This invention relates to endoscopic devices. This invention relates particularly to an apparatus for providing a working channel within an endoscope.
The field of endoscopy includes the use of tubular structures inserted intraluminally into a mammalian body cavity for visualizing, treating, and taking a biopsy of tissue regions within the mammalian body. Most endoscopes currently include at least one of a plurality of working channels which extend along the length of the endoscope to provide access to body tissue within the mammalian body cavity. These working channels typically include a rigid non-bendable section and a flexible bendable section. The working channels allow for air insufflation, water flow, suction, and biopsies. Conventional endoscopes utilize a wide variety of materials for the working channels, but all conventional endoscopes require the endoscopic working channel to be an integral part of the endoscope.
Because endoscopes are subjected to repeated use and are required to follow tortuous pathways within the body, a frequent cause of failure of the endoscope working channel is the bending, kinking or fracture of a section of the working channel. This renders the endoscope useless until it is repaired. Unfortunately, repair of the endoscopic working channel requires disassembly of the endoscope and replacement of the endoscope working channel.
Another problem confronting reusability of working channels is the potential for residual contaminants on the working channel after a procedure. Most working channels prevent the permeation of contaminants by making the channel out of nonporous materials only. Unfortunately, such materials are susceptible to kinking, exacerbating this cause of failure. A working channel that is impermeable to contaminants and resistant to kinking and ovaling is needed.
The endoscopic working channel of U.S. Pat. No. 5,885,209 is designed to be retrofitted as a replacement bendable section of the working channel of an endoscope. The structure of the endoscopic working channel of this patent, however, is relatively complex and is relatively expensive to manufacture because it requires mixing and maintaining very specific liquid elastomer coatings that have significant materials and labor costs. It is desirable to provide an improved endoscopic working channel that is simpler and less expensive to manufacture.
Attempted solutions to the kinking problem have corrugated the working channel in order to provide flexibility and support while the working channel is bent. However, in certain applications this corrugation may be unwanted by the user due to an increased chance of catching a part of the corrugated surface on a body part or another surgery tool or harboring contaminants. It is desirable to provide a working channel that has a smooth exterior surface that prevent such dangers.
Therefore, it is an object of this invention to provide a working channel for an endoscope that may be used to replace a broken working channel. It is a further object that the working channel be easy to manufacture and cost-effective as a replacement channel. It is a further object that the working channel protect its interior from contaminants while being highly resistant to kinking and other unwanted compression. Another object of the invention is to provide a method of manufacture whereby a working channel may be produced with either a corrugated or smooth external surface.
An improved working channel for an endoscope or similar device has concentric polymer tubes that are adhered or bonded together. The inner tube is a nonporous material that prevents permeation of contaminants, and the outer tube is a porous material that gives the working channel flexibility while supporting the inner tube against kinking and ovaling. The outer tube may have a smooth or corrugated external surface. A support wire may be encapsulated between the inner tube and outer tube to reinforce the channel. Methods for manufacturing the working channel include using a compression die to bond the inner tube and outer tube, and wrapping a compression wrap around the outer tube before sintering the tubes.
Reference now should be made to the drawings, in which the same reference numbers are used throughout the different figures to designate the same or similar components.
The outer tube 16 is a tube of porous polymer, preferably expanded PTFE (“ePTFE”), that is made by extrusion or other means, and is preferably solidified by sintering. The outer tube 16 has an internal diameter that encompasses the inner tube 12 and is in a close relationship to the external diameter of the inner tube 12. The wall thickness of the outer tube 16 is dependent on the wall thickness of the inner tube 12 as well as the prescribed use of the working channel 10. Typically, the ratio of outer tube 16 thickness to inner tube 12 thickness is in the range of 2:1 to 8:1. For example, if the inner tube 12 has a wall thickness of 0.004 inches, then the wall thickness of the outer tube 16 ranges between 0.008 inches and 0.032 inches. These are not critical dimensions, since the thickness of the outer tube 16 may be varied, but obviously must be within the concept of the design of its intended use or implementation to maintain a low-profile working channel 10 with high flexibility and high resistance to kinking. The ranges given are practical ranges for most applications. In the preferred embodiment, the outer tube 16 is 0.017 inches thick, so that the preferred ratio to the inner tube 12 is about 3.1:1.
ePTFE and similar materials comprise a matrix of nodes and fibers that form a porous structure. The nodes are oriented perpendicularly to the fiber, which run longitudinally through the material. The nodes are a relatively static or solid portion of the ePTFE micro-structure, while the fibers which interconnect the nodes are collapsible, allowing the outer tube 16 to undergo longitudinal compression and elongation without dimensional changes, much like the performance of a spring. It is the ratio of fiber length to node width that allows various amounts of flexion in ePTFE material. Longer fiber lengths and smaller nodes provide material with high flexibility and low radial support. Since the length of the fibers relates to the porosity of the material, the relationship between fiber lengths and material density is inverse. For example, an outer tube 16 made of ePTFE with a 25 micron fiber length could have a volume density of 0.55 g/cc, while an outer tube 16 with a 10 micron fiber length would have a density of 1.2 g/cc or higher. The volume density range for ePTFE to function in the design of the product described and shown in
Referring to
The inner tube 12 and outer tube 16 are bound together, encapsulating the support wire 14 if one is used. The binding may be effected during extrusion or initial sintering of the tubes 12, 16, but preferably the tubes 12, 16 are bound using a second sintering process performed after the tubes 12, 16 are formed. After the support wire 14 is wrapped around the inner tube 12 and the outer tube 16 is placed over the support wire 14 and inner tube 12, a compression wrap 18 is spirally wrapped around the outer tube 16. The compression wrap 18 covers as much as 100% of the external surface area of the outer tube 16, depending on the intended design, described below with reference to
In the preferred embodiment, the compression wrap 18 is a metal, preferably stainless steel, wire about 0.025 inches wide and about 0.003 inches thick, and fully covers the external surface of the outer tube 16 by being wrapped around the outer tube 16 with approximately zero spacing. See FIGS. 1 and 3A-B. Zero spacing may be achieved by ensuring each turn of the compression wrap 18 abuts the previous turn, or by slightly or substantially overlapping the turns. The preferred result is therefore a substantially smooth external surface on the outer tube 16. Depending on the compression wrap 18 used and potentially varying factors, such as nonuniform heating, in the bonding process, the external surface of the outer tube 16 may have slight corrugations or be otherwise unsmooth. See
In alternative embodiments, the compression wrap 18 may be a heat-conducting metal wire, such as stainless steel, having a round to substantially flat cross-section. Referring to FIGS. 2 and 3C-E, where the compression wrap 18 covers less than the full external surface area of the outer tube 16, a spiral-shaped depression 20 is formed in the region that the compression wrap 18 does cover. The depression 20 creates a corrugated external surface that increases the flexibility of the working channel 10 while still aiding in the boding process between the tubes 12, 16. In these illustrated embodiments and other embodiments where such a corrugated exterior is desired, the compression wrap 18 is a round or substantially flat wire wrapped with substantially uniform spacing around the outer tube 16. When a support wire 14 is used, the spacing of the compression wrap 18 may be the same as the spacing between adjacent turns of the support wire 14, but offset so that the compression wrap 18 is positioned in the space between adjacent turns of the support wire 14.
While the depression 20 increases flexibility, it may cause complications that a smooth external surface could avoid. The depression 20 therefore has a depth and shape that is dependent on the intended use of the working channel 10. A deep depression 20, illustrated in
The finished working channel 10 has the opposing ends of the tubes 12 and 16 cut co-planar to a plane which is perpendicular to the common central axis of the tubes 12, 16. One or both of the opposing ends of the finished product may be chemically etched using an etcher suitable for use with PTFE, such as that sold under the trademarks FLUOROETCH by Acton Technologies or TETRAETCH by W.L. Gore Associates. Chemical etching facilitates subsequent adhesive bonding of the etched end with the tip of an endoscope. The end of the working channel 10, which is intended to be the distal end, may be chemically etched in order to increase the capacity of the tubes 12, 16 to accept an adhesive bond at the distal section of an endoscope. The proximal end of the working channel 10 is not etched, as it typically is mechanically coupled to a proximal section of an endoscope. Alternatively, both ends of the working channel 10 may be chemically etched to increase their capacity to be adhesively bonded to a pre-existing working channel of the endoscope.
The completed working channel 10 has highly lubricious internal and external surfaces capable of a tight bend radius and a relatively low wall profile. The support wire 14 provides added resistance to kinking. In addition, the completed structure is chemical resistant and is resistant to wear or collapse during repeated flexion. The overall thickness of the finished structure typically is between 0.014 inches and 0.058 inches. The lubriciousness of each surface is determined by the coefficient of friction of the material used in the tubes 12, 16. PTFE and ePTFE are chemically resistant to most acids, bases, alcohols and so forth, and have temperature resistances of up to about 300 degrees Celsius. As described, the outer wall of the inner tube 12 and the inner wall of the outer tube 16 are bonded together via temperature and pressure, and require no adhesives or chemicals to create the bond between the tubes 12, 16. However, an adhesive may be used in place of the heat and pressure boding process if the intended use of the working channel 10 provides acceptable choices for such an adhesive. An example of an acceptable adhesive for use on a medical device is Loctite® 401 Prism used in combination with Loctite® 770 primer.
It has been found that completed units constructed according to the embodiment of
The outer tube 16 is then fit 22 over the inner tube 12. As described below, the outer tube 16 may be fit 22 over the inner tube 12 after the inner tube 12 is placed on a mandrel, but use of a mandrel is optional. The inner and outer tubes 12, 16 are then bonded 23 together. Once bonding 23 is complete, the ends of the working channel 10 are finished 24, such as by chemical etching.
Referring to
After the support wire 14 has been wound 33 on the inner tube 12, the outer tube 16 is fit 22 over the inner tube 12 and the support wire 14. It should be noted that the inner diameter of the outer tube 16 is equal to or slightly greater than the outer diameter of the inner tube 12 covered by the spiral winding of the support wire 14. The spiral winding machine is used to perform a compression winding 35 of the compression wrap 18 as described above. Non-compressed spaces may be left between adjacent turns of the compression wrap 18 if corrugation of the outer tube 16 is desired. The ends of the compression wrap 18 are secured 36 and the tubes 12, 16 are anchored 37 to the mandrel. Final sintering 38 is performed, and the assembly is then allowed to cool 39. Then, the anchors and compression wrap 18 are removed 40 and the two ends of the assembly are finished 24.
An alternative method of making a working channel 10 with no depression 20 in the external surface is to apply the above-described sintering process without compression-winding 35 the compression wrap 18 onto the outer tube 16 prior to final sintering 38. In this embodiment, steps 35 and 36 and the removal of the compression wrap 18 in the process described above and illustrated in
While there has been illustrated and described what is at present considered to be the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
This application is a continuation-in-part of and claims the benefit of co-pending U.S. patent Ser. No. 11/636,270 filed Dec. 7, 2006.
Number | Date | Country | |
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Parent | 11636270 | Dec 2006 | US |
Child | 12819075 | US |