Methods of manufacturing woven vascular treatment devices
Vascular treatment and methods include a plurality of self-expanding bulbs and a hypotube including interspersed patterns of longitudinally spaced rows of kerfs. Joints between woven structures and hypotubes include solder. Woven structures include patterns of radiopaque filaments measurable under x-ray. Structures are heat treated to include at least shapes at different temperatures. A catheter includes a hypotube including interspersed patterns of longitudinally spaced rows of kerfs. Heat treating systems include a detachable flange. Laser cutting systems include a fluid flow system.
1. A method of manufacturing a vascular treatment device, the method comprising:
arranging a plurality of spools on spindles on a yarn wheel, at least some of the spools comprising radiopaque wires and at least some of the spools comprising shape memory wires;
attaching an end of each of the wires to a ring over a first mandrel, the first mandrel comprising a substantially cylindrical shape;
braiding the radiopaque wires and the shape memory wires in a one-over-one-under-one pattern around the first mandrel to form a textile structure, wherein braiding comprises rotating the yarn wheel, rotating the spindles, and longitudinally pulling the ring along the first mandrel away from the yarn wheel;
shape setting the textile structure into a substantially cylindrical shape;
securing the shape-set textile structure on a second mandrel comprising bulbs and necks, wherein the second mandrel comprises bulbs threaded along a strand;
shape setting the shape-set textile structure on the second mandrel; and
removing the shape-set textile structure from the second mandrel.
2. The method of claim 1 , wherein securing the shape-set textile structure on the second mandrel comprises wrapping a wire around the necks of the second mandrel.
3. The method of claim 1 , further comprising forming the second mandrel.
4. The method of claim 3 , wherein forming the second mandrel comprises stringing the bulbs along the strand.
5. The method of claim 4 , wherein stringing the bulbs along the strand comprises selecting shapes of the bulbs, sizes of the bulbs, and spacing between the bulbs.
6. The method of claim 1 , wherein arranging the plurality of spools comprises positioning at least two of the spools comprising radiopaque wires adjacent to each other.
7. The method of claim 1 , further comprising bonding the shape-set textile structure to a hypotube.
8. A method of manufacturing a vascular treatment device, the method comprising:
arranging a plurality of spools of wire on spindles on a yarn wheel;
braiding the wires around a mandrel comprising bulbs and necks to form a textile structure, wherein the mandrel comprises bulbs threaded along a strand, and wherein braiding comprises pulling a ring attached to an end of each of the wires away from the yarn wheel;
shape setting the textile structure on the mandrel; and
removing the shape-set textile structure from the mandrel.
9. The method of claim 8 , further comprising securing the textile structure on the mandrel before shape setting.
10. The method of claim 8 , further comprising forming the mandrel.
11. The method of claim 10 , wherein forming the mandrel comprises stringing the bulbs along the strand.
12. The method of claim 11 , wherein stringing the bulbs along the strand comprises selecting shapes of the bulbs, sizes of the bulbs, and spacing between the bulbs.
13. The method of claim 8 , further comprising bonding the shape-set textile structure to a hypotube.
14. The method of claim 1 , wherein the textile structure comprises two sine waves each comprising a radiopaque wire, the two sine waves phase shifted from each other by about 180°.
15. The method of claim 1 , wherein the textile structure comprises three sine waves each comprising a radiopaque wire, the three sine waves phase shifted from each other by about 120°.
16. The method of claim 1 , wherein the textile structure comprises a first sine wave comprising a radiopaque wire, a second sine wave comprising a radiopaque wire, the second sine wave phase shifted from the first sine wave by about 180°, a third sine wave comprising a radiopaque wire, the third sine wave phase shifted from the first sine wave by about 7.5°, and a fourth sine wave comprising a radiopaque wire, the fourth sine wave phase shifted from the third sine wave by about 7.5°.
17. The method of claim 1 , wherein securing the shape-set textile structure on the second mandrel comprises wrapping bangles around the necks of the second mandrel.
18. The method of claim 1 , wherein securing the shape-set textile structure on the second mandrel comprises wrapping c-shaped clamps around the necks of the second mandrel.
19. The method of claim 8 , wherein securing the shape-set textile structure on the second mandrel comprises wrapping a wire around the necks of the second mandrel.
20. The method of claim 8 , wherein securing the shape-set textile structure on the second mandrel comprises wrapping bangles around the necks of the second mandrel.
21. The method of claim 8 , wherein securing the shape-set textile structure on the second mandrel comprises wrapping c-shaped clamps around the necks of the second mandrel.