Catheter with hypotube connected by link member and method of manufacturing same

Abstract

The catheter (10) includes a first tubular structure, a second tubular structure, where the first tubular structure (202) and the second tubular structure (204) are arranged in series with one another along the longitudinal axis of the catheter, and a polymer connector (220) located between (1) a portion of the first tubular structure at an end of the first tubular structure and (2) a portion of the second tubular structure at an end of the second tubular structure, the polymer connector being configured to connect the first tubular structure and the second tubular structure to one another and / or to prevent the first tubular structure and the second tubular structure from separating from one another.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to medical devices, and more particularly to catheters and methods of manufacturing catheters. [Background technology]

[0002] The use of catheters, such as intravascular catheters, to access and treat various types of conditions is well known. For example, a suitable intravascular catheter can be inserted into a patient's vascular system. In a commonly used vascular application to access a target site in a patient, a guidewire is inserted through an incision in the femoral artery near the groin and advanced until it reaches the target site. A catheter is then advanced over the guidewire so that the open distal end of the catheter is positioned at the target site. Simultaneously with or after the distal end of the catheter is positioned at the target site, an intravascular implant is advanced through the catheter via a delivery wire.

[0003] In certain applications, such as neurovascular therapy, catheters must navigate tortuous and complex vasculature. By using appropriately sized catheters with the necessary performance characteristics—pushability, steerability, torqueability, and, most importantly, distal tip flexibility—virtually any target site within the vasculature, including the tortuous cerebral and peripheral vasculature, can be accessed. Furthermore, the force applied at the proximal end of these catheters must be transmitted to the distal end for adequate pushability (axial stiffness) and torqueability (rotational stiffness). Balancing these functions is highly desirable but challenging. For example, catheters can include variable stiffness sections (e.g., sections achieved by varying the ratio of materials, including selective reinforcement) suitable for providing sufficient flexibility, kink resistance, pushability, and torqueability for navigation through the vasculature.

[0004] In some cases, a catheter may include slots along its elongate body or selected portions thereof. Incorporating slots into such elongate medical devices can modify or customize the device's flexibility / rigidity. For example, the distal portion of a catheter, guidewire, or other delivery member can have a slot pattern that increases its flexibility (e.g., more slots per unit area, longer slots, and / or wider slots). When used as a component of a delivery system, the slotted elongate tubular device is preferably substantially sealed (e.g., using a sheath, jacket, coating, etc.) to prevent fluid exchange within the tube's internal lumen (into and out of the lumen) and to enhance lubricity. Exemplary slotted coated medical devices are disclosed in U.S. Patent Nos. 5,095,915, 5,443,455, 6,488,637, and 9,162,040, the disclosures of which are incorporated herein by reference in their entirety. Summary of the Invention

[0005] The catheter includes a first tubular structure, a second tubular structure, where the first tubular structure and the second tubular structure are arranged in series with each other along the longitudinal axis of the catheter, and a polymer connector located between (1) a portion of the first tubular structure at an end of the first tubular structure and (2) a portion of the second tubular structure at an end of the second tubular structure, where the polymer connector is configured to connect the first tubular structure and the second tubular structure to each other and / or to prevent the first tubular structure and the second tubular structure from separating from each other.

[0006] Optionally, the first tubular structure has a first opening at an end of the first tubular structure, the second tubular structure has a first opening at an end of the second tubular structure, and the polymer connector comprises a first connector portion disposed within the first opening at the end of the first tubular structure and a second connector portion disposed within the first opening at the end of the second tubular structure.

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

[0008] Optionally, the first tubular structure includes a protrusion at an end thereof, and the second tubular structure includes an opening at an end thereof, the opening being sized to accommodate at least a portion of the protrusion, and a polymer connector being disposed within a portion of the opening to prevent the protrusion of the first tubular structure from moving within the opening.

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

[0010] Optionally, the catheter further includes a liner, the liner being provided on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and the polymer connector being connected to the liner.

[0011] Optionally, the catheter further includes a jacket, the jacket being provided on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, and the polymer connector being connected to the jacket.

[0012] Optionally, the jacket and at least a portion of the polymer connector are made from the same material.

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

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

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

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

[0017] Optionally, the polymer connector is configured to transmit one or more forces between the first tubular structure and the second tubular structure, the one or more forces comprising a compressive force, a tensile force, a shear force, a torsional force, or any combination thereof.

[0018] Optionally, the ends of the first tubular structure and the ends of the second tubular structure are connected to one another without the use of welding, soldering or adhesives.

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

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

[0021] Optionally, the catheter further includes an additional polymer connector configured to connect the first tubular structure and the second tubular structure to one another and / or to prevent the first tubular structure and the second tubular structure from separating from one another.

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

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

[0024] Optionally, the polymer connector and the second polymer connector are part of a filling structure having a tubular or ring-like configuration.

[0025] Optionally, each of the first and second tubular structures includes structural elements, the structural elements of the first tubular structure configured to abut and engage with structural elements of the second tubular structure, the structural elements configured to transmit shear forces.

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

[0027] Optionally, in the method, the first tubular structure includes a first opening at an end of the first tubular structure, the second tubular structure includes a first opening at an end of the second tubular structure, and the formed polymer connector includes a first connector portion disposed within the first opening at the end of the first tubular structure and a second connector portion disposed within the first opening at the end of the second tubular structure.

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

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

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

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

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

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

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

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

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

[0037] Optionally, the method further includes providing a liner, the liner being on the first inner surface of the first tubular structure and on the second inner surface of the second tubular structure, and the polymer connector being connected to the liner.

[0038] Optionally, the method further includes providing a jacket on the first outer surface of the first tubular structure and on the second outer surface of the second tubular structure, with a polymer connector connected to the jacket.

[0039] Optionally, providing a liner, providing a jacket, and forming a polymer connector includes disposing a liner inside the first and second tubular structures, disposing a polymer connector material in a space between an end of the first tubular structure and an end of the second tubular structure, disposing a jacket around the first and second tubular structures, and curing the polymer connector material to form the polymer connector.

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

[0041] Optionally, in the method, the jacket is made from a jacket material, and forming the polymer connector includes flowing a portion of the jacket material into a space between an end of the first tubular structure and an end of the second tubular structure.

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

[0043] Optionally, in the method, the liner material flows from the liner side and the jacket material flows from the jacket side, and the liner material and jacket material meet at some location in the space.

[0044] Optionally, providing the liner, providing the jacket, and forming the polymer connector includes dipping the first and second tubular structures in a material to coat the first and second tubular structures with the material, and curing the material to form the liner, jacket, and polymer connector.

[0045] Optionally, providing the liner, providing the jacket, and forming the polymer connector includes spraying a material onto the first and second tubular structures to coat the first and second tubular structures with the material, and curing the material to form the liner, jacket, and polymer connector.

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

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

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

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

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

[0051] Optionally, in the method, the formed polymer connector is configured to transmit one or more forces between the first tubular structure and the second tubular structure, the one or more forces comprising a compressive force, a tensile force, a shear force, a torsional force, or any combination thereof.

[0052] Optionally, in the method, the end of the first tubular structure and the end of the second tubular structure are connected to one another without the use of welding, soldering, or adhesives.

[0053] Optionally, the method further includes forming an additional polymer connector, the additional polymer connector configured to connect the first tubular structure and the second tubular structure to one another and / or prevent the first tubular structure and the second tubular structure from separating from one another.

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

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

[0056] Optionally, in the method, the polymer connector and the second polymer connector are part of a filling structure having a tubular or ring-like configuration.

[0057] Optionally, in the method, each of the first and second tubular structures includes a structural element, the structural element of the first tubular structure configured to abut and engage with the structural element of the second tubular structure, and the structural elements configured to transmit shear forces.

[0058] Other and further aspects and features of the embodiments will become apparent from the following detailed description when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0059] [Figure 1] FIG. 1 shows a catheter. [Figure 2]FIG. 2 shows a portion of the catheter of FIG. 1, particularly a portion having two tubular structures connected to one another. [Figure 3] Figure 3A shows an example of a tubular structure before it has been connected, and Figure 3B shows the tubular structure of Figure 3A after it has been connected. [Figure 4] 4A to 4C show examples of polymer connectors for connecting two tubular structures. [Figure 5] FIG. 5 shows an exemplary force transmitted by a polymer connector connecting two tubular structures. [Figure 6] FIG. 6 shows a side view of a portion of the catheter of FIG. 1, particularly showing the polymer connector integrated with the liner and jacket. [Figure 7] FIG. 7 shows a side view of a portion of the catheter of FIG. 1, particularly showing the polymer connector formed by the two connector portions. [Figure 8] FIG. 8 shows another example of a catheter having a polymer connector connecting two tubular structures. [Figure 9] FIG. 9 shows another example of a catheter having a polymer connector connecting two tubular structures. [Figure 10] FIG. 10 illustrates a method for manufacturing a portion of a catheter. DETAILED DESCRIPTION OF THE INVENTION

[0060] Various embodiments will now be described with reference to the drawings. Note that the drawings are not drawn to scale, and elements of similar structure or function are represented by the same reference numerals throughout the drawings. Note also that the drawings are intended only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention or as limiting the scope of the invention. Furthermore, the illustrated embodiments need not have all the aspects or advantages shown. An aspect or advantage discussed in connection with a particular embodiment is not necessarily limited to that embodiment and may be implemented in any other embodiment, even if not so illustrated or explicitly described.

[0061] Described herein are new catheters and new techniques for manufacturing such catheters. An exemplary catheter includes at least two tubular structures arranged in series along the catheter's longitudinal axis. The two tubular structures are circumferentially aligned relative to one another and connected to one another via one or more polymer connectors. Using a polymer connector to connect two tubular structures is advantageous because it can connect two tubular structures regardless of whether they are made of the same or different materials (e.g., nitinol and stainless steel, nitinol and platinum iridium, different polymers, etc.) and / or whether they have the same inner diameter, different inner diameters, the same outer diameter, or different inner diameters. This is advantageous over tubing connections that utilize welding (which may not work if the tubular structures are made of dissimilar materials) or adhesives (which are cumbersome to implement and may not provide desirable structural and / or dimensional properties). The polymer connectors described herein are also advantageous because they can be configured to be compliant in one or more degrees of freedom.

[0062] In one exemplary approach described herein, a cut pattern is formed on the end of a first tubular structure (e.g., a first hypotube) and a cut pattern is formed on the end of a second tubular structure (e.g., a second hypotube). The two ends of each tubular structure are then aligned so that the cut patterns on each end of the tubular structure are connectable. A polymer jacket is placed over the two tubular structures and a polymer liner is placed within the two tubular structures, sandwiching the two tubular structures between the polymer jacket and the polymer liner. The polymer jacket and / or polymer liner are then heated to cause a portion of the polymer material (from the jacket and / or liner) to flow into the cut patterns on the ends of the tubular structures and / or into the space between the ends of the tubular structures. Once the polymer cools / hardens, a polymer connector is formed.

[0063] 1 illustrates a catheter 10 according to some embodiments. The catheter 10 is configured for insertion into a blood vessel. The catheter 10 may be a delivery catheter configured to deliver an item (e.g., an implant (e.g., a coil, a stent, etc.), a drug, a diagnostic agent, etc.) into a human body and / or to withdraw an item (e.g., blood, a biopsy, etc.) from the human body and deliver it to the outside of the human body; a treatment catheter including an energy delivery device configured to provide treatment; a diagnostic catheter configured to image the interior of the human body; or another type of catheter (e.g., a balloon catheter).

[0064] The catheter 10 includes an elongate member 11 having a proximal end 15, a distal end 16, and a body 13 extending between the proximal and distal ends 15 and 16. The elongate member 11 includes a tubular member 14. The tubular member 14 is configured to provide one or more specific structural features along the longitudinal axis of the elongate member 11. The tubular member 14 can be any elongate device or component having a lumen formed from any material, such as any suitable biocompatible metal, polymer, or combination thereof. In some embodiments, the tubular member 14 can have a circular cross-section. In other embodiments, the tubular member 14 of the elongate member 11 can have any cross-sectional shape, such as an oval shape, or any custom-designed shape. Also, in some embodiments, the tubular member 14 can have different cross-sectional shapes and / or dimensions along the longitudinal axis of the tubular member 14.

[0065] The tubular member 14 can have a wall thickness anywhere in the range of 0.001 inches to 0.01 inches, or anywhere in the range of 0.001 inches to 0.006 inches, or anywhere in the range of 0.002 inches to 0.004 inches. In other embodiments, the tubular member 14 can have a wall thickness greater than 0.01 inches or less than 0.001 inches. In some cases, the tubular member 14 can have an outer diameter anywhere in the range of 0.01 inches to 0.11 inches, or anywhere in the range of 0.08 inches to 0.11 inches, or anywhere in the range of 0.01 inches to 0.03 inches (e.g., 0.024 inches ± 0.002 inches), or anywhere in the range of 0.01 inches to 0.02 inches. In other embodiments, the tubular member 14 can have an outer diameter greater than 0.11 inches. In further embodiments, tubular member 14 may have an outer diameter of less than 0.01 inches.

[0066] 2, the tubular member 14 of the catheter 10 includes a first tubular structure 202 and a second tubular structure 204, which are arranged in series with one another along a longitudinal axis 208 of the catheter 10. The tubular member 14 of the catheter 10 includes a polymer connector 220 located between (1) a portion of the first tubular structure 202 at an end 222 of the first tubular structure 202 and (2) a portion of the second tubular structure 204 at an end 224 of the second tubular structure 204. The polymer connector 220 is configured to connect the first tubular structure 202 and the second tubular structure 204 to one another and / or prevent the first tubular structure 202 and the second tubular structure 204 from separating from one another.

[0067] 2, in some embodiments, the first tubular structure 202 includes a first opening 242 at the end 222 of the first tubular structure 202, and the second tubular structure 204 includes a first opening 244 at the end 224 of the second tubular structure 204. The polymer connector 220 includes a first connector portion 252 disposed within the first opening 242 at the end 222 of the first tubular structure 202, and a second connector portion 254 disposed within the first opening 244 at the end 224 of the second tubular structure 204.

[0068] In some embodiments, the first opening 242 at the end 222 of the first tubular structure 202 is a laser cut opening. Also, in some embodiments, the first opening 244 at the end 224 of the second tubular structure 204 is a laser cut opening. In other embodiments, one or both of the openings 242, 244 can be created by mechanical cutting, drilling, chemical etching, etc.

[0069] In some embodiments, the first tubular structure 202 may be a first hypotube made from a metal, alloy, or polymer, and the second tubular structure 204 may be a second hypotube made from the metal, the alloy, the polymer, another metal, another alloy, or another polymer.

[0070] Also, in some embodiments, the first tubular structure 202 can have a plurality of slots, openings, etc., which form the porous wall of the first tubular structure 202. Similarly, in some embodiments, the second tubular structure 204 can have a plurality of slots, openings, etc., which form the porous wall of the second tubular structure 204. By way of non-limiting example, each of the first tubular structure 202 and the second tubular structure 204 can be a tube with laser cut openings, a braided tubular structure, a wire mesh, a coil, a tube with laser cut or machine cut slots / gaps, etc.

[0071] In some embodiments, the openings / slots / gaps in each of the first and second tubular structures 202, 204 can be formed by sawing the tubular structures 202 / 204 with a circular blade, micromachining, laser cutting, electro-discharge machining, plasma arc cutting, grinding, milling, casting, molding, chemical etching, or other known suitable methods, etc. In other embodiments, the tubular structures 202 / 204 with the openings / slots / gaps can be manufactured using "additive" manufacturing (e.g., 3D printing) rather than the various "subtractive" approaches described above.

[0072] In some cases, the first tubular structure 202 can have a plurality of first openings 242 at the end 222 of the first tubular structure 202, and the second tubular structure 204 can have a plurality of first openings 244 at the end 224 of the second tubular structure 204. The first openings 242 of the first tubular structure 202 are configured to align with the first openings 244 of the second tubular structure 204, respectively, such that each pair of aligned first openings 242 forms a space for accommodating a corresponding polymer connector 220.

[0073] 3A illustrates an example of a first tubular structure 202, particularly one having multiple ring elements 302 arranged in series along the longitudinal axis of the first tubular structure 202. Adjacent ring elements 302 are connected by multiple structural members 312. The ring elements 302 and structural members 312 cooperate to transmit one or more forces during use of the catheter 10. By way of non-limiting example, the one or more forces may be axial compression, axial tension, bending, shear, torsion, or any combination thereof.

[0074] Similarly, the second tubular structure 204 has a plurality of ring elements 304 arranged in series along the longitudinal axis of the second tubular structure 204. Adjacent ring elements 304 are connected by a plurality of structural members 314. The ring elements 304 and the structural members 314 cooperate to transmit one or more forces during use of the catheter 10. By way of non-limiting example, the one or more forces may be axial compression, axial tension, bending, shear, torsion, or any combination thereof.

[0075] The openings defined by the ring elements and structural members of the tubular structures 202, 204 are advantageous because they increase the flexibility of the tubular member 14 of the catheter 10, while the structural members (e.g., beams) and ring elements (annular segments) provide relatively high torsional stiffness while retaining a desired level of lateral bending flexibility.

[0076] It should be noted that the tubular structures 202 / 204 are not limited to having the configurations and features described in the above examples, and that the tubular structures 202 / 204 may have other configurations and features in other embodiments. For example, in other embodiments, each of the tubular structures 202, 204 may have a different arrangement and configuration of ring elements and structural members. In some embodiments, at least some or all of the structural members are arranged so that their respective longitudinal axes form the same or a similar angle (e.g., 0 degrees ± 10 degrees) with the longitudinal axis of the catheter 10. In other embodiments, the structural members are arranged so that their respective longitudinal axes form a different angle with the longitudinal axis of the catheter 10. It should be understood that the distribution and / or configuration of the ring elements and structural members may have any suitable variations and combinations thereof.

[0077] Also, in some cases, the tubular structures 202, 204 having cut patterns can provide one or more mechanical requirements (e.g., axial stiffness, hoop strength, bending stiffness, bend radius, torsional stiffness, etc., or any combination thereof).

[0078] Additionally, in some cases, it may be desirable to provide increased stiffness in the proximal portion of the catheter 10. This can be achieved by using tubular structures 202, 204 having different geometric, mechanical and / or material properties (e.g., different thicknesses, different materials, different tube opening patterns, etc.).

[0079] 3A, the first tubular structure 202 has a plurality of first openings 242 at an end thereof, and the second tubular structure 204 has a plurality of first openings 244 at an end thereof. Also shown, the first tubular structure 202 also has a structural element 332 (e.g., a tube portion having an opening) configured to abut and engage with a corresponding structural element 334 (e.g., a protrusion) at the end of the second tubular structure 204. The structural elements 332, 334 form indexing elements configured to circumferentially align pairs of openings 242, 244. In some embodiments, the structural elements 332, 334 are configured to transfer shear forces between the first and second tubular structures 202, 204 after the first and second tubular structures 202, 204 are bonded together.

[0080] Figure 3A shows the first and second tubular structures 202, 204 before they are bonded together. Figure 3B shows the first and second tubular structures 202, 204 abutting each other and illustrating how indexing elements (pairs of mating structural elements 332, 334) circumferentially align a set of first openings 242 at the end of the first tubular structure 202 with a set of first openings 244 at the end of the second tubular structure 204. Each pair of first openings 242, 244 defines a space within which a polymer connector 220 is formed.

[0081] FIG. 4A illustrates an example of a polymer connector 220. As shown, the polymer connector 220 has a shape corresponding to the shape of the space formed by the pair of first openings 242, 244. In the illustrated embodiment, the polymer connector 220 has a dumbbell shape. In particular, the polymer connector 220 has a first enlarged portion 402 at a first end of the polymer connector, a second enlarged portion 404 at a second end of the polymer connector, and a relatively small central portion 406. In other embodiments, the polymer connector 220 can have other shapes. For example, in other embodiments, the polymer connector 220 can have two enlarged portions 402, 404 at both ends of the polymer connector 220 and also have an enlarged central portion 406 ( FIG. 4B ). The enlarged central portion 406 can function as an indexing element configured to align the first tubular structure 202 and the second tubular structure 204 with each other and / or to transmit force between the first and second tubular structures 202, 204. In a further embodiment, the polymer connector 220 can also have an I-shape (FIG. 4C).

[0082] In some embodiments, the polymer connector 220 can be fabricated from one or more polymeric materials, such as polyurethane, cellulose acetate, mixed ester cellulose, PTFE / polyester, acrylic copolymers, other biocompatible polymers, or any combination thereof. Other examples of materials that can be used to fabricate the polymer connector 220 include polyether block amide (PEBA), thermoplastic elastomers (TPEs, such as PEBAX® and VESTAMID® E), polyamides (PAs, such as nylon), thermoplastic polyurethanes (TPUs), polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyolefin elastomers (POE), styrene-ethylene-butylene-styrene (SEBS), polyethylene terephthalate (PET or PETE), polylactic acid (PLA), fluorinated ethylene propylene (FEP) polymers, or other polymers. The polymer connector 220 can also optionally include one or more non-polymeric materials. Thus, the term "polymeric connector" is not limited to components made solely from polymeric materials, but can refer to components made from one or more polymeric materials and optionally including one or more non-polymeric materials.

[0083] In some cases, the polymer connector 220 can be made from a material having a modulus of elasticity anywhere in the range of 2 MPa to 2000 MPa, which gives the polymer connector 220 a significantly higher modulus of elasticity than the material of the tubular structures 202, 204. In some cases, the polymer connector 220 also makes the tubular member 14 more flexible (compared to solutions in which the tubular structures are connected by welding), which allows the tubular member 14 to pass through relatively tight bends during use of the catheter 10.

[0084] In some cases, the polymer connector 220 can have a length that allows the tubular member 14 to achieve a desired radius of curvature by bending the tubular member 14. The desired radius of curvature of the tubular member 14 can be anywhere between 0.02 inches and 0.16 inches, or between 0.03 inches and 0.10 inches, or between 0.035 inches and 0.08 inches, or between 0.04 inches and 0.06 inches, or between 0.055 inches and 0.06 inches, or within a range of 0.039 inches ±0.01 inches. In some cases, the polymer connector 220 can have an overall longitudinal length (measured parallel to the longitudinal axis of the tubular member 14) that is anywhere between 0.2 mm and 2 mm, more preferably between 0.2 mm and 1 mm, and even more preferably between 0.4 mm and 0.8 mm. Each of the anchors on either side of the polymer connector 220 can have a longitudinal length (measured in a direction parallel to the longitudinal axis of the tubular member 14) ranging from 0.05 mm to 0.15 mm, for example, 0.1 mm. In other embodiments, each of the anchors on either side of the polymer connector 220 can have a longitudinal length greater than 0.15 mm. Additionally, the central portion of the polymer connector 220 extending between the anchors on either side can have a longitudinal length (measured in a direction parallel to the longitudinal axis of the tubular member 14) ranging from 0 mm to 5.5 mm, or from 0 mm to 4 mm, or from 0 mm to 3 mm, or from 0 mm to 2 mm, or from 0.4 mm to 1.5 mm, or from 0.4 mm to 1.0 mm, or from 0.4 mm to 0.9 mm, or from 0.5 mm to 0.9 mm. In some cases, when the polymer connector 220 is implemented more distally (e.g., closer to the distal end of the tubular member 14), the polymer connector 220 may have a shorter longitudinal length (compared to a scenario in which the polymer connector 220 is implemented more proximally).

[0085] Also, in some cases, multiple polymer connectors 220 may be circumferentially disposed (at one longitudinal location) between the first and second tubular structures 202, 204. In such cases, the total shear strength V provided by the polymer connectors 220 may be T is the shear strength V of each polymer connector 220 c multiplied by the number N of polymer connectors 220. In such a case, the total shear strength V provided by all of the polymer connectors 220 is T may be higher than the shear strength of each of the tubular structures 202, 204.

[0086] In some cases, the polymer connector 220 can be configured to achieve a stiffness profile and / or force-displacement profile that meets the clinical requirements of a particular application.

[0087] In some embodiments, each polymer connector 220 has an uncompressed volume (neutral volume) and is compressible to a compressed volume of less than 50%, less than 40%, less than 30%, less than 20%, less than 10%, or less than 5% of the neutral volume. In some embodiments, each polymer connector 220 has an unstretched (neutral) volume and is stretchable to a stretched volume that is greater than 105%, greater than 110%, greater than 120%, greater than 130%, greater than 140%, or greater than 150% of the neutral volume. In other embodiments, each polymer connector 220 is compressible and / or stretchable to a strain (compressive or tensile) of at least 0.1, at least 0.2, at least 0.3, at least 0.4, or at least 0.5, where strain is defined as the change in length of the polymer connector 220 divided by the original length of the polymer connector 220 (e.g., strain = change in length / original length). In further embodiments, each polymer connector 220 may be compressible and / or stretchable to reach strains (compressive or tensile) of less than 0.1.

[0088] Additionally, in some cases, the polymer connector 220 can be configured to have an extension limit that is less than the longitudinal length of the indexing elements (e.g., the indexing elements described with reference to structural elements 332, 334), thereby allowing the indexing elements to continue to transmit forces (e.g., shear) between the tubular structures 202, 204 as the polymer connector 220 stretches. In other aspects, the polymer connector 220 can be configured to have an extension limit that is greater than the longitudinal length of the indexing elements.

[0089] It should be noted that the polymer connector 220 is not limited to having the configuration shown in the above example, and the polymer connector 220 may have other configurations in other embodiments.

[0090] As shown in FIG. 5 , in some embodiments, the polymer connector 220 is configured to transmit one or more forces between the first tubular structure 202 and the second tubular structure 204. The one or more forces may include a compressive force, a tensile force, a shear force, a torsional force, or any combination thereof. In some cases, the first and second tubular structures 202, 204 may include indexing elements, such as the structural elements 332, 334 described herein. In such cases, the indexing elements may function to transmit one or more forces, such as axial tension, axial compression, shear, or torsion. In other aspects, the catheter 10 may not include indexing elements in the tubular structures 202, 204. In such cases, the polymer connector 220 may function to transmit one or more forces, as described herein.

[0091] 6 , the catheter 10 may optionally further include a liner 600. The liner 600 is provided on a first inner surface 602 of the first tubular structure 202 and on a second inner surface 604 of the second tubular structure 204. The catheter 10 may optionally further include a jacket 610. The jacket 610 is provided on a first outer surface 612 of the first tubular structure 202 and on a second outer surface 614 of the second tubular structure 204. The polymer connector 220 may be connected to the liner 600 and / or the jacket 610.

[0092] In some cases, the jacket 610 and at least a portion of the polymer connector 220 can be made from the same material. Also, in some cases, the liner 600 and at least a portion of the polymer connector 220 can be made from the same material. In other embodiments, the polymer connector 220 can be made from a material that is different from the material of the jacket 610 and / or the material of the liner 600.

[0093] The polymer connector 220 can be connected to the liner 600 by being integrally formed with the liner 600 or by forming the polymer connector 220 on the liner 600. In other embodiments, the polymer connector 220 can be connected to the liner 600 via an adhesive (e.g., glue). Similarly, the polymer connector 220 can be connected to the liner jacket 610 by being integrally formed with the jacket 610 or by forming the polymer connector 220 on the jacket 610. In other embodiments, the polymer connector 220 can be connected to the jacket 610 via an adhesive (e.g., glue). As shown in FIG. 6 , in some cases, the polymer connector 220 can be integral with both the liner 600 and the jacket 610. This can be achieved by attaching the first and second tubular structures 202, 204 to the liner 600, or vice versa. The polymer connector 220 material, in uncured and / or liquid form, is then disposed in the space between the first and second tubular structures 202, 204. A jacket 610 is then placed over the first and second tubular structures 202, 204 to cover the polymer connector 220 material. Alternatively, the jacket 610 material in uncured or liquid form can be placed on the outer surfaces 612, 614 of the respective first and second tubular structures 202, 204. After the polymer connector 220 material (and the jacket 610 material if applied in liquid form) has cured or solidified, the polymer connector 220 is formed and integrated with the liner 600 and jacket 610.

[0094] In other embodiments, the liner 600 is first bonded to the first and second tubular structures 202, 204. The polymer connector 220, in solid form, can then be placed in the space between the first and second tubular structures 202, 204. The jacket 610 is then placed around the first and second tubular structures 202, 204. The liner 600, polymer connector 220, and jacket 610 can then be heated to fuse the ends of the polymer connector 220 to the liner 600 and jacket 610, respectively. In some cases, the ends of the polymer connector 220 can include a heat-activated adhesive. In other cases, the polymer connector 220 can be made from a material with a lower melting point than the materials of the liner 600 and jacket 610. This allows the material of the polymer connector 220 to melt while housed between the liner 600 and jacket 610. After the material of the polymer connector 220 has solidified or hardened, the polymer connector 220 is integrated with the liner 600 and jacket 610 .

[0095] In some cases, the liner 600 can be provided as a tube over which the first and second tubular structures 202, 204 are disposed. The liner 600 can have a surface with a layer of material configured to adhere to the surface of the first and second tubular structures 202, 204. For example, the layer of material can be an adhesive or a heat-activated adhesive. After the tube (liner 600) is heated, the first and second tubular structures 202, 204 are attached to the liner 600.

[0096] Similarly, the jacket 610 can be provided as a tube that is placed over the first and second tubular structures 202, 204. The jacket 610 can have a surface with a layer of material configured to adhere to the surfaces of the first and second tubular structures 202, 204. For example, the layer of material can be an adhesive or a heat-activated adhesive. After the tube (jacket 610) is heated, the first and second tubular structures 202, 204 are attached to the jacket 610.

[0097] In some cases, the polymer connector 220 material (in liquid or solid form) can be placed in the space between the first and second tubular structures 202, 204 before the jacket 610 is placed over the first and second tubular structures 202, 204. After the polymer connector 220 material is placed and the jacket 610 is placed over the first and second tubular structures 202, 204, heat can be applied to the liner 600 and jacket 610 to heat them. The heated liner 600 adheres the liner 600 to the inner surfaces of the first and second tubular structures 202, 204 and also to the polymer connector 220 material. Similarly, the heated jacket 610 adheres the jacket 610 to the outer surfaces of the first and second tubular structures 202, 204 and also to the polymer connector 220 material.

[0098] In a further embodiment, the first and second tubular structures 202, 204 can be dipped into a solution (material) that, when solidified, forms a liner 600 on the inner surface 602, 604 of each of the first and second tubular structures 202, 204, a polymer connector 220 between the first and second tubular structures 202, 204, and a jacket 610 on the outer surface 612, 614 of each of the first and second tubular structures 202, 204.

[0099] In other embodiments, a solution (material) can be sprayed onto the first and second tubular structures 202, 204. When the solution solidifies, it forms a liner 600 on the inner surfaces 602, 604 of the respective first and second tubular structures 202, 204, a polymer connector 220 between the first and second tubular structures 202, 204, and a jacket 610 on the outer surfaces 612, 614 of the respective first and second tubular structures 202, 204.

[0100] In other embodiments, forming the polymer connector 220 includes laminating a portion of the liner 600 and a portion of the jacket 610 across a space to form the polymer connector 220 .

[0101] In other embodiments, the polymer connector 220 can have a first connector portion 220a and a second connector portion 220b (FIG. 7). As shown, the first connector portion 220a and the second connector portion 220b are different layers that form the polymer connector 220. The first connector portion 220a and the second connector portion 220b can be made of the same material or different materials. The first connector portion 220a can be closer to the jacket 610 than the liner 600 and / or directly coupled to the jacket 610. The second connector portion 220b can be closer to the liner 600 than the jacket 610 and / or directly coupled to the liner 600. The seam between the first connector portion 220a and the second connector portion 220b is located midway, such that the thickness of the first connector portion 220a (measured perpendicular to the longitudinal axis 208 of the catheter 10) is equal to the thickness of the second connector portion 220b. In other embodiments, the thicknesses of the first connector portion 220a and the second connector portion 220b may be different from one another. For example, the thickness of the first connector portion 220a may be greater than the thickness of the second connector portion 220b, or the thickness of the first connector portion 220a may be less than the thickness of the second connector portion 220b.

[0102] The configuration of the polymer connector 220 shown in FIG. 7 can be achieved by flowing a portion of the material of the liner 600 into the space between the first and second tubular structures 202, 204 when the material is in liquid form, and flowing a portion of the material of the jacket 610 into the space between the first and second tubular structures 202, 204 when the material is in liquid form. The material of the liner 600 and the material of the jacket 610 are poured into the space between the first and second tubular structures 202, 204 from both ends of the space. Therefore, the material of the liner 600 disposed in the space between the first and second tubular structures 202, 204 occupies only a portion of the space. Similarly, the material of the jacket 610 disposed in the space between the first and second tubular structures 202, 204 occupies only a portion of the space.

[0103] In other embodiments, the catheter 10 may not include the liner 600 and / or the jacket 610. For example, in other embodiments, the polymer connector 220 may not extend beyond the lateral boundaries of the space between the tubular structures 202, 204 (e.g., the inner surfaces of the tubular structures 202, 204 and / or the outer surfaces of the tubular structures 202, 204). In further embodiments, the polymer connector 220 may extend beyond the inner surfaces of the tubular structures 202, 204 and / or beyond the outer surfaces of the tubular structures 202, 204. For example, in other embodiments, the catheter 10 may include a jacket 610 and a polymer connector 220 attached to the jacket 610, and the polymer connector 220 may extend beyond the inner surface of the wall of the tubular structure 202 and / or the inner surface of the wall of the tubular structure 204 into the lumen of the tubular member 14. In another example, the catheter 10 can include a liner 600 and a polymer connector 220 attached to the liner 600, where the polymer connector 220 can extend beyond the outer surface of the wall of the tubular structure 202 and / or the outer surface of the wall of the tubular structure 204. In some cases, the portion of the polymer connector 220 that extends beyond the lateral boundary of the space between the tubular structures 202, 204 can be a bump, an elongated protrusion, a block, or can have a random shape (e.g., due to a manufacturing artifact, etc.). In a further embodiment, the portion of the polymer connector 220 that extends beyond the inner surface of the tubular structures 202 / 204 can extend into an inner layer (e.g., the liner 600) disposed on the inner surface of the tubular structures 202 / 204, in which case the portion of the polymer connector 220 can be separately attached to the inner layer or integrally formed therewith. In further embodiments, the portion of the polymer connector 220 that extends beyond the outer surface of the tubular structure 202 / 204 may extend to an outer layer (e.g., jacket 600) disposed on the outer surface of the tubular structure 202 / 204, in which case the portion of the polymer connector 220 may be separately attached to the outer layer or may be integrally formed with the outer layer.In other embodiments, the polymer connector 220 can have a first portion that extends beyond the outer surface of the tubular structure 202 / 204 and a second portion that extends beyond the inner surface of the tubular structure 202 / 204. In such cases, the first portion of the polymer connector 220 can be separately attached to an outer layer (e.g., jacket 610) disposed on the outer surface of the tubular structure 202 / 204, and the second portion of the polymer connector 220 can be separately attached to an inner layer (e.g., liner 600) disposed on the inner surface of the tubular structure 202 / 204.

[0104] As shown in the above examples, the catheter 10 can have multiple polymer connectors 220 (such as those shown in FIGS. 2 and 3) connected to one another via a liner 600 and / or jacket 610. In some cases, the liner and / or jacket, together with the polymer connectors 220, form a filling structure having a tubular or ring-like configuration. The filling structure can include one or more filling portions that fill one or more spaces between two adjacent tubular structures.

[0105] 6 and 7, the first tubular structure 202 and the second tubular structure 204 have the same inner diameter and / or the same outer diameter. In other embodiments, the first tubular structure 202 and the second tubular structure 204 have different respective inner diameters and / or different respective outer diameters.

[0106] Also, in some cases, the first tubular structure 202 and the second tubular structure 204 are made from the same material, while in other embodiments, the first tubular structure 202 and the second tubular structure 204 are made from different respective materials.

[0107] In the above examples, the catheter 10 has been described as having multiple polymer connectors 220 (e.g., a polymer connector and an additional polymer connector). Each of the polymer connectors (e.g., a polymer connector, an additional polymer connector) is configured to couple the first tubular structure 202 and the second tubular structure 204 to one another and / or prevent the first tubular structure 202 and the second tubular structure 204 from separating from one another. In other embodiments, the catheter 10 may have only a single polymer connector 220 connecting each pair of adjacent tubular structures.

[0108] In other embodiments, the catheter 10 may have more than two tubular structures (e.g., three tubular structures, four tubular structures, etc.), in which case each adjacent pair of tubular structures may be connected by one or more polymer connectors 220.

[0109] 2 and 3, the polymer connectors 220 are circumferentially arranged around the longitudinal axis 208 of the catheter 10 and lie in a plane (e.g., a common plane) perpendicular to the longitudinal axis 208 of the catheter 10. The polymer connectors 220 are evenly distributed around the circumferential direction. This has the advantage of allowing catheter bodies to be formed with the same connection strength on different sides of the catheter. Alternatively or additionally, the polymer connectors 220 may lie in different planes perpendicular to the longitudinal axis 208 of the catheter 10. For example, as shown in FIG. 8, the catheter 10 has two sets 700, 702 of polymer connectors 220. The polymer connectors 220 of the first set 700 are circumferentially arranged around the longitudinal axis 208 of the catheter 10 and lie in a first common plane perpendicular to the longitudinal axis 208 of the catheter 10. The polymer connectors 220 of the second set 702 are arranged circumferentially around the longitudinal axis 208 of the catheter 10 and lie in a second common plane perpendicular to the longitudinal axis 208 of the catheter 10, the second common plane being different from the first common plane.

[0110] In the above example, the polymer connector 220 has enlarged portions at both ends that function as anchors to mechanically couple the first and second tubular structures 202, 204 to one another. In other embodiments, the polymer connector 220 can have different configurations. For example, in other embodiments, the polymer connector 220 can have only one enlarged portion that functions as an anchor, or multiple enlarged portions. Additionally, the polymer connector 220 need not "actively" connect the first and second tubular structures 202, 204 to one another, but may be a "passive" connector in some cases. For example, as shown in FIG. 9 , the first tubular structure 202 can have a protrusion 902 at its end, configured to be positioned in an opening 904 at the end of the second tubular structure 204. In the illustrated example, the protrusion 902 is in the form of a hook sized and shaped to be inserted into the opening 904. The opening 904 has a hook shape that corresponds to the hook shape of the protrusion 902. The opening 904 is sized to accommodate at least a portion of the protrusion 902. During manufacture, the first tubular structure 202 is positioned toward the second tubular structure 204, or vice versa, to insert the protrusion 902 into the opening 904. After the protrusion 902 is inserted into the opening 904, the first tubular structure 202 can be rotated about its longitudinal axis relative to the second tubular structure 204, or vice versa, to move the protrusion 902 from one position within the opening 904 to another position within the opening 904, thereby longitudinally locking the protrusion 902 relative to the opening 904. As shown, a polymer connector 220 is positioned in a portion of the opening 904 to prevent the protrusion 902 of the first tubular structure 202 from moving within the opening 904 after the protrusion 902 is inserted into the opening 904. As a result, the protrusion 902 cannot move circumferentially out of the opening 904, thereby allowing the first and second tubular structures 202, 204 to remain connected to one another.Thus, as used herein, the term "connector" is not limited to a mechanical element that "connects," but may include a mechanical element (such as a lock, blocker, filler, stopper, etc.) that prevents separation of two items (e.g., two tubular structures).

[0111] 10 illustrates a method 1100 of manufacturing a portion of a catheter. The method 1100 includes the steps of providing a first tubular structure (item 1102), providing a second tubular structure (item 1104), disposing the first and second tubular structures in series with one another (item 1106), and forming a polymer connector in a space between an end of the first tubular structure and an end of the second tubular structure, the formed polymer connector joining the first and second tubular structures to one another and / or preventing the first and second tubular structures from separating from one another (item 1108).

[0112] Optionally, in method 1100, the first tubular structure includes a first opening at an end of the first tubular structure, and the second tubular structure includes a first opening at an end of the second tubular structure, and the formed polymer connector includes a first connector portion disposed within the first opening at the end of the first tubular structure and a second connector portion disposed within the first opening at the end of the second tubular structure.

[0113] Optionally, in method 1100, the first opening in the end of the first tubular structure is a laser cut opening.

[0114] Optionally, in method 1100, the first tubular structure includes a protrusion at an end of the first tubular structure, and the second tubular structure includes an opening at an end of the second tubular structure, the opening being sized to accommodate at least a portion of the protrusion, and the formed polymer connector being positioned in a portion of the opening to prevent the protrusion of the first tubular structure from moving within the opening.

[0115] Optionally, in method 1100, the first tubular structure is a first hypotube made from a metal, alloy, or polymer, and the second tubular structure is a second hypotube made from the metal, the alloy, the polymer, another metal, another alloy, or another polymer.

[0116] Optionally, in method 1100, the thickness of the first tubular structure is equal to the thickness of the second tubular structure.

[0117] Optionally, in method 1100, the thickness of the first tubular structure is different from the thickness of the second tubular structure.

[0118] Optionally, in method 1100, the material of the first tubular structure is the same as the material of the second tubular structure.

[0119] Optionally, in method 1100, the material of the first tubular structure is different from the material of the second tubular structure.

[0120] Optionally, in method 1100, the formed polymer connector has a first enlarged portion at a first end of the polymer connector and a second enlarged portion at a second end of the polymer connector.

[0121] Optionally, in method 1100, the polymer connector has a dumbbell or I-shape.

[0122] Optionally, method 1100 further includes providing a liner, the liner being on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and a polymer connector being connected to the liner.

[0123] Optionally, method 1100 further includes providing a jacket, the jacket being on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, with a polymer connector connected to the jacket.

[0124] Optionally, providing a liner, providing a jacket, and forming a polymer connector includes disposing a liner inside the first and second tubular structures, disposing a polymer connector material in a space between an end of the first tubular structure and an end of the second tubular structure, disposing a jacket around the first and second tubular structures, and curing the polymer connector material to form the polymer connector.

[0125] Optionally, in method 1100, the liner is made from a liner material, and forming the polymer connector includes pouring a portion of the liner material into a space between an end of the first tubular structure and an end of the second tubular structure.

[0126] Optionally, in method 1100, the jacket is made from a jacket material, and forming the polymer connector includes pouring a portion of the jacket material into a space between an end of the first tubular structure and an end of the second tubular structure.

[0127] Optionally, in method 1100, the liner material flows from the liner side to the jacket side.

[0128] Optionally, in method 1100, the jacket material flows from the jacket side to the liner side.

[0129] Optionally, in method 1100, the liner material flows from the liner side and the jacket material flows from the jacket side, and the liner material and jacket material meet at some location in the space.

[0130] Optionally, providing the liner, providing the jacket, and forming the polymer connector includes dipping the first and second tubular structures in a material to coat the first and second tubular structures with the material, and curing the material to form the liner, jacket, and polymer connector.

[0131] Optionally, providing the liner, providing the jacket, and forming the polymer connector includes spraying a material onto the first and second tubular structures to coat the first and second tubular structures with the material, and curing the material to form the liner, jacket, and polymer connector.

[0132] Optionally, forming the polymer connector includes laminating a portion of the liner and a portion of the jacket across the space to form the polymer connector.

[0133] Optionally, in method 1100, at least a portion of the jacket and the polymer connector are made from the same material.

[0134] Optionally, in method 1100, the liner and at least a portion of the polymer connector are made from the same material.

[0135] Optionally, in method 1100, the first tubular structure and the second tubular structure have different respective inner diameters and / or different respective outer diameters.

[0136] Optionally, in method 1100, the first tubular structure and the second tubular structure have the same inner diameter and / or the same outer diameter.

[0137] Optionally, in method 1100, the formed polymer connector is configured to transmit one or more forces between the first tubular structure and the second tubular structure, the one or more forces including a compressive force, a tensile force, a shear force, a torsional force, or any combination thereof.

[0138] Optionally, in method 1100, the end of the first tubular structure and the end of the second tubular structure are connected to one another without the use of welding, soldering, or adhesives.

[0139] Optionally, method 1100 further includes forming an additional polymer connector, the additional polymer connector configured to connect the first tubular structure and the second tubular structure to one another and / or prevent the first tubular structure and the second tubular structure from separating from one another.

[0140] Optionally, in method 1100, the polymer connector and the additional polymer connector are circumferentially arranged around the longitudinal axis of the catheter and lie in a plane perpendicular to the longitudinal axis of the catheter.

[0141] Optionally, in method 1100, the polymer connector and the additional polymer connector are in different respective planes perpendicular to the longitudinal axis of the catheter.

[0142] Optionally, in method 1100, the polymer connector and the second polymer connector are part of a filling structure having a tubular or ring-like configuration.

[0143] Optionally, in method 1100, each of the first and second tubular structures includes structural elements, the structural elements of the first tubular structure configured to abut and engage with the structural elements of the second tubular structure, and the structural elements configured to transmit shear forces.

[0144] The polymer connector 220 described herein is advantageous because it connects two adjacent tubular structures without the use of welding, soldering, or adhesives. Therefore, the tubular structures 202, 204 are not affected by the heat generated by welding or soldering. Additionally, in some cases, the joining of the two tubular structures 202, 204 can be performed simultaneously with the formation of the catheter jacket 610 / liner 600. This allows manufacturing flexibility to assemble a family of catheters by simply modifying individual sections of the catheter design. Furthermore, the polymer connector 220 allows for the assembly of two tubular structures (e.g., hypotubes) regardless of the material and / or shape of the two tubular structures, e.g., the two tubular structures may be made of the same or different materials, the two tubular structures may have the same or different thicknesses, the two tubular structures may have the same or different inner diameters (ID), and / or the two tubular structures may have the same or different outer diameters (OD). In some cases, one or more polymer connectors 220 may be able to withstand higher compression, tension, shear, and / or torsion than a butt joint without the use of welding or adhesives.

[0145] In the above examples, the polymer connector 220 has been described as being located in the space between the tubular structures 202, 204. As shown in Figure 2, the space between the tubular structures 202, 204 that houses the polymer connector 220 includes an opening 242 defined by a portion of the tubular structure 202 at the end of the tubular structure 202 and an opening 244 defined by a portion of the tubular structure 204 at the end of the tubular structure 204. Alternatively or additionally, the space between the tubular structures 202, 204 can include the region between the tip of the tubular structure 202 and the tip of the tubular structure 204.

[0146] Also, an "end" of a member / structure (e.g., tubular structure 202, tubular structure 204, etc.) may be a segment of the member / structure that is 1 / 10, 1 / 20, 1 / 30, 1 / 40, or 1 / 50 of the total length of the member / structure as measured from the tip of the member / structure. In some cases, the "end" of a member / structure can have a longitudinal length of 1 inch, 0.5 inch, 0.4 inch, 0.3 inch, 0.2 inch, 0.1 inch, or less than 0.1 inch.

[0147] In this specification, all numerical values ​​are intended to be modified by the term "about," whether explicitly stated or not. The term "about" generally refers to a range of numerical values ​​that one of ordinary skill in the art would consider equivalent to the stated value (i.e., having the same function or result). In many cases, the term "about" includes numerical values ​​rounded to the nearest significant figure. In some cases, the term "about" may refer to a range of values ​​within ±10% of a value. For example, a value of 2, or a value of approximately 2, can refer to any value within the range of 2 ±10% (= 2 ± 0.2 = 1.8 to 2.2).

[0148] The recitation of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

[0149] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. As used herein and in the appended claims, the term "or" is generally used in its sense including "and / or" unless the content clearly dictates otherwise.

[0150] While particular embodiments have been disclosed and described, it should be understood that this is not intended to limit the invention to the preferred embodiments. It will also be apparent to those skilled in the art that various changes and modifications (e.g., the dimensions and / or shape of various parts) can be made without departing from the spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. The invention is intended to cover alternatives, modifications, and equivalents.

Claims

1. A catheter, a first tubular structure; a second tubular structure, wherein the first tubular structure and the second tubular structure are arranged in series with one another along a longitudinal axis of the catheter; a polymer connector located between (1) a portion of a first tubular structure at an end of the first tubular structure and (2) a portion of a second tubular structure at an end of the second tubular structure; The catheter is characterized in that the polymer connector is configured to connect the first tubular structure and the second tubular structure to each other and / or to prevent the first tubular structure and the second tubular structure from separating from each other.

2. The catheter of claim 1, the first tubular structure has a first opening at an end of the first tubular structure; the second tubular structure has a first opening at an end of the second tubular structure; A catheter characterized in that the polymer connector comprises a first connector portion disposed within a first opening at the end of the first tubular structure and a second connector portion disposed within a first opening at the end of the second tubular structure.

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

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

5. The catheter according to any one of claims 1 to 4, A catheter characterized in that the first tubular structure is a first hypotube made from a metal, alloy, or polymer, and the second tubular structure is a second hypotube made from the metal, alloy, polymer, another metal, another alloy, or another polymer.

6. The catheter according to any one of claims 1 to 5, A catheter further comprising a liner, the liner being disposed on a first inner surface of the first tubular structure and on a second inner surface of the second tubular structure, and the polymer connector being connected to the liner.

7. The catheter according to claim 6, a jacket disposed on a first outer surface of the first tubular structure and on a second outer surface of the second tubular structure, the polymer connector being connected to the jacket.

8. The catheter of claim 7, A catheter, wherein the jacket and at least a portion of the polymer connector are made from the same material.

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

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

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

12. The catheter according to any one of claims 1 to 11, The catheter, characterized in that the polymer connector is configured to transmit one or more forces between the first tubular structure and the second tubular structure, the one or more forces comprising a compressive force, a tensile force, a shear force, a torsional force, or any combination thereof.

13. The catheter according to any one of claims 1 to 12, A catheter characterized in that the end of the first tubular structure and the end of the second tubular structure are connected to each other without the use of welding, soldering, or adhesives.

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

15. The catheter according to any one of claims 1 to 14, a catheter further comprising an additional polymer connector configured to connect the first tubular structure and the second tubular structure to one another and / or to prevent the first tubular structure and the second tubular structure from separating from one another.

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

17. 16. The catheter of claim 15, A catheter, wherein the polymer connector and the additional polymer connector lie in different respective planes perpendicular to the longitudinal axis of the catheter.

18. 16. The catheter of claim 15, A catheter, wherein the polymer connector and the second polymer connector are part of a filling structure having a tubular or ring-like configuration.

19. The catheter of claim 1, a catheter, characterized in that each of the first and second tubular structures includes a structural element, the structural element of the first tubular structure configured to abut and engage with a structural element of the second tubular structure, the structural element configured to transmit shear forces.

20. 1. A method for manufacturing a portion of a catheter, comprising: providing a first tubular structure; providing a second tubular structure; placing the first tubular structure and the second tubular structure in series with one another; and forming a polymer connector in the space between the end of the first tubular structure and the end of the second tubular structure, wherein the formed polymer connector bonds the first tubular structure and the second tubular structure to one another and / or prevents the first tubular structure and the second tubular structure from separating from one another.

Images