extending into the introducer needle passage 204 of the splittable sealing module 196. The blade 212 may be overmolded onto the distal portion 202 of the sealing module insert 198, thereby integrating the blade 212 therein. The blade 212, or its blade tip 214, may be disposed within the needle slot 150 below the distal end of the sheath opening 162, at least in the ready-to-operate state of the RICC insertion assembly 100. The blade 212 includes a distally facing blade edge 216 configured to decouple the sheath 142 from the needle shaft 144 as the introducer needle 104 is withdrawn from the coupler 108 through the introducer needle passage 204 during an introducer needle withdrawal step of the method described below. Decoupling the sheath 142 from the needle shaft 144 as the introducer needle 104 is withdrawn from the coupler 108 allows the access guidewire 106 to exit the needle shaft 144 via the needle slot 150 .

[0092] 1 and 3 show various views of the access guidewire 106 of the RICC insertion assembly 100, according to some embodiments. The access guidewire 106 includes a proximal portion including a proximal end and a distal portion including a distal end. In the ready-to-operate state of the RICC insertion assembly 100, the proximal end of the access guidewire 106 is coupled to the access guidewire connection side arm 174 by an access guidewire hub 218 around the proximal end portion of the access guidewire 106 including the distal end. In addition, the proximal portion of the access guidewire 106 extends along the primary lumen 130 of the RICC 102. A distal portion of the access guidewire 106 also extends along the primary lumen 130 of the RICC 102, but the distal portion of the access guidewire 106 further extends from the distal end of the RICC 102 as an extra-catheter portion of the access guidewire 106, by way of an access guidewire channel 164 into a splittable seal module 196 on the needle hub 146, through both the sheath opening 162 of the sheath 142 and the needle slot 150 of the needle shaft 144, and into the needle shaft 144, and along the needle lumen 158 of the introducer needle 104 in the ready-to-operate state of the RICC insertion assembly 100. As shown in FIG. 1, the distal end of the access guidewire 106 is disposed within the needle lumen 158 just proximal to the needle tip 148 in the ready-to-operate state of the RICC insertion assembly 100. Again, the proximal and distal ends of the access guidewire 106 provide a loop 110 of the access guidewire 106 with the RICC 102 positioned over the loop 110 when the RICC insertion assembly 100 is in a ready-to-operate state, thereby keeping the RICC insertion assembly 100 in a relatively compact configuration.

[0093] The access guidewire 106 can include a guidewire tip at a distal portion of the access guidewire 106, the guidewire tip assuming a "J" shape configured to prevent puncturing the posterior wall of a blood vessel. Such guidewire tip assumes a straight state in a ready-to-operate state of the RICC insertion assembly 100 and a curved state when the guidewire tip is advanced beyond the needle tip 148 (e.g., advanced into a blood vessel lumen) in one or more operational states of the RICC insertion assembly 100 in which the access guidewire 106 is deployed.

[0094] The access guidewire 106 may also include a bare wire portion and a wrapped wire portion distal to the bare wire portion, proximal to the bare wire portion, or both. Although not shown, if present, the bare wire portion extends distally through the access guidewire passageway 206 of the splittable sealing module 196, at least in the ready-to-operate state of the RICC insertion assembly 100, such that the splittable sealing module 196 forms a fluid-tight seal around the bare wire portion of the access guidewire 106. In particular, the aforementioned bare wire portion may instead be a flat-wrapped or ground-wrapped portion of the access guidewire 106, where the flat-wrapped portion includes a wrap of tape instead of a round wire, and the ground-wrapped portion includes a wrap of round wire that has been polished to flatten the wrap.

[0095] FIG. 1 shows a keeper 220 of a RICC insertion assembly 100, according to some embodiments. As shown, the keeper 220 can include a splittable casing 222 and a catheter hub holder 224 to which the proximal end of the splittable casing 222 is attached.

[0096] The splittable casing 222 can form a longitudinal composite with the catheter tube 114, with the access guidewire 106, or with both the catheter tube 114 and the access guidewire 106 in the RICC insertion assembly 100. For example, with respect to the RICC insertion assembly 100 of FIG. 1 , the splittable casing 222 overlies both the catheter tube 114 and the access guidewire 106 in the portion of the RICC insertion assembly 100 closest to the catheter hub holder 224, thus forming a longitudinal composite with both the catheter tube 110 and the access guidewire 106, where the access guidewire 106 is disposed within the primary lumen 130 of the RICC 102. 1, the splittable casing 222 overlies only the access guidewire 106 in the portion of the RICC insertion assembly 100 closest to the coupler 108 or its splittable casing retaining side arm 176, and thus forms a longitudinal composite with only the access guidewire 106, where the extra-catheter portion of the access guidewire 106 extends from the distal end of the RICC 102. The splittable casing 222 is configured to split along its length, for example, as it slides over the bifurcation point 194 of the splittable casing retaining side arm 176 of the coupler 108, thereby exposing the extra-catheter portion of the access guidewire 106 first and the distal portion of the catheter tube 114 thereafter. In this manner, the splittable casing 222 is configured to keep the catheter tube 114 and at least the distal portion of the access guidewire 106 sterile until they are deployed.

[0097] The catheter hub holder 224 is configured to retain the catheter hub 116 within the catheter hub holder 224 and for the splittable casing 222 to cover and hold in place the catheter tube 114 and the access guidewire 106, particularly the extra-catheter portion of the access guidewire 106. The catheter hub holder 224 includes a peripheral wall 226 around at least a portion (e.g., a proximal portion) of the circumference of the catheter hub holder 224. The peripheral wall 226 defines a recess into which the catheter hub 116 fits with an engineered fit (e.g., a clearance fit such as a running fit, a sliding fit, or a location fit, or an intermediate fit such as a similar fit and a fixed fit as classified by the International Organization for Standardization ["ISO"]), as well as one or more gaps for extending through the one or more extension legs 118. Additionally or alternatively, the catheter hub holder 224 can include wings that correspond to the suture wings of the catheter hub 116. Such wings may include posts configured for insertion into suture wing holes in the suture wing of the catheter hub 116 via an optical fit.

[0098] method The introducer needle 104 and RICC insertion assembly 100 methods each include at least a method for manufacturing the introducer needle 104 and a method for inserting the RICC 102 into a vascular lumen of a patient.

[0099] The method for manufacturing the introducer needle 104 includes one or more steps selected from metal strip rolling, seam welding, cold working, grinding, needle slot creation, wall bending, edge finishing, sheath placement, sheath opening creation, and needle hub fixation.

[0100] The metal strip rolling step includes rolling a metal strip, such as stainless steel, into a metal tube. For example, the metal strip rolling step can include rolling the metal strip into a metal tube using a milling machine or a stamping press. Such a metal tube can include a longitudinal seam formed between the edges of the longitudinal sides of the metal strip. However, such a metal tube can alternatively include a needle slot 150 formed between the edges of the longitudinal sides of the metal strip instead of a longitudinal seam. If a needle slot 150 of an appropriate gauge (e.g., 18G) is formed in the metal tube in the metal strip rolling step, a grinding step can be performed following the metal strip rolling step to produce a needle shaft 144 without additional post-processing such as an edge finishing step. (See, for example, the needle shaft 144 in FIG. 7A). In particular, such a needle shaft has a bending strength comparable to that formed after, for example, the seam welding step, the cold working step, the needle slot making step, and the edge finishing step.

[0101] The seam welding step includes welding a seam formed between the side edges of the metal strip. For example, the seam welding step can include laser welding a seam formed between the side edges of the metal strip.

[0102] The cold working step involves forcing the metal tube through one or more dies one or more times, thereby simultaneously reducing the outer diameter of the metal tube (e.g., 18G) and increasing the thickness of the metal tube wall of the metal tube. Following the cold working step, the metal tube may be scored and divided into two or more smaller metal tubes that are batched together for the grinding step. However, for ease of explanation, such further processing will be described with reference to the metal tube described above.

[0103] The grinding step involves grinding the end of the metal tube at multiple angles to form a needle shaft 144 with a beveled needle tip 148. For example, grinding the end of the metal tube at a first angle forms a primary bevel 154 that includes a bevel heel. Grinding the end of the metal tube at two similar but opposing second angles forms a bevel tip bevel 152.

[0104] The needle slot creation step includes creating the needle slot 150 in the needle shaft 144. In one example, the needle slot creation step can include cutting the needle slot 150 into the needle shaft 144 by machining or laser cutting, for example, using a computer numerical control ("CNC") laser cutting machine, which can be useful to cut and rotate the needle shaft 144 during cutting to form the needle slot 150 when it is at least partially non-linear, such as helical, as described above. The opposing needle slot walls 230 resulting from cutting the needle slot 150 into the needle shaft 144 face each other and are parallel to each other. In addition, the needle slot walls 230 are opposed to the bottom of the needle slot 150. In another example, the needle slot creation step can include grinding the needle slot 150 into the needle shaft 144. The opposing needle slot walls 230 resulting from grinding the needle slot 150 into the needle shaft 144 face away from the bottom of the needle slot 150. As mentioned above, the needle slot 150 extends from the proximal portion of the needle shaft 144 through the needle tip 148, which includes a tip bevel 152 and a bevel having a heel.

[0105] The wall bending step involves bending the needle slot wall 230 toward the bottom of the needle slot 150 , thereby increasing the bending strength of the needle shaft 144 . The edge finishing step involves finishing (e.g., grinding, polishing, etc.) the edges of the needle slot walls 230 to thereby minimize or eliminate sharp access guidewire frayed edges or burrs in the needle slot 150.

[0106] The sheath placement step includes placing the sheath 142 over the needle shaft 144, where the sheath 142 seals the needle slot 150 below. Placing the sheath 142 over the needle shaft 144 may include inserting the needle shaft 144 into the sheath 142 and heat shrinking the sheath 142 over the needle shaft 144 to seal the needle slot 150 below.

[0107] The sheath opening creation step includes creating a sheath opening 162 in the sheath 142. Creating the sheath opening 162 in the sheath 142 may include cutting (e.g., laser cutting) the sheath opening 162 into the needle shaft 144 after placing the sheath 142 over it in the sheath placement step. As described above, the sheath 142 seals the needle slot 150 underneath it, except for the sheath opening 162 in a proximal portion of the sheath 142.

[0108] The needle hub securing step includes securing the needle hub 146 around both the proximal portion of the needle shaft 144 and the proximal portion of the sheath 142, thereby forming the introducer needle 104. The needle hub securing step may include forcing both the proximal portion of the needle shaft 144 and the proximal portion of the sheath 142 into the needle hub 146 with an engineered fit selected from a neutral fit and an interference fit. Additionally or alternatively, the needle hub securing step may include gluing the needle hub 146 to both the proximal portion of the needle shaft 144 and the proximal portion of the sheath 142.

[0109] Describing a method for inserting a RICC 102 into a vascular lumen of a patient, the method can include one or more steps selected from an insertion assembly acquisition step, a status verification step, a needle path establishment step, a blood aspiration step, an access guidewire advancement step, a sheath splitting step, an introducer needle withdrawal step, a RICC advancement step, an access guidewire withdrawal step, a steering guidewire advancement step, another RICC advancement step, and a steering guidewire withdrawal step.

[0110] The insertion assembly obtaining step optionally includes obtaining a RICC insertion assembly 100 already in its ready-to-operate state. As described above, the RICC insertion assembly 100 includes a RICC 102, an introducer needle 104, an access guidewire 106, and a coupler 108 coupling the RICC 102 and the introducer needle 104 to one another. In addition, the RICC insertion assembly 100 includes a splittable sealing module 196 formed between at least a sealing module cavity 178 of a coupler housing 172 of the coupler 108, a distal portion 202 of a sealing module insert 198 disposed within the sealing module cavity 178, and a proximal portion 200 of the sealing module insert 198 coupled to a distal portion of a needle hub 146 of the introducer needle 104. The splittable sealing module 196, at least in the ready-to-operate state of the RICC insertion assembly 100, separately seals around a proximal portion of the introducer needle 104 and a distal portion of the access guidewire 106. Within the splittable sealing module 196, the distal portion of the access guidewire 106 is disposed through the needle slot 150 and into the needle shaft 144. This is accomplished by a connection between the distal end of the access guidewire passageway 206 and an inner portion of the introducer needle passageway 204 within the sealing module insert 198.

[0111] The state verification step includes verifying that the RICC insertion assembly 100 is in its ready-to-operate state prior to the path establishment step. Such verification ensures that the proximal and distal portions 200, 202 of the sealing module insert 198 are compressed within the sealing module cavity 178 to seal the introducer needle passage 204 and the access guidewire passage 206 around the introducer needle 104 and the access guidewire 106, respectively. In particular, if the RICC insertion assembly 100 is not in a ready-to-operate state when the RICC insertion assembly 100 is acquired in the insertion assembly acquisition step, the RICC insertion assembly 100 may be adjusted to place the RICC insertion assembly 100 in a ready-to-operate state for subsequent steps.

[0112] The needle path establishment step includes establishing a needle path from the area of ​​skin to the blood vessel lumen with the introducer needle 104. The needle path establishment step may also include ensuring that blood flows back into the introducer needle 104 (e.g., the needle hub 146 of the introducer needle 104), into the syringe 112 fluidly connected to the introducer needle 104 (e.g., the syringe tip, the barrel of the syringe 112, or both), or into both the introducer needle 104 and the syringe 112, thereby confirming that the needle path extends into the blood vessel lumen. To enhance blood backflow, a slight vacuum may be drawn with the syringe 112 while establishing the needle path.

[0113] The blood aspirating step involves aspirating blood using the syringe 112 to ensure that the needle tract extends into the blood vessel lumen prior to withdrawing the introducer needle 104 from the coupler 108 in the introducer needle withdrawal step. Again, the sheath 142 covering the needle shaft 144 seals the needle slot 150 of the needle shaft 144 underneath. In particular, the sheath 142 seals the needle slot 150 outside of the splittable sealing module 196. The splittable sealing module 196 then seals over the sheath opening 162 of the sheath 142, which allows the access guidewire 106 to pass from the access guidewire passage 206 formed between the proximal and distal portions 200, 202 of the sealing module insert 198, through the needle slot 150 and into the needle shaft 144. The splittable sealing module 196 also seals around the distal portion of the access guidewire 106. Such a seal allows the syringe 112 to aspirate blood during the blood aspirating step.

[0114] The access guidewire advancement step involves advancing a distal portion of the access guidewire 106 through both the splittable sealing module 196 and the needle slot 150 of the needle shaft 144, thereby advancing the distal end of the access guidewire 106 from its initial position within the introducer needle 104 into the blood vessel lumen. As described above, when the RICC insertion assembly 100 is in its ready-to-operate state, the initial position of the distal end of the access guidewire 106 is just proximal to the needle tip 148.

[0115] If the RICC insertion assembly 100 does not include a keeper 220 and a splittable casing 222 on both the catheter tube 114 of the RICC 102 and the extra-catheter portion of the access guidewire 106, the access guidewire advancement step includes pinching the extra-catheter portion of the access guidewire 106 extending from the distal end of the RICC 102 and forcing the access guidewire 106 into the needle shaft 144 via the splittable sealing module 196 of the coupler 108. Advancing the access guidewire 106 in this manner reduces the loop 110 of the access guidewire 106 over which the RICC 102 is positioned. As described above, the loop 110 is achieved by the distal portion of the access guidewire 106 being positioned within the needle shaft 144 and the access guidewire hub 218 of the access guidewire 106 being connected to the connector 188 of the access guidewire connection side arm 174 of the coupler 108.

[0116] If the RICC insertion assembly 100 includes a keeper 220 and a splittable casing 222 over both the catheter tube 114 of the RICC 102 and the extra-catheter portion of the access guidewire 106, the access guidewire advancement step includes pinching the splittable casing 222 over both the catheter tube 114 of the RICC 102 and the extra-catheter portion of the access guidewire 106 extending from the distal end of the RICC 102. The access guidewire advancement step also includes pushing the splittable casing 222 into the primary channel 190 of the splittable casing retaining side arm 176 of the coupler 108 while pinching the splittable casing 222. By pinching and forcing the splittable casing 222 into the primary channel 190 of the splittable casing retaining side arm 176 in this manner, the access guidewire 106 splits away from the splittable casing 222, over the branch point 194 of the splittable casing retaining side arm 176 between the primary channel 190 and the secondary channel 192, into the secondary channel 192 of the splittable casing retaining side arm 176, and through the splittable sealing module 196 of the coupler 108 into the needle shaft 144. Advancing the access guidewire 106 in this manner reduces the loop 110 of the access guidewire 106 with the RICC 102 and splittable casing 222 disposed over the loop 110. The loop 110 is realized by at least a splittable casing 222 held within the primary channel 190 of the splittable casing holding side arm 176 and the access guidewire hub 218 of the access guidewire 106 connected to the connector 188 of the access guidewire connecting side arm 174 of the coupler 108.

[0117] The introducer needle withdrawal step involves withdrawing the introducer needle 104 from the coupler 108 prior to the RICC advancement step, thereby leaving the access guidewire 106 within the vessel lumen. Withdrawing the introducer needle 104 from the coupler 108 removes the needle hub 146 of the introducer needle 104 from the needle hub receptacle 180 and, along with the needle hub 146, removes the proximal portion 200 of the sealing module insert 198 from the sealing module cavity 178, thereby splitting the proximal and distal portions 200, 202 of the sealing module insert 198 away from one another and unsealing the proximal portion of the introducer needle 104 and the distal portion of the access guidewire 106, allowing the access guidewire 106 to exit the splittable sealing module 196.

[0118] The introducer needle withdrawal step may also include decoupling the needle slot sealing sheath 142 of the introducer needle 104 from the needle shaft 144. As described above, the coupler housing 172 of the coupler 108 may include a blade 212 extending into the splittable sealing module 196 such that the blade 212 is positioned in the needle slot 150 below the distal end of the sheath opening 162 of the sheath 142 with a distally facing blade edge 216 for decoupling the sheath 142 from the needle shaft 144. If the coupler housing 172 does not include a blade 212, the method may further include a sheath splitting step, which includes splitting the sheath 142. Decoupling or splitting the sheath 142 from the needle shaft 144 allows the access guidewire 106 to exit the needle shaft 144 via the needle slot 150, which may be modified as described above. Additionally, the coupler housing slot 182 in the coupler housing 172 allows the access guidewire 106 to exit the coupler housing 172 after the introducer needle 104 is withdrawn from the coupler 108 .

[0119] The RICC advancement step involves inserting the RICC 102 into the vessel lumen by advancing the catheter tube 114 of the RICC 102 over the access guidewire 106 into the vessel lumen.

[0120] The access guidewire withdrawal step involves withdrawing the access guidewire 106 while leaving the catheter tube 114 within the vessel lumen. The steering guidewire advancement step includes advancing a steering guidewire through the primary lumen 130 of the RICC 102 and into the lumen of the blood vessel, and advancing the steering guidewire to the lower third of the SVC of the patient's heart.

[0121] Another RICC advancement step involves advancing the catheter tube 114 further into the vessel lumen over the steering guidewire to the lower third of the SVC of the patient's heart. The steering guidewire withdrawal step involves withdrawing the steering guidewire, leaving the catheter tube 114 in place in the lower third of the superior vena cava.

[0122] Although some specific embodiments are disclosed herein and the specific embodiments are disclosed in some detail, the specific embodiments are not intended to limit the scope of the concepts provided herein. Further adaptations or modifications may become apparent to those skilled in the art, and the broader aspects of the present invention encompass these adaptations or modifications as well. Thus, departures from the specific embodiments disclosed herein may be made without departing from the scope of the concepts provided herein.

Claims

1. an introducer needle, a needle shaft including a needle slot extending from a proximal portion of the needle shaft to a distal needle tip having a beveled tip and a heel, the needle shaft comprising: a) opposing needle slot walls face each other and are parallel to each other in line with the needle slot cut into the needle shaft; b) the opposing needle slot walls face each other but are angled relative to each other in accordance with the needle shaft being stamped or rolled to form the needle slot; c) the opposing needle slot walls face away from the bottom of the needle slot in alignment with the needle slot ground into the needle shaft; d) the opposing needle slot walls face toward the bottom of the needle slot in conformity with the opposing needle slot walls being bent toward the bottom of the needle slot; and e) the opposing needle shaft walls are parallel to one another in accordance with the needle shaft being stamped or rolled to form the needle slot; a needle shaft comprising one or more features selected from the group of features consisting of: a sheath covering the needle shaft and sealing the needle slot below the sheath except for a sheath opening at a proximal portion of the sheath; a needle hub around both the proximal portion of the needle shaft and the proximal portion of the sheath.

2. The introducer needle of claim 1 , wherein the needle slot extends along at least a portion of an upper portion of the needle shaft, the upper portion of the needle shaft including the heel of the bevel.

3. The introducer needle of claim 1 , wherein the needle slot extends along at least a portion of a bottom of the needle shaft, the bottom of the needle shaft including the distal bevel of the bevel.

4. 2. The introducer needle of claim 1, wherein the needle slot extends along at least a portion of a side of the needle shaft, the side of the needle shaft being between the heel of the bevel and the tip bevel.

5. The introducer needle of any one of claims 1 to 4, wherein the needle slot bisects the heel of the bevel.

6. The introducer needle of any one of claims 1 to 4, wherein the needle slot bisects the distal bevel of the bevel.

7. 5. The introducer needle of claim 1, wherein the needle slot intersects the heel, the tip bevel, or both the heel and the tip bevel of the bevel without bisecting the heel or the tip bevel of the bevel.

8. The introducer needle of any one of claims 1 to 4, wherein the needle slot is linear from the proximal portion of the needle shaft to the distal needle tip.

9. The introducer needle of any one of claims 1 to 4, wherein the needle slot is non-linear from the proximal portion of the needle shaft to the distal needle tip.

10. The introducer needle of claim 9 , wherein the needle slot is at least partially helical, the needle slot forming at least a portion of a helix between the proximal portion of the needle shaft and the distal needle tip.

11. The introducer needle of any one of claims 1 to 4, wherein the needle slot has a constant needle slot width.

12. The introducer needle of any one of claims 1 to 4, wherein the needle slot has a variable needle slot width.

13. The introducer needle of claim 12 , wherein the needle slot includes one or more needle slot openings that are wider than the remainder of the needle slot.

14. The introducer needle of claim 12 , wherein the needle slot comprises a taper, a reverse taper, or a gradual change in the needle slot width from the proximal portion of the needle shaft to the distal needle tip.

15. The introducer needle of any one of claims 1 to 4, wherein the needle slot is located short of the proximal end of the needle shaft.

16. The introducer needle of any one of claims 1 to 4, wherein the needle slot extends through the proximal end of the needle shaft.

17. The introducer needle of any one of claims 1 to 4, wherein the edges of the needle slot walls are finished to thereby minimize or eliminate sharp access guidewire fraying edges in the needle slot.

18. 1. A rapid insertion central venous catheter ("RICC") insertion assembly comprising: a RICC comprising a catheter tube and a primary lumen through said catheter tube; an introducer needle, a needle shaft including a needle slot extending from a proximal portion of the needle shaft to a distal needle tip having a beveled tip and a heel, the needle shaft comprising: a) opposing needle slot walls face each other and are parallel to each other in line with the needle slot cut into the needle shaft; b) the opposing needle slot walls face each other but are angled relative to each other in accordance with the needle shaft being stamped or rolled to form the needle slot; c) the opposing needle slot walls face away from the bottom of the needle slot in alignment with the needle slot ground into the needle shaft; d) the opposing needle slot walls face toward the bottom of the needle slot in conformity with the opposing needle slot walls being bent toward the bottom of the needle slot; and e) the opposing needle shaft walls are parallel to one another in accordance with the needle shaft being stamped or rolled to form the needle slot; a needle shaft comprising one or more features selected from the group of features consisting of: a sheath covering the needle shaft and sealing the needle slot below the sheath except for a sheath opening at a proximal portion of the sheath; an introducer needle including a needle hub around both the proximal portion of the needle shaft and the proximal portion of the sheath; an access guidewire including a proximal portion disposed within the primary lumen of the RICC and a distal portion disposed within the needle shaft through both the sheath opening and the needle slot; a coupler that couples the RICC and the introducer needle together.

19. 20. The RICC insertion assembly of claim 18, wherein the needle slot extends along at least a portion of the upper portion of the needle shaft, the upper portion of the needle shaft including the heel of the bevel.

20. 20. The RICC insertion assembly of claim 18, wherein the needle slot extends along at least a portion of the bottom of the needle shaft, the bottom of the needle shaft including the distal bevel of the bevel.

21. 20. The RICC insertion assembly of claim 18, wherein the needle slot extends along at least a portion of a side of the needle shaft, the side of the needle shaft being between the heel of the bevel and the tip bevel.

22. 22. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot bisects the heel of the bevel.

23. 22. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot bisects the distal bevel of the bevel.

24. 22. The RICC insertion assembly of claim 18, wherein the needle slot intersects the heel, the tip bevel, or both the heel and the tip bevel of the bevel without bisecting the heel or the tip bevel of the bevel.

25. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot is linear from the proximal portion of the needle shaft to the distal needle tip.

26. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot is non-linear from the proximal portion of the needle shaft to the distal needle tip.

27. 27. The RICC insertion assembly of claim 26, wherein the needle slot is at least partially helical, the needle slot forming at least a portion of a helix between the proximal portion of the needle shaft and the distal needle tip.

28. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot has a constant needle slot width.

29. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot has a variable needle slot width.

30. 30. The RICC insertion assembly of claim 29, wherein the needle slot includes one or more needle slot openings that are wider than the remainder of the needle slot.

31. 30. The RICC insertion assembly of claim 29, wherein the needle slot comprises a taper, a reverse taper, or a gradual change in the needle slot width from the proximal portion of the needle shaft to the distal needle tip.

32. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot is located short of the proximal end of the needle shaft.

33. The RICC insertion assembly of any one of claims 18 to 21, wherein the needle slot extends through the proximal end of the needle shaft.

34. 22. The RICC insertion assembly of any one of claims 18 to 21, wherein the edges of the needle slot walls are finished to thereby minimize or eliminate sharp access guidewire fraying edges of the needle slot.

35. The coupler comprises: a coupler housing including a sealed module cavity; 22. The RICC insertion assembly of claim 18, further comprising: a sealing module insert disposed within the sealing module cavity, wherein the sealing module cavity and the sealing module insert form a sealing module of the RICC insertion assembly, the sealing module being configured to separately seal around a proximal portion of the introducer needle including the sheath opening and a distal portion of the access guidewire when compressed within the sealing module cavity.

36. 36. The RICC insertion assembly of claim 35, wherein the coupler housing includes a longitudinal coupler housing slot configured to allow the access guidewire to exit the coupler housing after a distal portion of the sealing module insert is removed from the sealing module cavity by withdrawal of the introducer needle from the coupler.

37. 36. The RICC insertion assembly of claim 35, wherein the coupler includes a blade extending into the sealing module to be positioned within the needle slot below the distal end of the sheath opening, the blade including a distally facing blade edge configured to decouple the sheath from the needle shaft when the introducer needle is withdrawn from the coupler, thereby allowing the access guidewire to exit the needle shaft through the needle slot.

38. 1. A method of manufacturing an introducer needle, comprising: creating a needle slot in the needle shaft, the needle slot extending from a proximal portion of the needle shaft to a distal needle tip having a beveled tip and a heel; placing a sheath over the needle shaft, the sheath sealing the needle slot below the sheath; and securing a needle hub around both the proximal portion of the needle shaft and the proximal portion of the sheath, thereby forming the introducer needle.

39. 39. The method of claim 38, wherein creating the needle slot comprises cutting the needle slot into the needle shaft by machining or laser cutting.

40. 40. The method of claim 39, wherein opposing needle slot walls face each other and are parallel to each other after cutting, said needle slot walls facing the bottom of said needle slot.

41. 39. The method of claim 38, wherein creating the needle slot comprises grinding the needle slot into the needle shaft.

42. 39. The method of claim 38, wherein opposing needle slot walls face away from the bottom of the needle slot after grinding.

43. 43. The method of claim 40 or 42, further comprising bending the needle slot walls toward the bottom of the needle slot, thereby increasing the bending strength of the needle shaft.

44. 43. The method of claim 40 or 42, comprising finishing the edges of the needle slot walls, thereby minimizing or eliminating sharp access guidewire fraying edges in the needle slot.

45. 43. The method of any one of claims 38 to 42, wherein placing the sheath over the needle shaft comprises inserting the needle shaft into the sheath.

46. 46. ​​The method of claim 45, wherein disposing the sheath over the needle shaft further comprises heat shrinking the sheath over the needle shaft.

47. 43. The method of any one of claims 38 to 42, further comprising creating a sheath opening in the sheath, the sheath sealing the needle slot below the sheath except for the sheath opening in a proximal portion of the sheath.

48. 48. The method of claim 47, wherein creating the sheath opening comprises cutting the sheath opening into the needle shaft by laser cutting after placing the sheath over the needle shaft.

49. 43. The method of any one of claims 38 to 42, wherein securing the needle hub around both the proximal portion of the needle shaft and the proximal portion of the sheath comprises bonding the needle hub to both the proximal portion of the needle shaft and the proximal portion of the sheath.

50. 43. The method of any one of claims 38 to 42, wherein securing the needle hub around both the proximal portion of the needle shaft and the proximal portion of the sheath comprises forcing both the proximal portion of the needle shaft and the proximal portion of the sheath into the needle hub using an engineered fit selected from an intermediate fit and an interference fit.

51. rolling a metal strip into a metal tube, the metal tube including a longitudinal seam formed between longitudinal side edges of the metal strip; welding the longitudinal seam; forcing the metal tube through one or more dies, thereby reducing the outer diameter of the metal tube and simultaneously increasing a metal tube wall thickness of the metal tube; 43. The method of any one of claims 38-42, further comprising grinding the end of the metal tube at multiple angles to form the needle shaft having the beveled distal needle tip.

Images