CATHETERS WITH LASER CUT HYPOTUBE SCAFFOLD FOR FLOW UNDER SIGNIFICANT PRESSURE DIFFERENTIALS
Medical catheters for transfer of fluids comprise a laser cut hypotube and an embedded polymer flowed into the cuts of the laser-cut hypotube. The laser cut hypotube may be configured to extend along at least about the distal 30% of the catheter length. The laser cut hypotube may further comprise a plurality of sections, each of the plurality of sections having a distinct laser cut pattern. The distinct laser cut pattern may be associated with a flexibility of the corresponding section. The catheter may further comprise a low friction polymer coating over an exterior surface, an interior surface, or both.
1 . A medical catheter for transfer of fluids comprising:
a laser-cut hypotube having a proximal end and a distal end; and
an embedded polymer flowed into the cuts of the laser-cut hypotube, wherein the polymer has a Shore Durometer value from about 35 A to about 76 A.
2 . The medical catheter of claim 1 wherein the laser cut hypotube is configured to extend along at least about the distal 30% of the catheter length.
3 . The medical catheter of claim 1 wherein the laser cut hypotube comprises a plurality of sections, each of the plurality of sections having a distinct laser cut pattern.
4 . The medical catheter of claim 3 wherein at least two sections comprise a spiral laser cut and each of the distinct laser cut patterns differ from one another by differences of one or more of a pitch, a degree of an uncut portion, and a cuts per revolution.
5 . The medical catheter of claim 3 wherein the distinct laser cut pattern is associated with a flexibility of the corresponding section.
6 . The medical catheter of claim 1 wherein a first section of the laser cut hypotube comprises a consistent pitch and a second section of the laser cut hypotube comprises a pitch transitioning from a first value at a distal end to a second value at a proximal end.
7 . The medical catheter of claim 1 wherein a section of the laser cut hypotube transitions from a first cuts per revolution at a first end to a second cuts per revolution at a second end.
8 . The medical catheter of claim 1 wherein the laser cut hypotube with embedded polymer has an average wall thickness from about 0.0020 inches (0.0508 mm) to about 0.010 inches (0.254 mm).
9 . The medical catheter of claim 1 wherein the laser cut hypotube with embedded polymer has an average wall thickness from about 0.0025 inches (0.0635 mm) to about 0.008 inches (0.216 mm).
10 . The medical catheter of claim 1 wherein the polymer has a Shore Durometer value from about 42 A to about 58 A.
11 . The medical catheter of claim 1 wherein the hypotube comprises stainless steel.
12 . The medical catheter of claim 1 comprising uncut segments at a distal end and a proximal end, the uncut segments independently having a length along the catheter from about 0.0020 in to about 0.1 and at least one section of spiral cut hypotube.
13 . The medical catheter of claim 1 further comprising a low friction polymer coating over an exterior surface, an interior surface, or both.
14 . The medical catheter of claim 13 wherein the low friction polymer coating comprises a hydrophilic polymer.
15 . The medical catheter of claim 1 wherein the proximal end of the laser cut hypotube is inserted into and secured to a hub.
16 . The medical catheter of claim 1 wherein a control structure is secured to the laser cut hypotube at or near the proximal end of the hypotube and a distal end of the control structure.
17 . The medical catheter of claim 16 wherein the control structure comprises a feature that interfaces with a mated feature cut into the hypotube to facilitate securing of the control structure.
18 . The medical catheter of claim 16 wherein a polymer jacket is placed over the secured distal end of the control structure to form a connection section.
19 . The medical catheter of claim 1 wherein the laser cut hypotube has a port near the distal end.
20 . The medical catheter of claim 19 wherein the port is formed by a gap in the embedded polymer to allow fluid flow through the laser cuts, or the port is formed through a specific hole formed though the hypotube and embedded polymer.
21 . The medical catheter of claim 1 wherein a difference between a catheter wall thickness and a laser cut hypotube wall thickness ranges from about zero to about 0.0015 inches (0.0381 mm).
22 . The medical catheter of claim 1 further comprising a radiopaque marker band that is laser cut or comprises radiopaque wire, and wherein the embedded polymer further embeds the radiopaque marker band.