Multi-wire catheter braid with varying weave patterns

Abstract

The catheter braid (100) comprises a first region (110) having a plurality of wire segments arranged in a first weave pattern and a second region (120) having a plurality of wire segments arranged in a second weave pattern. The first weave pattern transitions to the second weave pattern at a first transition point at an intersection of the first and second regions, where at least one wire of the plurality of wires in the first region is removed from the second region. The catheter braid includes a uniform cross-sectional area across a majority of the first region and a majority of the second region.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present disclosure relates generally to devices and methods for accessing blood vessels during intravascular medical care. More particularly, the present disclosure relates to catheters having braided support structures. [Background technology]

[0002] Catheters serve a wide variety of functions in intravascular medical procedures. They typically comprise thin tubes made of medical-grade materials that can be inserted into the body and used to deliver drugs or other devices, perform surgical procedures, remove blockages from blood vessels, and for a variety of other purposes. By varying the material or adjusting the way the catheter is manufactured, it is possible to tailor different sections of the catheter for specific applications.

[0003] Many designs and methods have been proposed for navigating catheters to designated points. Current catheter designs typically incorporate several polymer durometers, which are utilized to transition the catheter's stiffness from a very stiff material to a less stiff material toward the catheter's distal tip. The functional effectiveness of a catheter design is evaluated based on its ability to track through a specific anatomical structure, its flexibility, and its ability to track through that anatomical structure with as little friction as possible, known as push efficiency. While the catheter design approaches described above transition material stiffness along the catheter length to provide a greater degree of flexibility, column strength is sacrificed due to plastics being typically weaker than metals. These design tradeoffs considered in current catheter designs present significant challenges to practitioners implementing them within highly tortuous anatomical structures. Furthermore, a lack of column strength can result in an increased likelihood of catheter device buckling, reducing functional effectiveness and overall procedural success. Summary of the Invention [Problem to be solved by the invention]

[0004] Thus, there is a need for systems, devices, and methods that can provide improvements in catheter design, particularly those that provide improved pushing efficiency and flexibility while maintaining column strength when utilized within anatomical environments with high degrees of tortuosity. [Means for solving the problem]

[0005] An exemplary embodiment of the present disclosure provides a catheter braid that can include a first region that can include a plurality of wire segments arranged in a first weave pattern that can have a first picks per inch, and a second region that can include a plurality of wire segments arranged in a second weave pattern that can have a second picks per inch. The second picks per inch can be smaller than the first picks per inch, and the second region can be distal to the first region. The first weave pattern can transition to the second weave pattern at a first transition point that can be disposed at an intersection of the first region and the second region. The first transition point can be a location where at least one wire of the plurality of wires in the first region can be removed from the second region, which can reduce the first picks per inch to a second picks per inch. The catheter braid can have a uniform cross-sectional area across a majority of the first region and a majority of the second region.

[0006] In any of the embodiments disclosed herein, the first weave pattern may be a 4x4 arrangement of the plurality of wire segments in the first region.

[0007] In any of the embodiments disclosed herein, the second weave pattern may be a 4x3 arrangement of wire segments in the second region.

[0008] In any of the embodiments disclosed herein, the catheter braid can further include a third region, which can include a plurality of wire segments arranged in a third weave pattern, which can have a third picks per inch. The third picks per inch can be smaller than the second picks per inch, and the third region can be distal to the second region. The second weave pattern can transition to the third weave pattern at a second transition point, which can be disposed at an intersection of the second and third regions. The second transition point can be where at least one wire of the plurality of wires in the second region is removed from the third region, which can reduce the second picks per inch to a third picks per inch.

[0009] In any of the embodiments disclosed herein, the third weave pattern may be a 3x3 arrangement of wire segments in the third region.

[0010] In any of the embodiments disclosed herein, the catheter braid can further include a fourth region, where the fourth region can include a plurality of wire segments arranged in a fourth weave pattern, which can have a fourth picks per inch. The fourth picks per inch can be smaller than the third picks per inch, and the fourth region can be distal to the third region. The third weave pattern can transition to the fourth weave pattern at a third transition point, which can be disposed at an intersection of the third and fourth regions. The third transition point can be where at least one wire of the plurality of wires in the third region can be removed from the fourth region, which can reduce the third picks per inch to a fourth picks per inch.

[0011] In any of the embodiments disclosed herein, the fourth weave pattern may be a 2x2 arrangement of wire segments in the fourth region.

[0012] In any of the embodiments disclosed herein, the catheter braid can further include a fifth region, which can include a plurality of wire segments arranged in a fifth weave pattern, which can have a fifth picks per inch. The fifth picks per inch can be smaller than the fourth picks per inch, and the fifth region can be distal to the fourth region. The fourth weave pattern can transition to the fifth weave pattern at a fourth transition point, which can be located at an intersection of the fourth and fifth regions. The fourth transition point can be where at least one wire of the plurality of wires in the fourth region can be removed from the fifth region, which can reduce the fourth picks per inch to the fifth picks per inch.

[0013] In any of the embodiments disclosed herein, the fifth weave pattern may be a 1x1 arrangement of wire segments in the fifth region.

[0014] In any of the embodiments disclosed herein, the first weave pattern can have a braid angle that is approximately equal to the braid angle of the second weave pattern.

[0015] Another embodiment of the present disclosure provides a catheter braid that can include a first region that can include a first plurality of wire segments, a second region that can include a second plurality of wire segments that can be less than the first plurality of wire segments, and a third region that can include a third plurality of wire segments that can be more than the second plurality of wire segments.

[0016] In any of the embodiments disclosed herein, at least a portion of the third plurality of wire segments may include a distal hoop.

[0017] In any of the embodiments disclosed herein, the third region can be configured to expand, when unconstrained, to an outer diameter that can be greater than the outer diameter of the second region and the outer diameter of the first region.

[0018] In any of the embodiments disclosed herein, the second plurality of wire segments can consist of unidirectionally wound wire segments.

[0019] In any of the embodiments disclosed herein, the terminations of the wires between the first region, the second region, and the third region can be secured via laser welding or adhesive bonding.

[0020] Another embodiment of the present disclosure provides a catheter braid including a first region that can include a first plurality of wire segments arranged in a first weave pattern and a second region that can include a second plurality of wire segments arranged in a second weave pattern. The second plurality of wire segments can include fewer wire segments than the first plurality of wire segments. The first region can have a circumference approximately equal to the circumference of the second region.

[0021] In any of the embodiments disclosed herein, the first weave pattern can include four separate wire segments of the first plurality of wire segments that can be traversed over four separate wire segments of the first plurality of wire segments.

[0022] In any of the embodiments disclosed herein, the second weave pattern may include four separate wire segments of the second plurality of wire segments that may be traversed over three separate wire segments of the second plurality of wire segments.

[0023] In any of the embodiments disclosed herein, a first portion of the first plurality of wire segments can terminate at a transition between the first and second portions, and the second plurality of wires can include wire segments extending from the second portion of the first plurality of wire segments.

[0024] In any of the embodiments disclosed herein, the catheter braid can further include a third region that can include a third plurality of wire segments arranged in a third weave pattern, where the third plurality of wire segments can include fewer wire segments than the second plurality of wire segments. A first portion of the second plurality of wire segments can terminate at a transition between the second and third portions. The third plurality of wire segments can include wire segments extending from a second portion of the second plurality of wire segments.

[0025] In any of the embodiments disclosed herein, the third weave pattern can include three separate wire segments of the third plurality of wire segments that can be traversed over three separate wire segments of the third plurality of wire segments.

[0026] In any of the embodiments disclosed herein, the catheter braid can further include a fourth region that can include a fourth plurality of wire segments that can be arranged in a fourth weave pattern, where the fourth plurality of wire segments can include fewer wire segments than the third plurality of wire segments. A first portion of the third plurality of wire segments can terminate at a transition between the third and fourth portions. The fourth plurality of wire segments can include wire segments that can extend from a second portion of the third plurality of wire segments.

[0027] In any of the embodiments disclosed herein, the fourth weave pattern can include two separate wire segments of the fourth plurality of wire segments that can be traversed over two separate wire segments of the fourth plurality of wire segments.

[0028] In any of the embodiments disclosed herein, the catheter braid can further include a fifth region that can include a fifth plurality of wire segments arranged in a fifth weave pattern, where the fifth plurality of wire segments can include fewer wire segments than the fourth plurality of wire segments. A first portion of the fourth plurality of wire segments can terminate at a transition between the fourth and fifth portions. The fifth plurality of wire segments can include wire segments that can extend from a second portion of the fourth plurality of wire segments.

[0029] In any of the embodiments disclosed herein, the fifth weave pattern can include a wire segment of the fifth plurality of wire segments that can be crossed over a wire segment of the fifth plurality of wire segments.

[0030] In any of the embodiments disclosed herein, the first weave pattern can include a braid angle that can be approximately equal to the braid angle of the second weave pattern.

[0031] Another embodiment of the present disclosure provides a device that can include a tubular braid that can include a first region that can include a plurality of strand segments arranged in a first weave pattern that can have a first picks per inch, and a second region that can include a plurality of strand segments arranged in a second weave pattern that has a second picks per inch that is less than or equal to the first picks per inch. The second region can be distal to the first region. The first weave pattern can transition to the second weave pattern at a first transition point that can be disposed at an intersection of the first region and the second region. The first transition point can be a location where at least one strand of the plurality of strand segments in the first region can be removed from the second region, which can reduce the first picks per inch to a second picks per inch. The tubular braid can include a uniform circumference throughout the first region and the second region.

[0032] In any of the embodiments disclosed herein, the strand segments may include wire strands.

[0033] In any of the embodiments disclosed herein, the device may further include a catheter body supported by the tubular braid.

[0034] In any of the embodiments disclosed herein, the first weave pattern can have a braid angle that can be approximately equal to the braid angle of the second weave pattern.

[0035] Another embodiment of the present invention provides a method. The method can include arranging a first plurality of strand segments in a first weave pattern that can have a first picks per inch, terminating a first portion of the first plurality of strand segments at a first transition point, and arranging a second plurality of strand segments in a second weave pattern that can have a picks per inch less than the first picks per inch. The second weave pattern can be distal to the first transition point such that a second plurality of wire segments can extend from a second portion of the first plurality of strand segments. The second weave pattern can have a circumference that can be approximately equal to the first weave pattern.

[0036] These and other aspects of the present disclosure are described in the following detailed description and accompanying drawings. Other aspects and features of the embodiments will become apparent to those skilled in the art upon reviewing the following description of certain exemplary embodiments in conjunction with the drawings. While features of the present disclosure may be discussed with respect to particular embodiments and drawings, all embodiments of the present disclosure may include one or more of the features or elements discussed herein. Furthermore, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features may be used with various embodiments discussed herein. Similarly, while exemplary embodiments may be discussed below as device, system, or method embodiments, it should be understood that such exemplary embodiments can be implemented in various devices, systems, and methods of the present disclosure. [Brief explanation of the drawings]

[0037] The above and further aspects of the present invention will be further discussed with reference to the following description taken in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in the various drawings. The drawings are not necessarily to scale, focus instead being upon illustrating the principles of the invention. The figures depict one or more implementations of the apparatus of the present invention by way of example only, and not by way of limitation. [Figure 1]1 is an illustrative diagram of an exemplary embodiment of a catheter braid, in accordance with aspects of the present invention; [Figure 2] FIG. 2 is an illustrative diagram of an exemplary catheter braid showing a first transition point between a first region and a second region, according to an embodiment of the present invention. [Figure 3] FIG. 2 is an illustrative diagram of an exemplary catheter braid showing a second transition point between the second region and the third region, according to an embodiment of the present invention. [Figure 4] FIG. 10 is an illustrative diagram of an exemplary catheter braid showing a third transition point between the third and fourth regions, according to an embodiment of the present invention. [Figure 5] FIG. 1 is an illustrative method flow chart showing an exemplary method for manufacturing a catheter braid, in accordance with an aspect of the present invention. [Figure 6A] 1 is an illustrative diagram of an exemplary embodiment of a catheter braid, according to aspects of the present disclosure; [Figure 6B] 1 is an illustrative diagram of an exemplary embodiment of a catheter braid, according to aspects of the present disclosure; [Figure 6C] FIG. 6B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 6A, according to an embodiment of the present invention. [Figure 6D] FIG. 6B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 6A, according to an embodiment of the present invention. [Figure 6E] FIG. 6B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 6A, according to an embodiment of the present invention. [Figure 7A] 1 is an illustrative diagram of an exemplary embodiment of a catheter braid, according to aspects of the present disclosure; [Figure 7B] 1 is an illustrative diagram of an exemplary embodiment of a catheter braid, according to aspects of the present disclosure; [Figure 7C] FIG. 7B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 7A, according to an embodiment of the present invention. [Figure 7D] FIG. 7B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 7A, according to an embodiment of the present invention. [Figure 7E] FIG. 7B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 7A, according to an embodiment of the present invention. [Figure 8A]1 is an illustrative diagram of an exemplary embodiment of a catheter braid, in accordance with aspects of the present invention; [Figure 8B] FIG. 8B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 8A, according to an embodiment of the present invention. [Figure 8C] FIG. 8B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 8A, according to an embodiment of the present invention. [Figure 8D] FIG. 8B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 8A, according to an embodiment of the present invention. [Figure 8E] FIG. 8B is a cross-sectional illustrative view of a catheter braid as shown in FIG. 8A, according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0038] The disclosed technology can include a catheter braid subdivided into regions having distinct weave patterns, each of which can include multiple metal wire segments arranged in the weave pattern. The regions of the catheter braid can include a varying number of metal wire segments along the length of the catheter braid, providing a relatively soft, flexible shaft in the distal section, a relatively stiff shaft in the proximal section, and a gradual transition between the flexible and rigid shaft sections. To achieve the gradual transition between the flexible and rigid shaft sections, at least one metal wire segment of the multiple metal wire segments that can comprise each of the segment regions can be removed at one or more transition points along the length of the catheter braid. By gradually removing at least one metal wire segment of the multiple metal wire segments at one or more transition points along the length of the catheter braid, the likelihood of kinking can be reduced while maintaining push efficiency and column strength.

[0039] While exemplary embodiments of the disclosed technology are described in detail herein, it should be understood that other embodiments are contemplated. Accordingly, it is not intended that the scope of the disclosed technology be limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosed technology is capable of other embodiments and of being practiced or carried out in various ways.

[0040] It should also be noted that, as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. "Comprising" or "containing" or "including" means that at least the referenced compound, element, particle, or method step is present in a composition or article or method, but does not exclude the presence of other compounds, materials, particles, or method steps, even if such other compounds, materials, particles, or method steps have the same function as the referenced one.

[0041] In describing the exemplary embodiments, technical terminology is utilized for clarity. Each term is intended to have its broadest meaning as understood by one of ordinary skill in the art and is intended to include all technical equivalents that operate in a similar manner to accomplish a similar purpose. It should also be understood that a reference to one or more steps of a method does not preclude the presence of additional or intervening method steps between those explicitly identified steps. Method steps may be performed in an order different from that described herein without departing from the scope of the disclosed technology. Similarly, it should also be understood that a reference to one or more components in a device or system does not preclude the presence of additional or intervening components between those explicitly identified components.

[0042] As discussed herein, the vasculature may be that of any "subject" or "patient," including any human or animal. It should be understood that the animal may be of any of a variety of relevant types, including, but not limited to, mammals, veterinary animals, livestock animals, or companion animals. By way of example, the animal may be a laboratory animal (e.g., rats, dogs, pigs, monkeys, etc.) specifically selected to have certain characteristics similar to humans. It should be understood that the subject may be, for example, any relevant human patient.

[0043] As discussed herein, the term "about" or "approximately" used in connection with any numerical value or range of numerical values ​​indicates a suitable dimensional tolerance that enables a portion of a component or a collection of components to function in accordance with its intended purpose as described herein. More specifically, "about" or "approximately" may refer to a range of values ​​of ±20% of the recited value; for example, "about 90%" may refer to a range of values ​​of 71% to 99%.

[0044] The figures illustrate generally hollow or tubular structures in accordance with the present invention. As used herein, the terms "tubular" and "pipe / tube" are intended to be broadly interpreted and are not limited to structures that are right cylindrical or strictly circular in cross section, or to structures that are uniform in cross section along their entire length. For example, a tubular structure or tubular system is generally illustrated as a substantially right cylindrical structure. However, a tubular system may have a tapered or curved outer surface without departing from the scope of the present invention.

[0045] FIG. 1 illustrates an example of a catheter braid (100). The catheter braid (100) can have a diameter (D1) and can extend along a longitudinal axis (10) in a proximal direction (12) and a distal direction (14). The catheter braid (100) can be subdivided into multiple regions (110, 120, 130, 140), each of which can include a distinct weave pattern. The diameter (D1) of the braid (100) can be substantially constant throughout the regions (110, 120, 130, 140), such that each region has approximately equal diameter. For a braid with a circular cross-section, a constant diameter (D1) means that the cross-sectional area of ​​the lumen through the braid (100) is constant and the circumference of the braid (100) is constant. The braid can have alternative cross-sectional shapes and maintain a constant diameter (D1), cross-sectional area, or circumference throughout the regions (110, 120, 130).

[0046] The catheter braid (100) may include a first region (110) that may include a first weave pattern having a length (L1) along the longitudinal axis (10), a second region (120) that may include a second weave pattern having a length (L2) along the longitudinal axis (10), a third region (130) that may include a third weave pattern having a length (L3) along the longitudinal axis (10), and a fourth region (140) that may include a fourth weave pattern having a length (L4) along the longitudinal axis (10). The catheter braid (100) may also have a uniform cross-section throughout a majority of the first region (110) and a majority of the second region (120). Each of the distinct regions of the catheter braid (100) may include multiple wire segments. The wire segments may be made from one or a combination of stainless steel, cobalt chromium, molybdenum and niobium alloys, tungsten, nitinol, tantalum, platinum, or any other hard metal alloy. The catheter braid (100) can have various picks per inch along the length of each of its subdivided regions. For example, the first region (110) of the catheter braid (100) can have a first weave pattern that is denser than the second weave pattern of the second region (120), which can be denser than the third weave pattern of the third region (130), which can be denser than the fourth weave pattern of the fourth region (140). Thus, the axial stiffness of the catheter supported by the braid (100) can decrease distally due to the decreasing density of the weave pattern of the braid (100) in the distal direction (14).

[0047] 2-4 illustrate transitions between regions (110, 120, 130, 140). Each of the distinct regions (110, 120, 130, 140) of the catheter braid (100) can transition at a transition point that can be disposed between two distinct regions. The number and arrangement of wire segments illustrated in and described in connection with FIGS. 2-4 are provided for illustrative purposes; numerous other numbers and arrangements of wire segments can be utilized as variations of the presented examples. Such variations, as understood by one skilled in the art, are within the scope of this disclosure.

[0048] 2 illustrates a transition between a first region (110) and a second region (120). The weave pattern of the first region (110) can be arranged in a 4x4 arrangement of wire segments. The weave pattern of the second region (120) can be arranged in a 4x3 arrangement of wire segments. The first weave pattern of the first region (110) can transition into the second region (120) at a first transition point (210) at the intersection of the first region (110) and the second region (120). The first transition point (210) can be marked by removing at least one wire from the plurality of wires of the first region (110) from the second region (120). As a result, by removing at least one wire from the plurality of wires in the first region (110) from the second region, the picks per inch in the first region (110) can be reduced to a second picks per inch in the second region (120).

[0049] The first plurality of wire segments in the first region (110) can be arranged in a first weave pattern having a braid angle (116), and the second plurality of wire segments in the second region (120) can be arranged in a second weave pattern having a braid angle (122) approximately equal to the braid angle (116) of the first region (110). Thus, the braid (100) can reduce picks per inch while maintaining a constant braid angle (116, 122) from one region to the next. The first region (110) can have a circumference that can be approximately equal to the circumference of the second region (120).

[0050] The weave pattern of the first region (110) can include four separate wire segments of the first plurality of wire segments that can be traversed over four separate wire segments of the first plurality of wire segments. The weave pattern of the second region (120) can include four separate wire segments of the second plurality of wire segments that can be traversed over three separate wire segments of the second plurality of wire segments. A first portion (112) of the first plurality of wire segments can terminate (212) at a first transition point (210). The second plurality of wire segments of the second region (120) can include wire segments that can extend from a second portion (114) of the first plurality of wire segments through the first transition point (210).

[0051] 3 is an illustrative diagram of a transition between the second region (120) and the third region (130) of the catheter braid (100). The third region (130) can include a plurality of wire segments that can be arranged in a third weave pattern having a third picks per inch that is smaller than the second picks per inch of the second region (120) and can be located distal (14) to the second region (120). The second region (120) transitions into the third region at a second transition point (220), which can be located at the intersection of the second region (120) and the third region (130). The second transition point (220) may be where at least one wire of the plurality of wire segments in the second region (120) is removed from the third region (13), which reduces the second picks per inch in the second region (120) to a third picks per inch in the third region (130).

[0052] The third plurality of wire segments in the third region (130) can be arranged in a third weave pattern having a braid angle (132) approximately equal to the braid angle (122) of the second region (120) and approximately equal to the braid angle (116) of the first region (110). Thus, the braid (100) can reduce picks per inch while maintaining a constant braid angle (116, 122, 132) from one region to the next. The third region (130) can have a circumference that can be approximately equal to the circumference of the second region (120).

[0053] The third plurality of wire segments in the third region (130) can include fewer segments than the second plurality of wire segments in the second region (120). The weave pattern of the third region (130) can include three separate wire segments of the third plurality of wire segments that can be traversed over three separate wire segments of the third plurality of wire segments. A first portion (124) of the second plurality of wire segments can terminate (222) at a second transition point (220). The second plurality of wire segments (126) in the second region can include wire segments that can extend through the second transition point (220) into the third region (130).

[0054] FIG. 4 is an illustrative diagram of a transition portion (240) between the third region (130) and the fourth region (140) of the catheter braid (100). The fourth region (140) can include a plurality of wire segments that can be arranged in a fourth weave pattern having a fourth picks per inch that can be smaller than the third picks per inch. The fourth region (140) can be distal (14) to the third region (130). The weave pattern of the fourth region (140) can be a 2x2 arrangement of wire segments. The third region (130) can transition into the fourth region (140) at a third transition point (240) that can be disposed at the intersection of the third region (130) and the fourth region (140). The third transition point (240) may be where at least one wire of the plurality of wire segments in the third region (130) is removed from the fourth region (140), which may reduce the third picks per inch to a fourth picks per inch.

[0055] The fourth region (140) can include a fourth plurality of wire segments that can be arranged in a fourth weave pattern. The fourth plurality of wire segments can include fewer segments than the third plurality of wire segments of the third region (130). The weave pattern of the fourth region (140) can include two separate wire segments of the fourth plurality of wire segments that can be crossed over two separate wire segments of the four plurality of wire segments. A first portion of the third plurality of wire segments (134) can terminate (242) at the third transition point (240). The fourth plurality of wire segments of the fourth region (140) can include wire segments that can extend from a second portion of the second plurality of wire segments (136) through the third transition point (240) to the fourth region (140).

[0056] FIG. 5 illustrates a method (500) for manufacturing a catheter braid (100). In block (502), a first plurality of strand segments can be arranged in a first weave pattern that can have a first picks per inch. In block (504), a portion of a first portion of the plurality of strand segments can terminate at a first transition point (210). In block (506), a second plurality of strand segments can be arranged in a second weave pattern that has a second picks per inch that is less than the first picks per inch. The second weave pattern can be distal to the first transition point such that the second plurality of strand segments extend from a second portion of the first plurality of strand segments and such that the second weave pattern has a circumference approximately equal to the first weave pattern.

[0057] Figure 6A is an illustrative diagram of a plan view of an exemplary catheter having a braid 600, and Figure 6B is an isometric view of the catheter and braid 600 illustrated in Figure 6A. Figures 6C, 6D, and 6E show cross-sectional views of the catheter and braid 600 as shown in Figure 6A.

[0058] 6A-6E collectively, the catheter braid (600) can include a first region (606) having a first plurality of wire segments, a second region (604) having a second plurality of wire segments that is less than the first plurality of wire segments, and a third region (602) having a third plurality of wire segments that is more than the second plurality of wire segments. At least a portion of the plurality of wire segments in the third region (602) can include distal hoops (608). These distal hoops (608) in the third region (602) can also be described as funnel-shaped atraumatic ends and are intended to minimize trauma to surrounding tissue while maintaining pushing efficiency. The distal hoops (608) can be formed by folding back braid strands and weaving them into a coil extending from the second region (604). Alternatively, the distal hoop (608) can be formed by first wrapping eight wires around a circumferential array of pins on a mandrel, then hooking the 16 free ends of the eight wires into a braiding machine and braiding at varying picks per inch as desired, then laser welding the braid intersections at the transitions from D4 to D3 and from D3 to D2, and then cutting and removing excess braid wire from D3.

[0059] The third region (602) can be configured to expand to an outer diameter (D2) when unconstrained, which can be greater than the outer diameter (D3) of the second region (604) and the outer diameter (D4) of the first region (606). The outer diameter (D3) of the second segment (604) can be less than the outer diameter (D4) of the first segment (606). The third region (602) can have a cross-sectional area (A1) that is greater than the cross-sectional area (A2) of the second region (604) and greater than the cross-sectional area (A3) of the first region (606). The cross-sectional area (A2) of the second region (604) can be approximately equal to the cross-sectional area (A3) of the first region (606). The third region (602) can have a circumference (C1) that is greater than the circumference (C2) of the second region (604) and greater than the circumference (C3) of the first region (606). The circumference (C2) of the second segment (604) can be less than the circumference (C3) of the first segment (606). The third region (602) can provide resistance to collapsing under suction when the catheter braid (600) is advanced through a small guide catheter or blood vessel.

[0060] As illustrated, the first region (606) can have a 16-wire braid woven with eight clockwise wires and eight counterclockwise wires. The first region (606) can have a first range of variable picks per inch that decreases distally. The second region (604) can have all eight clockwise wires removed, such that the second region (604) includes the remaining eight counterclockwise wires wound in a coil. The coil can have a variable pitch that increases distally. The third region (602) can be woven with 16 wires and a third range of variable picks per inch, with no wires removed. The third region (602) can include all distal portions of the eight counterclockwise wires of the second region (604) folded back at the distal hoop (608) to form a weave with eight counterclockwise wire portions and eight clockwise wire portions.

[0061] To maintain the column strength of the catheter braid 600 and prevent the wires from unraveling during assembly, the terminations of the wires between the first region 606, the second region 604, and the third region 602 can be secured by laser welding or adhesive bonding. Additionally, to provide improved pushing efficiency, the first region 606, the second region 604, and the third region 606 of the catheter braid 600 can include variable braid angles within each region.

[0062] Figure 7A is an illustrative diagram of a plan view of an exemplary catheter having a braid (700), and Figure 7B is an isometric view of the catheter and braid (700) illustrated in Figure 7A. Figures 7C, 7D, and 7E are cross-sectional views of the catheter and braid (700) shown in Figure 7A. The catheter braid (700) illustrated in Figures 7A-7E is similar to the braid (700) illustrated in Figures 6A-6E, except that all of the wires in a given direction have been removed from the second region (604) of the braid (600) of Figure 6A, and half of the clockwise wires and half of the counterclockwise wires have been removed from the second region (704) of the braid (600) of Figure 7A.

[0063] 7A-7E collectively, the catheter braid (700) can include a first region (706) having a first plurality of wire segments, a second region (704) having a second plurality of wire segments that is less than the first plurality of wire segments, and a third region (702) having a third plurality of wire segments that is more than the second plurality of wire segments. At least a portion of the plurality of wire segments in the third region (702) can include distal hoops (708). These distal hoops (708) in the third region (702) can also be described as funnel-shaped atraumatic ends, and are intended to minimize trauma to surrounding tissue while maintaining pushing efficiency. The distal hoops (708) can be formed by folding back braid strands and weaving them into a coil extending from the second region (704).

[0064] The third region (702) can be configured to expand, when unconstrained, to an outer diameter (D2), cross-sectional area (A1), and / or circumference (C1) that can be greater than the outer diameter (D3, D4), cross-sectional area (A2, A3), and / or circumference (C2, C3) of the second region (704) and / or first region (706). The outer diameter (D3, D4), cross-sectional area (A2, A3), and / or circumference (C2, C3) of the second region (704) can be approximately equal to that of the first region (706). The third region (702) can provide resistance to collapsing under suction when the catheter braid (700) is advanced through a small guide catheter or blood vessel.

[0065] As illustrated, the first region (706) can have a 16-wire braid woven with eight clockwise wires and eight counterclockwise wires. The first region (706) can have a first range of variable picks per inch that decreases distally. The second region (704) can remove all four clockwise wires and four counterclockwise wires, resulting in half the picks per inch at the transition from the first region (706) to the second region (704). The second region (704) can have a second range of variable picks per inch that decreases distally. The third region (702) can be woven with 16 wires and a third range of variable picks per inch in which no wires are removed. The third region (702) can include the distal portions of all eight wires of the second region (704) folded back at the distal hoop (708) to form a weave with eight counterclockwise wire portions and eight clockwise wire portions.

[0066] To maintain the column strength of the catheter braid 700, the wire terminations between the first region 706, the second region 704, and the third region 702 can be secured through laser welding or adhesive bonding. Additionally, to provide improved pushing efficiency, the first region 706, the second region 704, and the third region 702 of the catheter braid 700 can include variable braid angles within each region.

[0067] FIG. 8A is an illustrative diagram of an exemplary embodiment of a braid 800 having a weave density that gradually decreases from a first section (810), a second section (820), a third section (830), and a fourth section (840). FIGS. 8B, 8C, 8D, and 8E are cross-sectional illustrative views of the braid 800 shown in FIG. 8A. The first section 810 of the braid 800 has wires grouped into four groups in a 4x4 weave. One wire in each group in the first section 810 terminates at the junction between the first section 810 and the second section 820. The second section 820 of the braid 800 has wires grouped into three groups in a 3x3 weave. One wire in each group in the second section 820 terminates at the junction between the second section 820 and the third section 830. The third section (830) of the braid (800) has wires grouped in two groups in a 2x2 weave. One wire in each group in the third section (830) terminates at the junction between the third section (830) and the fourth section (840). The fourth section (840) of the braid (800) has wires in a 1x1 weave. The circumference, diameter, and cross-sectional area of ​​the braid (800) are substantially consistent throughout the regions (810, 820, 830, 840).

[0068] The descriptions contained herein are examples of embodiments of the present invention and are not intended to limit the scope of the present invention in any way. As described herein, the present invention contemplates many variations and modifications of braids, including numerous wire shapes, weave patterns, and wire counts. Furthermore, features of various embodiments are interchangeable and can be combined to produce variations of each embodiment. The embodiments can also be modified by techniques understood by those skilled in the art to produce variations of each embodiment. These and other modifications understood by those skilled in the art are included in this disclosure.

[0069] The following clauses list non-limiting embodiments of the present disclosure.

[0070] Clause 1. A catheter braid comprising: a first region including a plurality of wire segments arranged in a first weave pattern having a first picks per inch; and a second region distal to the first region including a plurality of wire segments arranged in a second weave pattern having a second picks per inch that is less than the first picks per inch, wherein the first weave pattern transitions to the second weave pattern at a first transition point disposed at an intersection of the first region and the second region, at which point at least one wire of the plurality of wire segments of the first region is removed from the second region, thereby reducing the first picks per inch to the second picks per inch, and wherein the catheter braid comprises a lumen therethrough that includes a uniform cross-section throughout a majority of the first region and a majority of the second region.

[0071] Clause 2. The catheter braid of clause 1, wherein the first weave pattern is a 4x4 arrangement of the plurality of wire segments in the first region.

[0072] Clause 3. The catheter braid of clause 1, wherein the second weave pattern is a 4x3 arrangement of the wire segments in the second region.

[0073] Clause 4. The catheter braid of clause 1, further comprising a third region distal to the second region, the third region including a plurality of wire segments arranged in a third weave pattern having a third picks per inch less than the second picks per inch, wherein the second weave pattern transitions to the third weave pattern at a second transition point disposed at an intersection of the second region and the third region, and at the second transition point, at least one wire of the plurality of wires of the second region is removed from the third region, thereby reducing the second picks per inch to the third picks per inch.

[0074] Clause 5. The catheter braid of clause 4, wherein the third weave pattern is a 3x3 arrangement of the wire segments in the third region.

[0075] Clause 6. The catheter braid of clause 4, further comprising a fourth region distal to the third region, the fourth region including a plurality of wire segments arranged in a fourth weave pattern having a fourth picks per inch less than the third picks per inch, wherein the third weave pattern transitions to the fourth weave pattern at a third transition point disposed at an intersection of the third region and the fourth region, and at the third transition point, at least one wire of the plurality of wires of the third region is removed from the fourth region, thereby reducing the third picks per inch to the fourth picks per inch.

[0076] Clause 7. The catheter braid of clause 6, wherein the fourth weave pattern is a 2x2 arrangement of the wire segments in the fourth region.

[0077] Clause 8. The catheter braid of clause 6, further comprising a fifth region distal to the fourth region, the fifth region including a plurality of wire segments arranged in a fifth weave pattern having a fifth picks per inch less than the fourth picks per inch, wherein the fourth weave pattern transitions to the fifth weave pattern at a fourth transition point located at an intersection of the fourth region and the fifth region, and at the fourth transition point, at least one wire of the plurality of wires of the fourth region is removed from the fifth region, thereby reducing the fourth picks per inch to the fifth picks per inch.

[0078] Clause 9. The catheter braid of clause 8, wherein the fifth weave pattern is a 1x1 arrangement of the wire segments in the fifth region.

[0079] Clause 10. The catheter braid of clause 1, wherein the first weave pattern includes a braid angle approximately equal to the braid angle of the second weave pattern.

[0080] Clause 11. A catheter braid comprising: a first region including a first plurality of wire segments; a second region including a second plurality of wire segments having fewer wire segments than the first plurality of wire segments; and a third region including a third plurality of wire segments having more wire segments than the second plurality of wire segments.

[0081] Clause 12. The catheter braid of clause 11, wherein at least a portion of the third plurality of wire segments includes a distal hoop.

[0082] Clause 13. The catheter braid of clause 11, wherein the third region is configured to expand, when unconstrained, to an outer diameter greater than the outer diameter of the second region and the outer diameter of the first region.

[0083] Clause 14. The catheter braid of clause 11, wherein the first region, the second region, and / or the third region include a variable braid angle within each region.

[0084] Clause 15. The catheter braid of clause 11, wherein the second plurality of wire segments comprises unidirectionally wound segments.

[0085] Clause 16. A catheter braid as described in clause 11, wherein the terminal ends of the wires between the first region, the second region, and the third region are secured by laser welding or adhesive bonding.

[0086] Clause 17. A catheter braid, comprising: a first region including a first plurality of wire segments arranged in a first weave pattern; and a second region including a second plurality of wire segments arranged in a second weave pattern, wherein the second plurality of wire segments includes fewer wire segments than the first plurality of wire segments, and wherein the first region includes a circumference approximately equal to the circumference of the second region.

[0087] Clause 18. The catheter braid of clause 17, wherein the first weave pattern includes four separate wire segments of the first plurality of wire segments that are traversed over four separate wire segments of the first plurality of wire segments.

[0088] Clause 19. The catheter braid of clause 17, wherein the second weave pattern includes four separate wire segments of the second plurality of wire segments that are traversed over three separate wire segments of the second plurality of wire segments.

[0089] Clause 20. The catheter braid of clause 17, wherein a first portion of the first plurality of wire segments terminates at a transition between the first region and the second region, and the second plurality of wire segments includes wire segments extending from a second portion of the first plurality of wire segments.

[0090] Clause 21. The catheter braid of clause 17, further comprising a third region including a third plurality of wire segments arranged in a third weave pattern, the third plurality of wire segments including fewer wire segments than the second plurality of wire segments, a first portion of the second plurality of wire segments terminating at a transition between the second region and the third region, and the third plurality of wire segments including wire segments extending from a second portion of the second plurality of wire segments.

[0091] Clause 22. The catheter braid of clause 21, wherein the third weave pattern includes three separate wire segments of the third plurality of wire segments that are traversed over three separate wire segments of the third plurality of wire segments.

[0092] Clause 23. The catheter braid of clause 21, further comprising a fourth region including a fourth plurality of wire segments arranged in a fourth weave pattern, the fourth plurality of wire segments including fewer wire segments than the third plurality of wire segments, a first portion of the third plurality of wire segments terminating at a transition between the third region and the fourth region, and the fourth plurality of wire segments including wire segments extending from a second portion of the third plurality of wire segments.

[0093] Clause 24. The catheter braid of clause 23, wherein the fourth weave pattern includes two separate wire segments of the fourth plurality of wire segments that are traversed over two separate wire segments of the fourth plurality of wire segments.

[0094] Clause 25. The catheter braid of clause 23, further comprising a fifth region including a fifth plurality of wire segments arranged in a fifth weave pattern, the fifth plurality of wire segments including fewer wire segments than the fourth plurality of wire segments, a first portion of the fourth plurality of wire segments terminating at a transition between the fourth portion and the fifth portion, and the fifth plurality of wire segments including wire segments extending from a second portion of the fourth plurality of wire segments.

[0095] Clause 26. The catheter braid of clause 25, wherein the fifth weave pattern includes one wire segment of the fifth plurality of wire segments being crossed over one wire segment of the fifth plurality of wire segments.

[0096] Clause 27. The catheter braid of clause 17, wherein the first weave pattern includes a braid angle approximately equal to the braid angle of the second weave pattern.

[0097] Clause 28. A device comprising a tubular braid including: a first region including a plurality of strand segments arranged in a first weave pattern having a first picks per inch; and a second region distal to the first region including a plurality of strand segments arranged in a second weave pattern having a second picks per inch that is less than the first picks per inch, wherein the first weave pattern transitions to the second weave pattern at a first transition point disposed at an intersection of the first region and the second region, and at the first transition point, at least one strand of the plurality of strands of the first region is removed from the second region, thereby reducing the first picks per inch to the second picks per inch, and the tubular braid includes a uniform circumference throughout the first region and the second region.

[0098] Clause 29. The device of clause 28, wherein the strand segments comprise wire strands.

[0099] Clause 30. The device of clause 28, further comprising a catheter body supported by the tubular braid.

[0100] Clause 31. The catheter braid of clause 28, wherein the first weave pattern includes a braid angle approximately equal to the braid angle of the second weave pattern.

[0101] Clause 32. A method comprising: arranging a first plurality of strand segments in a first weave pattern having a first picks per inch; terminating a first portion of the first plurality of strand segments at a first transition point; and arranging a second plurality of strand segments in a second weave pattern having a second picks per inch less than the first picks per inch, the second weave pattern being distal to the first transition point such that the second plurality of strand segments extend from a second portion of the first plurality of strand segments and such that the second weave pattern includes a circumference approximately equal to the first weave pattern.

[0102] [Embodiment] (1) A catheter braid, a first region including a plurality of wire segments arranged in a first weave pattern having a first picks per inch; a second region distal to the first region, the second region including a plurality of wire segments arranged in a second weave pattern having a second picks per inch that is smaller than the first picks per inch; the first weave pattern transitions to the second weave pattern at a first transition point disposed at an intersection of the first region and the second region, and at the first transition point, at least one wire of the plurality of wire segments of the first region is removed from the second region, thereby reducing the first picks per inch to the second picks per inch; and A catheter braid, the catheter braid including a lumen therethrough that includes a uniform cross-section across a majority of the first region and a majority of the second region. (2) A catheter braid as described in embodiment 1, wherein the first weave pattern is a 4x4 arrangement of the plurality of wire segments in the first region. (3) A catheter braid as described in embodiment 1, wherein the second weave pattern is a 4x3 arrangement of the wire segments in the second region. (4) a third region distal to the second region, the third region including a plurality of wire segments arranged in a third weave pattern having a third picks per inch that is less than the second picks per inch; 2. The catheter braid of claim 1, wherein the second weave pattern transitions to the third weave pattern at a second transition point disposed at an intersection of the second region and the third region, and at the second transition point, at least one wire of the plurality of wire segments of the second region is removed from the third region, thereby reducing the second picks per inch to the third picks per inch. (5) A catheter braid as described in embodiment 4, wherein the third weave pattern is a 3x3 arrangement of the wire segments in the third region.

[0103] (6) a fourth region distal to the third region, the fourth region including a plurality of wire segments arranged in a fourth weave pattern having a fourth picks per inch that is smaller than the third picks per inch; 5. The catheter braid of claim 4, wherein the third weave pattern transitions to the fourth weave pattern at a third transition point disposed at an intersection of the third region and the fourth region, and at the third transition point, at least one wire of the plurality of wire segments of the third region is removed from the fourth region, thereby reducing the third picks per inch to the fourth picks per inch. (7) a fifth region distal to the fourth region, the fifth region including a plurality of wire segments arranged in a fifth weave pattern having a fifth picks per inch that is less than the fourth picks per inch; 7. The catheter braid of claim 6, wherein the fourth weave pattern transitions to the fifth weave pattern at a fourth transition point located at the intersection of the fourth region and the fifth region, and at the fourth transition point, at least one wire of the plurality of wire segments of the fourth region is removed from the fifth region, thereby reducing the fourth picks per inch to the fifth picks per inch. (8) A catheter braid as described in embodiment 1, wherein the first weave pattern includes a braid angle approximately equal to the braid angle of the second weave pattern. (9) A catheter braid, a first region including a first plurality of wire segments; a second region including a second plurality of wire segments having fewer wire segments than the first plurality of wire segments; a third region including a third plurality of wire segments having more wire segments than the second plurality of wire segments. (10) A catheter braid as described in embodiment 9, wherein at least a portion of the third plurality of wire segments includes a distal hoop.

[0104] (11) A catheter braid as described in embodiment 9, wherein the third region is configured to expand to an outer diameter greater than the outer diameter of the second region and the outer diameter of the first region when unconstrained. (12) The catheter braid of embodiment 9, wherein the first region, the second region, and / or the third region include a variable braid angle within each region. (13) A catheter braid as described in embodiment 9, wherein the second plurality of wire segments consists of unidirectionally wound segments. (14) A catheter braid as described in embodiment 9, wherein the terminal ends of the wires between the first region, the second region, and the third region are fixed by laser welding or adhesive bonding. (15) A catheter braid, a first region including a first plurality of wire segments arranged in a first weave pattern; a second region including a second plurality of wire segments arranged in a second weave pattern; the second plurality of wire segments includes fewer wire segments than the first plurality of wire segments; and A catheter braid, wherein the first region comprises a circumference approximately equal to the circumference of the second region.

[0105] (16) The catheter braid of embodiment 15, wherein the first weave pattern includes four separate wire segments of the first plurality of wire segments being traversed over four separate wire segments of the first plurality of wire segments. (17) The catheter braid of embodiment 15, wherein the second weave pattern includes four separate wire segments of the second plurality of wire segments traversed over three separate wire segments of the second plurality of wire segments. (18) A first portion of the first plurality of wire segments terminates at a transition between the first region and the second region; and 16. A catheter braid as described in embodiment 15, wherein the second plurality of wire segments includes wire segments extending from second portions of the first plurality of wire segments. (19) The electrical wiring system further comprises a third region including a third plurality of wire segments arranged in a third weave pattern, the third plurality of wire segments including fewer wire segments than the second plurality of wire segments; a first portion of the second plurality of wire segments terminates at a transition between the second region and the third region; and 16. A catheter braid as described in embodiment 15, wherein the third plurality of wire segments includes wire segments extending from second portions of the second plurality of wire segments. (20) The catheter braid of embodiment 15, wherein the first weave pattern includes a braid angle approximately equal to the braid angle of the second weave pattern.

Claims

1. A catheter braid, comprising: a first region including a plurality of wire segments arranged in a first weave pattern having a first picks per inch; a second region distal to the first region, the second region including a plurality of wire segments arranged in a second weave pattern having a second picks per inch that is smaller than the first picks per inch; the first weave pattern transitions to the second weave pattern at a first transition point disposed at an intersection of the first region and the second region, and at the first transition point, at least one wire of the plurality of wire segments of the first region is removed from the second region, thereby reducing the first picks per inch to the second picks per inch; and A catheter braid comprising a lumen therethrough, the catheter braid comprising a uniform cross-section across a majority of the first region and a majority of the second region.

2. The catheter braid of claim 1 , wherein the first weave pattern is a 4×4 arrangement of the plurality of wire segments in the first region.

3. The catheter braid of claim 1 , wherein the second weave pattern is a 4×3 arrangement of the wire segments in the second region.

4. a third region distal to the second region, the third region including a plurality of wire segments arranged in a third weave pattern having a third picks per inch that is less than the second picks per inch; 2. The catheter braid of claim 1, wherein the second weave pattern transitions to the third weave pattern at a second transition point disposed at an intersection of the second region and the third region, and wherein at the second transition point, at least one wire of the plurality of wire segments of the second region is removed from the third region, thereby reducing the second picks per inch to the third picks per inch.

5. The catheter braid of claim 4 , wherein the third weave pattern is a 3×3 arrangement of the wire segments in the third region.

6. a fourth region distal to the third region, the fourth region including a plurality of wire segments arranged in a fourth weave pattern having a fourth picks per inch that is less than the third picks per inch; 5. The catheter braid of claim 4, wherein the third weave pattern transitions to the fourth weave pattern at a third transition point disposed at an intersection of the third region and the fourth region, and wherein at the third transition point, at least one wire of the plurality of wire segments of the third region is removed from the fourth region, thereby reducing the third picks per inch to the fourth picks per inch.

7. a fifth region distal to the fourth region, the fifth region including a plurality of wire segments arranged in a fifth weave pattern having a fifth picks per inch that is less than the fourth picks per inch; 7. The catheter braid of claim 6, wherein the fourth weave pattern transitions to the fifth weave pattern at a fourth transition point located at an intersection of the fourth region and the fifth region, and wherein at the fourth transition point at least one wire of the plurality of wire segments of the fourth region is removed from the fifth region, thereby reducing the fourth picks per inch to the fifth picks per inch.

8. The catheter braid of claim 1 , wherein the first weave pattern includes a braid angle approximately equal to a braid angle of the second weave pattern.

9. A catheter braid, comprising: a first region including a first plurality of wire segments; a second region including a second plurality of wire segments having fewer wire segments than the first plurality of wire segments; a third region including a third plurality of wire segments having more wire segments than the second plurality of wire segments.

10. The catheter braid of claim 9 , wherein at least a portion of the third plurality of wire segments includes a distal hoop.

11. 10. The catheter braid of claim 9, wherein the third region is configured to expand, when unconstrained, to an outer diameter that is greater than an outer diameter of the second region and an outer diameter of the first region.

12. 10. The catheter braid of claim 9, wherein the first region, the second region, and / or the third region include a variable braid angle within each region.

13. The catheter braid of claim 9 , wherein the second plurality of wire segments comprises unidirectionally wound segments.

14. 10. The catheter braid of claim 9, wherein the ends of the wires between the first region, the second region, and the third region are secured by laser welding or adhesive bonding.

15. A catheter braid, comprising: a first region including a first plurality of wire segments arranged in a first weave pattern; a second region including a second plurality of wire segments arranged in a second weave pattern; the second plurality of wire segments includes fewer wire segments than the first plurality of wire segments; and A catheter braid wherein the first region comprises a circumference approximately equal to the circumference of the second region.

16. 16. The catheter braid of claim 15, wherein the first weave pattern includes four separate wire segments of the first plurality of wire segments traversed over four separate wire segments of the first plurality of wire segments.

17. 16. The catheter braid of claim 15, wherein the second weave pattern includes four separate wire segments of the second plurality of wire segments traversed over three separate wire segments of the second plurality of wire segments.

18. a first portion of the first plurality of wire segments terminates at a transition between the first region and the second region; and The catheter braid of claim 15 , wherein the second plurality of wire segments includes wire segments extending from a second portion of the first plurality of wire segments.

19. a third region including a third plurality of wire segments arranged in a third weave pattern, the third plurality of wire segments including fewer wire segments than the second plurality of wire segments; a first portion of the second plurality of wire segments terminates at a transition between the second region and the third region; and The catheter braid of claim 15 , wherein the third plurality of wire segments includes wire segments extending from a second portion of the second plurality of wire segments.

20. 16. The catheter braid of claim 15, wherein the first weave pattern includes a braid angle approximately equal to a braid angle of the second weave pattern.

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