Intraluminal device with variable wire configuration
Intraluminal devices and methods of fabricating intraluminal devices may be provided. In one implementation, an intraluminal device may be formed of a plurality of wires and may include a distal coil, a proximal coil, and an expandable mesh segment positioned between the distal and proximal coils. The proximal coil may include more wires of the plurality of wires than the distal coil and the expandable mesh segment. Due to the smaller number of wires forming the distal coil, the intraluminal device may be configured to have a soft and atraumatic distal tip and a more rigid proximal cable.
1 . An intraluminal device including an elongated body formed of a plurality of wires, the intraluminal device comprising:
a first region wherein the plurality of wires are twisted to form a first cable;
a second region, distal to the first region, in which the plurality of wires are woven to form an expandable mesh segment which is configured to capture a blood clot; and
a third region distal to the second region and forming a distal tip of the elongated body, wherein the plurality of wires in the third region are twisted to form a second cable,
wherein each of the wires extends continuously from the first region, through the second region to the third region providing a smooth device profile;
wherein the second region includes one or more wire crossings where one or more extraneous wires of the plurality of wires, adjacent to a different wire of the plurality of wires, is embedded by following a weave pattern of the different wire;
wherein the one or more wire crossings includes a crossing of a first grouping of wires and a second grouping of wires;
wherein the first grouping of wires include at least three wires, including the one or more extraneous wires;
wherein wires of the first grouping of wires excluding the one or more extraneous wires are twisted together to provide at least one twist at least one location away from the crossing.
2 . The intraluminal device of claim 1 , wherein the plurality of wires extend continuously from the first region, through the second region, to and through the third region to the distal tip.
3 . The intraluminal device of claim 1 , wherein the first region of the intraluminal device, the second region of the intraluminal device, and the third region of the intraluminal device are formed as a single unitary structure.
4 . The intraluminal device of claim 1 , wherein the plurality of wires form a plurality of groupings of wires in the second region, and wherein the at least one extraneous wire is embedded in a first grouping of wires of the plurality of groupings of wires.
5 . The intraluminal device of claim 4 , wherein the plurality of groupings of wires includes the first grouping of wires and a second grouping of wires, the first grouping of wires including three wires and the second grouping of wires including two wires.
6 . The intraluminal device of claim 1 , wherein at the one or more wire crossings the intraluminal device includes a first grouping of wires and a second grouping of wires, the first grouping of wires including at least two wires and the second grouping of wires including the one or more extraneous wires and the different wire; and
wherein the one or more extraneous wires and the different wire pass over a first wire of the first grouping of wires and under a second wire of the first grouping of wires to embed the one or more extraneous wire.
7 . The intraluminal device of claim 6 , wherein the second grouping of wires comprises a third wire, the first wire of the first grouping of wires crossing under the third wire of the second grouping of wires; and the second wire of the first grouping of wires crossing over the third wire of the second grouping of wires.
8 . The intraluminal device of claim 6 , wherein, at a subsequent crossing, the one or more extraneous wire and the different wire both pass over one of the wires of the first grouping of wires and under another of the wires of the second grouping of wires.
9 . The intraluminal device of claim 1 , comprising an elongated control member configured to apply force to the intraluminal device to affect expansion or contraction of the second region.
10 . The intraluminal device of claim 1 , wherein a number of the plurality of wires is selected to provide a desired rigidity to the first region.
11 . The intraluminal device of claim 10 , wherein the number of the plurality of wires is selected to provide a desired coiling angle in the first region, the desired coiling angle providing the desired rigidity of the first region.
12 . The intraluminal device of claim 1 , comprising a filter region adjacent to the second region, wherein a second region weave pattern provides a larger diameter to the second region in an expanded configuration than a weave pattern of the filter region which provides a smaller diameter to the filter region in the expanded configuration.
13 . The intraluminal device of claim 1 , wherein the at least one twist secures twisted wires of the first grouping against axial movement while leaving the one or more extraneous wire free to move axially.
14 . A method of manufacturing an intraluminal device including an elongated body formed of a plurality of wires, the method comprising:
twisting a plurality of wires upon a first segment of a mandrel so as to form a first cable of the elongated body;
weaving each of the wires upon a second segment of the mandrel distal to the first segment,
the weaving including forming one or more wire crossings with the plurality of wires, so as to form an expandable mesh segment of the elongated body which is configured to capture a blood clot,
wherein the weaving comprises embedding one or more extraneous wires of the plurality of wires, adjacent to a different wire of the plurality of wires, by following a weave pattern of the different wire;
wherein the forming one or more wire crossings comprises crossing a first grouping of wires and a second grouping of wires;
wherein the first grouping of wires includes at least three wires, including the one or more extraneous wires;
wherein the forming comprises twisting together wires of the first grouping of wires excluding the one or more extraneous wires to provide at least one twist at least one location away from the crossing; and
twisting each of the plurality of wires upon a third segment of the mandrel so as to form a second cable of the elongated body, each wire of the plurality of wires extending continuously from the first cable, through the expandable mesh segment, to the second cable, providing a smooth device profile;
wherein the second segment of the mandrel is positioned between the first segment of the mandrel and the third segment of the mandrel.
15 . The method of claim 14 , further comprising heat-treating the expandable mesh segment.