LOW TEMPERATURE HYDROPHILIC ADHESIVE FOR USE IN EXPANDABLE SHEATH FOR INTRODUCING AN ENDOVASCULAR DELIVERY DEVICE INTO A BODY

Abstract

Disclosed is an expandable sheath that can be used in conjunction with a catheter assembly to introduce a prosthetic device, such as a heart valve, into a patient. The disclosed sheaths can minimize trauma to the vessel by allowing for temporary expansion of a portion of the introducer sheath to accommodate the delivery apparatus, followed by a return to the original diameter once the prosthetic device passes through. Also disclosed is a sheath having inner and outer layers, where a folded portion of the inner layer extends through a slit in the outer layer, and a portion of the outer layer overlaps the folded portion of the inner layer and where a first polymer is disposed between the outer layer and the folded portion of the inner layer.

Description

FIELD

The present application concerns aspects of a sheath for use with catheter-based technologies for repairing and/or replacing heart valves and delivering a prosthetic device, such as a prosthetic valve to a heart via the patient's vasculature.

BACKGROUND

Endovascular delivery catheter assemblies are used to implant prosthetic devices, such as a prosthetic valve, at locations inside the body that are not readily accessible by surgery or where access without invasive surgery is desirable. For example, aortic, mitral, tricuspid, and/or pulmonary prosthetic valves can be delivered to a treatment site using minimally invasive surgical techniques.

An introducer sheath can be used to safely introduce a delivery apparatus into a patient's vasculature (e.g., the femoral artery). An introducer sheath generally has an elongated sleeve that is inserted into the vasculature and a housing that contains one or more sealing valves that allow a delivery apparatus to be placed in fluid communication with the vasculature with minimal blood loss. A conventional introducer sheath typically requires a tubular loader to be inserted through the seals in the housing to provide an unobstructed path through the housing for a valve mounted on a balloon catheter. A conventional loader extends from the proximal end of the introducer sheath, and therefore decreases the available working length of the delivery apparatus that can be inserted through the sheath and into the body.

Conventional methods of accessing a vessel, such as a femoral artery, prior to introducing the delivery system include dilating the vessel using multiple dilators or sheaths that progressively increase in diameter. This repeated insertion and vessel dilation can increase the amount of time the procedure takes and the risk of damage to the vessel.

Radially expanding intravascular sheaths have been disclosed. Such sheaths tend to have complex mechanisms, such as ratcheting mechanisms that maintain the shaft or sheath in an expanded configuration once a device with a larger diameter than the sheath's original diameter is introduced.

However, delivery and/or removal of prosthetic devices and other material to or from a patient still poses a significant risk to the patient. Furthermore, accessing the vessel remains a challenge due to the relatively large profile of the delivery system that can cause longitudinal and radial tearing of the vessel during insertion. The delivery system can additionally dislodge calcified plaque within the vessels, posing an additional risk of clots caused by the dislodged plaque.

Accordingly, there remains a need in the art for an improved introducer sheath for endovascular systems used for implanting valves and other prosthetic devices.

SUMMARY

The disclosed aspects are directed to an expandable sheath that can minimize trauma to the vessel by allowing for temporary expansion of a portion of the introducer sheath to accommodate a delivery system, followed by a return to the original diameter once the delivery system passes through. In some aspects, disclosed is a sheath having a smaller profile than that of prior art introducer sheaths. Furthermore, in certain aspects, the use of the disclosed sheaths can reduce the length of time a procedure takes and reduce the risk of a longitudinal or radial vessel tear or plaque dislodgement because only one sheath is required rather than several different sizes of sheaths. In some aspects, the expandable sheath can require only a single vessel insertion instead of requiring multiple insertions for the vessel's dilation.

Disclosed herein are aspects directed to a sheath for delivering a medical device. In some aspects, the sheath can have a proximal and a distal end and comprise: an expandable inner layer having an inner surface and an outer surface, wherein the inner surface of the expandable inner layer defines a lumen having a longitudinal axis and comprising at least one folded portion having an inner portion and outer portion; an outer layer having an inner surface and an outer surface and extending at least partially around the inner layer such that at least a first portion of the outer surface of the outer layer is positioned adjacent to the inner portion of the at least one folded portion of the inner layer, while a first portion of the inner surface of the outer layer is positioned adjacent to the outer portion of the at least one folded portion of the inner layer; a first polymer disposed between at least a portion of the inner layer and at least a portion of the outer layer, forming an intermediate layer, wherein, the first polymer exhibits a melting temperature from about 30° C. to about 45° C.; and wherein the at least one folded portion is configured to at least partially unfold during application of a radial outward force by passage of a medical device through the lumen of the inner layer.

In other aspects, the first polymer can be disposed between at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer. In yet another aspect, the first polymer can be disposed between at least the first portion of the inner surface of the outer layer and the outer portion of the at least one folded portion of the inner layer.

In still further aspects, the sheath can further comprise an outer jacket comprising an inner surface and outer surface extending at least partially around the outer layer such that the inner surface of the outer jacket overlies the outer surface of the outer layer.

Also disclosed herein are aspects comprising methods of making a sheath for delivering a medical device. In certain aspects, the methods disclosed herein are directed to making any of the disclosed herein sheaths.

In certain aspects, a method of making a sheath comprises providing a sheath comprising: an expandable inner layer having an inner surface and an outer surface, wherein the inner surface of the expandable inner layer defines a lumen having a longitudinal axis and comprising at least one folded portion having an inner portion and outer portion; and an outer layer having an inner surface and an outer surface and extending at least partially around the inner layer such that at least a first portion of the outer surface of the outer layer is positioned adjacent to the inner portion of the at least one folded portion of the inner layer, while a first portion of the inner surface of the outer layer is positioned adjacent to the outer portion of the at least one folded portion of the inner layer; applying a first polymer between at least a portion of the inner layer and at least a portion of the outer layer, thereby forming an intermediate layer, wherein, the first polymer exhibits a melting temperature from about 30° C. to about 45° C. and; wherein the at least one folded portion is configured to at least partially unfold during application of a radial outward force by passage of a medical device through the lumen of the inner layer.

In yet further aspects, the first polymer can be applied between the at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer. In still further aspects, the first polymer can be applied between the at least the first portion of the inner surface of the outer layer and the outer portion of the at least one folded portion of the inner layer. In still further aspect, the disclosed method further comprises positioning an outer jacket comprising an inner surface and outer surface such that it extends at least partially around the outer layer and such that the inner surface of the outer jacket overlies the outer surface of the outer layer.

The foregoing and other features and advantages of the disclosure will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation view of a sheath according to the present disclosure along with an endovascular delivery apparatus for implanting a prosthetic valve.

FIGS. 2A, B, and D are section views of a sheath for introducing a prosthetic device into a patient, and FIG. 2C is a perspective view of one component of such a sheath, in one aspect.

FIG. 3 is an elevation view of the sheath shown in FIG. 2.

FIGS. 4A-4B are elevation views of a sheath according to the present disclosure, having varying outer diameters in alternative aspects.

FIG. 5 illustrates an elevation view of a sheath, expanded at a first location to accommodate a delivery system in one aspect.

FIG. 6 shows an elevation view of the sheath of claim 5, expanded at a second location farther down the sheath.

FIG. 7 shows a section view of a sheath that further comprises an outer covering or shell in another aspect.

FIG. 8 illustrates an elevation view of a sheath with an outer covering or shell in another aspect.

FIG. 9 illustrates a partial elevation view of an intermediate tubular layer that can be used to construct a sheath according to the present disclosure in one aspect.

FIG. 10 illustrates a partial elevation view of an intermediate tubular layer having a variable diamond design in another aspect.

FIG. 11 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with spring struts in another aspect.

FIG. 12 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with straight struts in another aspect.

FIG. 13 illustrates a partial elevation view of an intermediate tubular layer having a saw tooth design with spring struts in another aspect.

FIG. 14 illustrates a partial elevation view of an intermediate tubular layer having a saw tooth design with straight struts in another aspect.

FIG. 15 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with straight struts in another aspect.

FIG. 16 illustrates a partial elevation view of an intermediate tubular layer having a helical or spiral design in another aspect.

FIG. 17 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with non-straight struts in another aspect.

FIG. 18 illustrates a partial elevation view of an intermediate tubular layer having an alternative diamond design with non-straight struts in another aspect.

FIG. 19 illustrates a partial elevation view of an intermediate tubular layer having yet another diamond design with non-straight struts in another aspect.

FIG. 20 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with struts in another aspect.

FIG. 21 illustrates a partial elevation view of an intermediate tubular layer having a design similar to that shown in FIG. 20, but with additional struts in another aspect.

FIG. 22 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with spiral struts in another aspect.

FIG. 23 illustrates a partial elevation view of an intermediate tubular layer having a diamond design with adjacent struts in another aspect.

FIG. 24 illustrates a section view of a sheath having a longitudinal notch in another aspect.

FIG. 25 shows a section view of a sheath having a longitudinal cut in the inner layer in another aspect.

FIG. 26 shows a perspective view of a sheath having a plurality of notches or cuts in the outer tubular layer in another aspect.

FIG. 27A illustrates a section view of a sheath, wherein the outer tubular layer contains a longitudinal cut, and the inner layer extends into the gap created by the cut in the outer tubular layer, in an unexpanded configuration; and FIGS. 27B-27E show section views of various aspects of a sheath in the unexpanded configuration in another aspect.

FIG. 28 shows a section view of the sheath of FIG. 27A in an expanded configuration.

FIGS. 29A-29D show section views of a sheath having overlapping sections in other aspects.

FIG. 30 illustrates a block diagram of a method of making a sheath according to the present disclosure in one aspect.

FIG. 31 illustrates a block diagram of a method of making a sheath according to the present disclosure in another aspect.

FIGS. 32A-32H illustrates section or elevation views of various method steps of the methods shown in FIGS. 30-31.

FIG. 33 illustrates a plan view of a sheath having a partial slit or scoreline in another aspect.

FIG. 34 illustrates a plan view of a sheath having a partial slit or scoreline in another aspect.

FIG. 35 is an elevation view of an expandable sheath according to the present disclosure and representative housing.

FIG. 36 is an enlarged cutaway view of the distal end of the sheath of FIG. 35.

FIGS. 37A-37B is a section view of the distal end of the sheath of FIG. 35, taken along line 37-37 in FIG. 36; FIG. 37A is a section view of the distal end of the sheath without an outer jacket, and FIG. 37B is a section view of the distal end of the sheath with an outer jacket present.

FIGS. 38A-38B is a section view of a proximal section of the sheath of FIG. 35, taken along line 38-38 in FIG. 35; FIG. 38A is a section view of the proximal end of the sheath without an outer jacket, and FIG. 38B is a section view of the proximal end of the sheath with an outer jacket present.

FIGS. 39A-39G is a section view of the sheath of FIG. 35 in a rest (unexpanded) configuration, taken along line 39-39 in FIG. 35; FIG. 39A-depicts a section view in one aspect without an exemplary first polymer, FIGS. 39B-39G depict a section view in various aspects with the presence of an exemplary first polymer.

FIG. 40A-40C is a section view of the sheath of FIGS. 39A-C, in an expanded configuration; FIG. 40A is a section view of the sheath of FIG. 39A without an exemplary first polymer, FIG. 40B is a section view of the sheath of FIG. 39B with an exemplary first polymer present, FIG. 40C is a section view of the sheath of FIG. 39E with an exemplary first polymer present.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present articles, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific or exemplary aspects of articles, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description of the disclosure is provided as an enabling teaching of the disclosure in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the disclosure described herein while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those of ordinary skill in the pertinent art will recognize that many modifications and adaptations to the present disclosure are possible and may even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is again provided as illustrative of the principles of the present disclosure and not in limitation thereof.

Definitions

As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Thus, for example, reference to a “polymer” includes aspects having two or more such polymers unless the context clearly indicates otherwise.

It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” can include the aspects “consisting of” and “consisting essentially of.” Additionally, the term “includes” means “comprises.”

For the terms “for example” and “such as,” and grammatical equivalences thereof, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise.

References in the specification and concluding claims to parts by weight of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a composition or a selected portion of a composition containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the composition.

A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

Ranges can be expressed herein as from “about” one particular value and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It should be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

As used herein, the term “substantially,” when used in reference to a composition, refers to at least about 80%, at least about 85%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% by weight, based on the total weight of the composition, of a specified feature or component.

As used herein, the term “substantially,” in, for example, the context “substantially free” refers to a composition having less than about 1% by weight, e.g., less than about 0.5% by weight, less than about 0.1% by weight, less than about 0.05% by weight, or less than about 0.01% by weight of the stated material, based on the total weight of the composition.

As used herein, the terms “substantially identical reference composition” or “substantially identical reference article” refer to a reference composition or article comprising substantially identical components in the absence of an inventive component. In another exemplary aspect, the term “substantially,” in, for example, the context “substantially identical reference composition,” refers to a reference composition comprising substantially identical components and wherein an inventive component is substituted with a common in the art component. For example, a substantially identical reference sheath can comprise a sheath comprising substantially identical components but without the presence of the first polymer. In a still further example, a substantially identical reference sheath can comprise a sheath comprising substantially identical components but without the presence of the first polymer and the second polymer; or a sheath comprising substantially identical components but without the presence of the first polymer, the second polymer and/or the third polymer,

Further, the terms “coupled” and “associated” generally mean electrically, electromagnetically, and/or physically (e.g., mechanically or chemically) coupled or linked and do not exclude the presence of intermediate elements between the coupled or associated items.

Although the operations of exemplary aspects of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed aspects can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may, in some cases, be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular aspect are not limited to that aspect and may be applied to any aspect disclosed.

Moreover, for the sake of simplicity, the attached figures may not show the various ways (readily discernable, based on this disclosure, by one of ordinary skill in the art) in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses. Additionally, the description sometimes uses terms such as “produce” and “provide” to describe the disclosed method. These terms are high-level abstractions of the actual operations that can be performed. The actual operations that correspond to these terms can vary depending on the particular implementation and are, based on this disclosure, readily discernible by one of ordinary skill in the art.

Sheath

In some aspects, the disclosure is directed to an expandable sheath that can minimize trauma to the vessel by allowing for temporary expansion of a portion of the introducer sheath to accommodate the delivery system, followed by a return to the original diameter once the device passes through. In certain aspects and as disclosed herein, a sheath has a smaller profile (e.g., a smaller diameter in the rest configuration) than that of prior art introducer sheaths. Furthermore, the sheaths disclosed in certain aspects of the present disclosure can reduce the length of time a procedure takes and reduce the risk of a longitudinal or radial vessel tear or plaque dislodgement because only one sheath is required rather than several different sizes of sheaths. In yet other aspects, the use of the disclosed expandable sheath can avoid the need for multiple insertions for the dilation of the vessel. Such expandable sheaths can be useful for many types of minimally invasive surgery, such as any surgery requiring introduction of an apparatus into a subject's vessel. For example, the sheath can be used to introduce other types of delivery apparatus for placing various types of intraluminal devices (e.g., stents, prosthetic heart valves, stented grafts, etc.) into many types of vascular and non-vascular body lumens (e.g., veins, arteries, esophagus, ducts of the biliary tree, intestine, urethra, fallopian tube, other endocrine or exocrine ducts, etc.).

In some aspects, the sheath disclosed herein for introducing a prosthetic device can comprise an inner layer and an outer layer. In certain aspects, at least a portion of the sheath can be designed or configured to locally expand from a first diameter to a second diameter as the prosthetic device is pushed through a lumen of the sheath and then at least partially return to the first diameter once the prosthetic device has passed through. In certain aspects, the sheath can additionally comprise an elastic outer cover disposed about the outer layer. Yet, in still other aspects, the sheath can include an outer jacket disposed about the outer layer.

One aspect, the sheath for introducing a prosthetic device into a body, can comprise a continuous inner layer defining a lumen therethrough, the inner layer having a folded portion and a discontinuous outer layer having an overlapping portion and an underlying portion. In some aspects, the inner layer can have at least two folded portions. The outer layer can be configured such that the overlapping portion overlaps the underlying portion, wherein at least a portion of the folded portion of the inner tubular layer is positioned between the overlapping and underlying portions. In yet other aspects, at least a portion of the sheath can be configured to expand to accommodate the prosthetic device.

In some aspects, at least a portion of the sheath can be configured such that a plurality of segments of the sheath each can locally expand one at a time from a rest configuration having a first diameter to an expanded configuration having a second diameter that is larger than the first diameter, to facilitate passage of the prosthetic device through the lumen of the inner layer. In certain aspects, each segment can have a length defined along the longitudinal axis of the sheath, and each segment of the sheath can be configured to at least partially return to the first diameter once the prosthetic device has passed through.

In some aspects, when each segment of the sheath is in the expanded configuration, a length of the folded portion corresponding to the length of the segment at least partially unfolds (e.g., by separating and/or straightening). In still further aspects, a length of the overlapping portion corresponding to the length of the segment can be configured to move with respect to the underlying portion when each segment of the sheath expands from the rest configuration to the expanded configuration.

In some exemplary aspects and as disclosed in detail below, the sheath can further comprise an elastic outer cover disposed on an external surface of the outer layer. In still further aspects, the elastic outer cover can be the outer jacket of the sheath. The elastic outer cover can comprise, for example, heat shrink tubing. In certain aspects, and as disclosed in detail below, the sheath can also comprise one or more radiopaque markers or fillers, such as a C-shaped band positioned between the inner and outer layers near the distal end of the sheath. In certain exemplary and unlimiting aspects, a soft tip can be secured to the distal end of the sheath.

In some aspects and as disclosed below, the inner layer can include at least one folded portion and at least one weakened portion. In certain aspects, the sheath can comprise a discontinuous outer layer. In such exemplary aspects, the discontinuous outer layer can have an outer surface, and an inner surface and a longitudinal gap, and a portion of the inner layer can extend through the longitudinal gap. The at least one folded portion of the inner layer can be positioned adjacent to a portion of the outer surface of the outer layer. In some aspects, the weakened portion can comprise a scoreline along at least a portion of the inner layer and/or a slit along at least a portion of the inner layer. The weakened portion can be positioned at the at least one folded portion of the inner layer. In some aspects, the longitudinal gap can be positioned between a first end and a second end of the outer layer.

In some exemplary aspects and as also disclosed in detail below, an expandable sheath can comprise a hydrophilic inner liner defining a generally horseshoe-shaped lumen therethrough, the inner liner, including at least two weakened portions and an elastic cover, positioned radially outward of the inner liner. In some aspects, when the sheath is in the expanded configuration, the inner liner splits apart at the weakened portions so as to form a discontinuous inner liner.

FIG. 1 illustrates an exemplary sheath 8 according to the present disclosure, in use with a representative delivery apparatus 10, for delivering a prosthetic device 12, such as a tissue heart valve to a patient. The apparatus 10 can include a steerable guide catheter 14 (also referred to as a flex catheter), a balloon catheter 16 extending through the guide catheter 14, and a nose catheter 18 extending through the balloon catheter 16. The guide catheter 14, the balloon catheter 16, and the nose catheter 18 in the illustrated aspect are adapted to slide longitudinally relative to each other to facilitate delivery and positioning of the valve 12 at an implantation site in a patient's body, as described in detail below.

In certain aspects, the sheath disclosed herein can comprise a proximal end and a distal end opposite one another. Generally, in certain aspects, sheath 8 can be inserted into a vessel, such as the transfemoral vessel, pass through the skin of the patient, such that the distal end of the sheath 8 can be inserted into the vessel. Sheath 8 can also comprise a hemostasis valve at/or near the opposite, proximal end of the sheath. Yet, in further aspects, the delivery apparatus 10 can be inserted into the sheath 8, and the prosthetic device 12 can then be delivered and implanted within the patient.

FIGS. 2A, 2B, and 2D show exemplary section views of a sheath 22, in one aspect, for use with a delivery apparatus such as that shown in FIG. 1. FIG. 2C shows a perspective view of one aspect of an inner layer 24 for use with the sheath 22 in one aspect. Sheath 22 includes an inner layer, such as inner polymeric tubular layer 24, an outer layer, such as outer polymeric tubular layer 26, and an intermediate tubular layer 28 disposed between the inner and outer polymeric tubular layers 24, 26. The sheath 22 defines a lumen 30 through which a delivery apparatus can travel into a patient's vessel in order to deliver, remove, repair, and/or replace a prosthetic device. Such introducer sheaths 22 can also be useful for other types of minimally invasive surgery, such as any surgery requiring introduction of an apparatus into a subject's vessel. For example, and without limitations, the sheath 22 also can be used to introduce other types of delivery apparatus for placing various types of intraluminal devices (e.g., stents, stented grafts, etc.) into many types of vascular and non-vascular body lumens (e.g., veins, arteries, esophagus, ducts of the biliary tree, intestine, urethra, fallopian tube, other endocrine or exocrine ducts, etc.).

In certain aspects, the inner layer can comprise polytetrafluoroethylene (PTFE), polyimide, polyetheretherketone (PEEK), polyurethane, nylon, polyethylene, polyamide, or combinations thereof.

In other aspects, the outer layer can comprise PTFE, polyimide, PEEK, polyurethane, nylon, polyethylene, polyamide, polyether block amides, polyether block ester copolymer, thermoset silicone, latex, poly-isoprene rubbers, high-density polyethylene (HDPE), Tecoflex, or combinations thereof.

In certain exemplary and unlimiting aspects, the outer polymeric tubular layer 26 and/or the inner polymeric tubular layer 24 can comprise, for example, PTFE (e.g., Teflon®), polyimide, PEEK, polyurethane, nylon, polyethylene, polyamide, polyether block amides (e.g., PEBAX®), polyether block ester copolymer, polyesters, fluoropolymers, polyvinyl chloride, thermoset silicone, latex, poly-isoprene rubbers, polyolefin, other medical grade polymers, or combinations thereof.

In some exemplary aspects, the inner layer can comprise PTFE and the outer layer can comprise a combination of HDPE and/or Tecoflex. In yet other exemplary aspects, the inner and outer layers can be thermally fused together. In some exemplary and unlimiting aspects, the inner layer can comprise a woven fabric and/or braided filaments such as yarn filaments of PTFE, PET, PEEK, and/or nylon.

The intermediate tubular layer 28 can comprise a shape memory alloy such as Nitinol and/or stainless steel, cobalt, chromium, spectra fiber, polyethylene fiber, aramid fiber, or combinations thereof.

In certain aspects, the inner polymeric tubular layer 24 can advantageously be provided with a low coefficient of friction on its inner surface. For example, the inner polymeric tubular layer 24 can have a coefficient of friction of less than about 0.5, less than about 0.4, less than about 0.3, less than about 0.2, less than about 0.1, less than about 0.05, or even less than about 0.01. In some aspects, a sheath 22 can include a lubricious liner on the inner surface 32 of the inner polymeric tubular layer 24. Such a liner can facilitate passage of a delivery apparatus through the lumen 30 of the sheath 22. Examples of suitable lubricious liners include materials that can reduce the coefficient of friction of the inner polymeric tubular layer 24, such as PTFE, polyethylene, polyvinylidene fluoride, and combinations thereof. Suitable materials for a lubricious liner also include other materials desirably having a coefficient of friction of about 0.5 or less, about 0.4 or less, about 0.3 or less, about 0.2 or less, about 0.1 or less, of about 0.09 or less, about 0.08 or less, about 0.07 or less, about 0.05 or less, about 0.04 or less, about 0.03 or less, about 0.02 or less, or about 0.01 or less.

The inner diameter of the intermediate tubular layer 28 can vary depending on the application and size of the delivery apparatus and prosthetic device. In some aspects, the inner diameter ranges from about 0.005 inches to about 0.400 inches, including exemplary values of about 0.01about 0.02, about 0.03, about 0.04, about 0.05, about 0.06, about 0.07, about 0.08, about 0.09, about 0.1, about 0.2, and about 0.3 inches. The thickness of the intermediate tubular layer 28 can also be varied depending on the desired amount of radial expansion, as well as the strength required. For example, and without limitations, the thickness of the intermediate tubular layer 28 can be from about 0.002 inches to about 0.025 inches, including exemplary values of about 0.003, about 0.004, about 0.005, about 0.006, about 0.007, about 0.008, about 0.009, about 0.01, about 0.011, about 0.012, about 0.013, about 0.014, about 0.015, about 0.016, about 0.017, about 0.018, about 0.019, about 0.020, about 0.021, about 0.022, about 0.023, and about 0.024 inches.

The thicknesses of the inner polymeric tubular layer 24 and the outer polymeric tubular layer 26 can also be varied depending on the particular application of the sheath 22. In some aspects, the thickness of the inner polymeric tubular layer 24 ranges from about 0.0005 inches to about 0.010 inches, including exemplary values of about 0.0006, about 0.0007, about 0.0008, about 0.0009, about 0.001, about 0.002, about 0.003, about 0.004, about 0.005, about 0.006, about 0.007, about 0.008, about 0.009 inches, and in one particular aspect, the thickness can be about 0.002 inches. Outer polymeric tubular layers 26 can have a thickness of from about 0.002 inches to about 0.015 inches, including exemplary values of about 0.003, about 0.004, about 0.005, about 0.006, about 0.007, about 0.008, about 0.009, about 0.01 inches, and in one particular aspect, the outer polymeric tubular layer 26 has a thickness of about 0.010 inches.

The hardness of each layer of the sheath 22 can also be varied depending on the particular application and desired properties of the sheath 22. In some aspects, the outer polymeric tubular layer 26 has a Shore hardness of from about 25 Durometer to about 75 Durometer, including exemplary values of about 30 Durometer, about 35 Durometer, about 40 Durometer, about 45 Durometer, about 50 Durometer, about 55 Durometer, about 60 Durometer, about 65 Durometer, and about 70 Durometer.

Additionally, in some aspects, the sheath 22 can comprise, as mentioned above, an exterior hydrophilic coating on the outer surface 34 of the outer polymeric tubular layer 26. Such a hydrophilic coating can facilitate insertion of the sheath 22 into a patient's vessel. Examples of suitable hydrophilic coatings include the Harmony™ Advanced Lubricity Coatings and other Advanced Hydrophilic Coatings available from SurModics, Inc., Eden Prairie, Minn. DSM medical coatings (available from Koninklijke DSM N.V, Heerlen, the Netherlands), as well as other hydrophilic coatings, are also suitable for use with the sheath 22.

In some aspects, the outer surface 34 of the outer polymeric tubular layer 26 can be modified. For example, surface modifications such as plasma etching can be performed on the outer surface 34. It is understood, however, that plasma etching is only an exemplary surface modification method, and other methods such as laser ablation, chemical etching, etc., can also be employed. Similarly, in certain aspects, if desired, other surfaces, both outer and inner, can be surface modified. In some aspects, surface modification can improve adhesion between the layers in the areas of the modification.

The sheath 22 also can have at least one radiopaque filler or marker. The radiopaque filler or marker can be associated with the outer surface 34 of the outer polymeric tubular layer 26. Alternatively, the radiopaque filler or marker can be embedded or blended within the outer polymeric tubular layer 24. Similarly, the radiopaque filler or marker can be associated with a surface of the inner polymeric tubular layer 24 or the intermediate tubular layer 28 or embedded within either or both of those layers.

In some aspects, suitable materials for use as a radiopaque filler or marker include, for example, barium sulfite, bismuth trioxide, titanium dioxide, bismuth subcarbonate, or combinations thereof. In certain aspects, the radiopaque filler can be mixed with or embedded in the material used to form the outer polymeric tubular layer 26, and can comprise from about 5% to about 45% by weight of the outer polymeric tubular layer, including exemplary values of about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, and about 40% by weight of the outer polymeric tubular layer. The more or less radiopaque material can be used in some aspects, depending on the particular application.

In some aspects, the inner polymeric tubular layer 24 can comprise a substantially uniform cylindrical tube. In alternative aspects, the inner polymeric tubular layer 24 can have at least one section of discontinuity along its longitudinal axis to facilitate radial expansion of the inner polymeric tubular layer 24. For example, the inner polymeric tubular layer 24 can be provided with one or more longitudinal notches and/or cuts 36 extending along at least a portion of the length of the sheath 22. Such notches or cuts 36 can facilitate radial expansion of the inner polymeric tubular layer 24, thus accommodating passage of a delivery apparatus or other device. Such notches and/or cuts 36 can be provided near the inner surface 32, near the outer surface 37, and/or substantially through the entire thickness of the inner polymeric layer 24. In aspects with a plurality of notches and/or cuts 36, such notches and/or cuts 36 can be positioned such that they are substantially equally spaced from one another circumferentially around the inner polymeric layer 24. Alternatively, notches and cuts 36 can be spaced randomly in relation to one another or in any other desired pattern. Some or all of any provided notches and/or cuts 36 can extend longitudinally along substantially the entire length of the sheath 22. Alternatively, some or all of any provided notches and/or cuts 36 can extend longitudinally only along a portion of the length of the sheath 22.

As shown in FIGS. 2B and 2C (which illustrates only the inner polymeric tubular layer 24), in some aspects, the inner polymeric tubular layer 24 contains at least one notch or cut 36 that extends longitudinally and parallel to an axis defined by the lumen 30, extending substantially the entire length of the sheath 22. Thus, upon introduction of a delivery apparatus, the inner polymeric tubular layer 24 can split open along the notch and/or cut 36 and expand, thus accommodating the delivery apparatus.

Additionally or alternatively, in some aspects, and as shown in FIG. 2D, the outer polymeric tubular layer 26 can comprise one or more notches and/or cuts 36. Notches and/or cuts 36, in some aspects, do not extend through the entire thickness of the outer tubular layer 26. The notches and/or cuts 36 can be separable upon radial expansion of the sheath 22. The outer polymeric tubular layer 26 can be retractable longitudinally or able to be pulled back away from the intermediate tubular layer 28 and the inner polymeric tubular layer 24. In aspects with a retractable outer polymeric tubular layer 26, the outer polymeric tubular layer 26 can be retracted to accommodate or facilitate passage of a delivery apparatus through the lumen 30, and then can be replaced to its original position on the sheath 22.

FIG. 3 illustrates an exemplary elevation view of the sheath 22 shown in FIG. 2A. In this view, only the outer polymeric tubular layer 26 is visible. The sheath 22 comprises a proximal end 38 and a distal end 40 opposite the proximal end 38. The sheath 22 can include a hemostasis valve inside the lumen of the sheath 22, at or near the proximal end 38 of the sheath 22. Additionally, the sheath 22 can comprise a soft tip 42 at the distal end 40 of the sheath 22. Such a soft tip 42 can be provided with a lower hardness than the other portions of the sheath 22. In some aspects, the soft tip 42 can have a Shore hardness from about 25 D to about 40 D, including exemplary values of about 26 D, about 27 D, about 28 D, about 29 D, about 30 D, about 31 D, about 32 D, about 33 D, about 34 D, about 35 D, about 36 D, about 37 D, about 38 D, and about 39 D.

In some aspects, the unexpanded original outer diameter can be substantially constant along at least a majority of the length of the sheath. While in other aspects, the unexpanded original outer diameter of the sheath can decrease along a gradient from the proximal end to the distal end of the sheath.

For example, as shown in FIG. 3, the unexpanded original outer diameter of the sheath 22 can be substantially constant across the length of the sheath 22, substantially from the proximal end 38 to the distal end 40. In alternative aspects, such as the ones illustrated in FIGS. 4A-4B, the original unexpanded outer diameter of the sheath 22 can decrease from the proximal end 38 to the distal end 40. As shown in the aspect in FIG. 4A, the original unexpanded outer diameter can decrease along a gradient, from the proximal end 38 to the distal end 40. In alternative aspects, as shown in FIG. 4B, the original unexpanded outer diameter of sheath 22 can incrementally step down along the length of the sheath 22, wherein the largest original unexpanded outer diameter is near the proximal end 38, and the smallest original unexpanded outer diameter is near the distal end 40 of the sheath 22.

As shown in FIGS. 5-6, the sheath 22 can be designed to locally expand as the prosthetic device is passed through the lumen of the sheath 22 and then substantially return to its original shape once the prosthetic device has passed through that portion of the sheath 22. For example, and without limitations, FIG. 5 illustrates a sheath 22 having a localized bulge 44, representative of a device being passed through the internal lumen of the sheath 22. FIG. 5 shows the device close to the proximal end 38 of the sheath 22, close to the area where the device is introduced into the sheath 22. FIG. 6 shows the sheath 22 of FIG. 5, with the device having progressed further along the sheath 22. The localized bulge 44 is now closer to the distal end 40 of the sheath 22 and thus is about to be introduced to a patient's vessel. As evident from FIGS. 5 and 6, once the localized bulge associated with the device has passed through a portion of the lumen of the sheath 22, that portion of the sheath 22 can automatically return to its original shape and size, at least in part due to the materials and structure of the sheath 22.

The sheath 22 has an unexpanded inner diameter equal to the inner diameter of the inner polymeric tubular layer (not visible in FIGS. 5-6) and an unexpanded outer diameter 46 equal to the outer diameter of the outer polymeric tubular layer 26. The sheath 22 is designed to be expanded to an expanded inner diameter and an expanded outer diameter 48, which are larger than the unexpanded inner diameter and the unexpanded outer diameter 46, respectively. In one representative aspect, the unexpanded inner diameter is about 16 Fr, and the unexpanded outer diameter 46 is about 19 Fr, while the expanded inner diameter is about 26 Fr, and the expanded outer diameter 48 is about 29 Fr. Different sheaths 22 can be provided with different expanded and unexpanded inner and outer diameters, depending on the size requirements of the delivery apparatus for various applications. Additionally, some aspects can provide more or less expansion depending on the particular design parameters, the materials, and/or configurations used.

In some aspects, and as shown in section in FIG. 7 and in elevation in FIG. 8, the sheath 22 can additionally comprise an outer covering, such as outer polymeric covering 50, disposed on the outer surface 52 of the outer polymeric tubular layer 26. In such exemplary and unlimiting aspects, the outer polymeric covering 50 can provide a protective covering for the underlying sheath 22. In some aspects, the outer polymeric covering 50 can contain a self-expandable sheath in a crimped or constrained state and then release the self-expandable sheath upon removal of the outer polymeric covering 50. For example, in some aspects of a self-expandable sheath, the intermediate layer 28 can comprise Nitinol and/or other shape memory alloys, and the intermediate layer 28 can be crimped or radially compressed to a reduced diameter within the outer polymeric tubular layer 26 and the outer polymeric covering 50. Once the self-expandable sheath is at least partially inserted into a patient's vessel, the outer polymeric covering 50 can be slid back, peeled away, or otherwise at least partially removed from the sheath. To facilitate removal of the outer polymeric covering 50, a portion of the outer polymeric covering 50 can remain outside the patient's vessel, and that portion can be pulled back or removed from the sheath to allow the sheath to expand. In some aspects, substantially the entire outer polymeric covering 50 can be inserted, along with the sheath, into a patient's vessel. In these aspects, an external mechanism attached to the outer polymeric covering 50 can be provided, such that the outer polymeric covering can be at least partially removed from the sheath once the sheath is inserted into a patient's vessel.

Once no longer constrained by the outer polymeric covering 50, the radially compressed intermediate layer 28 can self-expand, causing expansion of the sheath along the length of the intermediate layer 28. In some aspects, portions of the sheath can radially collapse, at least partially returning to the original crimped state, as the sheath is being withdrawn from the vessel after completion of the surgical procedure. In yet other aspects, such collapse can be facilitated and/or encouraged by an additional device or layer that, in some aspects, can be mounted onto a portion of the sheath prior to the sheath's insertion into the vessel.

The outer polymeric covering 50, in some aspects, is not adhered to the other layers of the sheath 22. For example, the outer polymeric covering 50 may be slidable with respect to the underlying sheath, such that it can be easily removed or retracted from its initial position on the sheath 22.

As seen in FIG. 8, the outer polymeric covering 50 can include one or more peel tabs 54 to facilitate manual removal of the outer polymeric covering 50. The outer polymeric covering 50 can be automatically or manually retractable and/or splittable to facilitate radial expansion of the sheath 22. Peel tabs 54 can be located approximately 90 degrees from any cut or notch present in the outer polymeric covering 50 and approximately 180 degrees offset from one another. In alternative aspects, the peel tabs 54 can extend substantially around the circumference of the outer polymeric covering 50, thus resulting in a single circular peel tab 54.

Suitable materials for the outer polymeric covering 50 are similar to those materials suitable for the inner polymeric tubular layer and the outer polymeric tubular layer as described above. In still further aspects, the materials can include PTFE and/or high density polyethylene.

Turning now to the intermediate tubular layer 28, several different configurations are possible. In some aspects, the intermediate tubular layer 28 can be a thin, hollow, substantially cylindrical tube comprising an arrangement, pattern, structure, or configuration of wires or struts, however other geometries can also be used. The intermediate tubular layer 28 can extend along substantially the entire length of the sheath 22, or alternatively, can extend only along a portion of the length of sheath 22. Suitable wires can be round, ranging from about 0.0005 inches thick to about 0.10 inches thick, including exemplary values of about 0.0006, about 0.0007, about 0.0008, about 0.0009, about 0.001, about 0.002, about 0.003, about 0.004, about 0.005, about 0.006, about 0.007, about 0.008, about 0.009, about 0.01, about 0.02, about 0.03, about 0.04, about 0.05, about 0.06, about 0.07, about 0.08, and about 0.09 inches, or flat, ranging from about 0.0005 inches×0.003 inches to about 0.003 inches×0.007 inches, including any exemplary values between the two foregoing values. However, other geometries and sizes are also suitable for certain aspects. If a braided wire is used, the braid density can be varied. Some aspects have a braid density of about thirty picks per inch to about eighty picks per inch and can include up to thirty-two wires in various braid patterns.

In one exemplary aspect, an intermediate tubular layer can comprise a braided Nitinol composite, which is at least partially encapsulated by an inner polymeric tubular member and an outer polymeric tubular member disposed on inner and outer surfaces of the intermediate tubular layer, respectively. Such encapsulation by polymeric layers can be accomplished by, for example, fusing the polymeric layers to the intermediate tubular layer or dip coating the intermediate tubular layer. In some aspects, an inner polymeric tubular member, an intermediate tubular layer, and an outer polymeric tubular layer can be arranged on a mandrel, and the layers can then be thermally fused or melted into one another by placing the assembly in an oven or otherwise heating it. The mandrel can then be removed from the resulting sheath. In yet other aspects, dip coating can be used to apply an inner polymeric tubular member to the surface of a mandrel. The intermediate tubular layer can then be applied, and the inner polymeric tubular member allowed to cure. The assembly can then be dip coated again, such as to apply a thin coating of, for example, polyurethane, which will become the outer polymeric tubular member of the sheath. The sheath can then be removed from the mandrel.

Additionally, in some aspects, the intermediate tubular layer 28 can be, for example, braided or laser cut to form a pattern or structure, such that the intermediate tubular layer 28 is amenable to radial expansion. FIGS. 9-23 illustrate exemplary partial elevation views of various structures for the intermediate tubular layer. Some illustrated structures, such as those shown in FIGS. 11-14 and 23 can include at least one discontinuity. For example, the struts 56, 58, 60, 62, 64, shown in FIGS. 11, 12, 13, 14, and 23, respectively, can result in a discontinuous intermediate tubular layer 28 in that the struts 56, 58, 60, 62, 64 separate adjacent sections of the intermediate tubular layer 28 from each other, where the sections are spaced apart from each other along a longitudinal axis parallel to the lumen of the sheath. Thus, the structure of the intermediate tubular layer 28 can vary from section to section, changing along the length of the sheath.

The structures shown in FIGS. 9-23 are not necessarily drawn to scale. Components and elements of the structures can be used alone or in combination within a single intermediate tubular layer 28. The scope of the intermediate tubular layer 28 is not meant to be limited to these particular structures; they are merely exemplary aspects.

Alternative aspects of a sheath for introducing a prosthetic device are also described. For example, FIGS. 24-26 illustrate a section view and a perspective view, respectively, of a sheath 66 for introducing a prosthetic device into a body. The sheath 66 can comprise an inner layer, such as inner polymeric layer 68, an outer layer, such as polymeric tubular layer 70, and a hemostasis valve (not shown). The inner polymeric layer 68 and the outer polymeric tubular layer 70 can at least partially enclose a lumen 72, through which a delivery apparatus and prosthetic device can pass from outside the patient's body into the patient's vessel. Either or both of the inner polymeric layer 68 and the outer polymeric layer 70 can be provided with at least one longitudinal notch and/or cut to facilitate radial expansion of the sheath.

For example, FIG. 24 illustrates a longitudinal notch 74 in the inner polymeric layer 68 that can facilitate radial expansion of the sheath 66. The longitudinal notch 74 can separate or split open completely upon application of a radial force due to insertion of a delivery apparatus or prosthetic device. Similarly, FIG. 25 illustrates a longitudinal cut 76 in the inner polymeric layer 68 that can also facilitate radial expansion of the sheath 66. The outer polymeric layer 70 can, additionally or alternatively, comprise one or more longitudinal cuts 76 or notches 74. Such cuts and/or notches, whether in the inner polymeric layer 68 or the outer polymeric layer 70, can extend substantially through the entire thickness of the layer, or can extend only partially through the thickness of the layer. The cuts and/or notches can be positioned at or near the inner or outer surface, or both surfaces, of the inner and/or outer polymeric layers 68, 70.

FIG. 26 illustrates a perspective view of an inner polymeric layer 68, in one aspect, with longitudinal notches 74 and a longitudinal cut 76. More or fewer notches 74 and/or cuts 76 can be provided. For clarity, the outer polymeric layer 70 is not shown in FIG. 26. As shown in FIG. 26, longitudinal notches 74 and/or cuts 76 can extend only along a portion of the length of sheath 66. In alternative aspects, one or more notches 74 and/or cuts 76 can extend substantially along the entire length of the sheath 66. Additionally, notches 74 and/or cuts 76 can be positioned randomly or patterned.

In one exemplary and unlimiting aspect, the sheath 66 can have a notch or cut in the outer polymeric layer 70 or the inner polymeric layer 68 that extends longitudinally along approximately 75% of the length of the sheath 66. If such a notch or cut extends only partially through the associated layer, it can have a relatively low tear force, such as a tear force of about 0.5 lbs., so that the notch splits open relatively easily during use.

The inner polymeric layer 68 and the outer polymeric layer 70 can optionally be adhered together or otherwise physically associated with one another. The amount of adhesion between the inner polymeric layer 68 and the outer polymeric layer 70 can be variable over the surfaces of the layers. For example, little to no adhesion can be present at areas around or near any notches and/or cuts present in the layers so as not to hinder the radial expansion of the sheath 66. Adhesion between the layers can be created by, for example, thermal bonding and/or coatings. In some aspects, the sheath 66 can be formed from an extruded tube, which can serve as the inner polymeric layer 68. The inner polymeric layer 68 can be surface-treated, such as by plasma etching, chemical etching, laser ablation, or other suitable methods of surface treatment. By treating the surface of the inner polymeric layer 68, the outer surface of the inner polymeric layer 68 can have areas with altered surface angles that can provide better adhesion between the inner polymeric layer 68 and the outer polymeric layer 70. The treated inner polymeric layer can be dip coated in, for example, a polyurethane solution to form the outer polymeric layer 70. In some configurations, the polyurethane may not adhere well to untreated surface areas of the inner polymeric layer 68. Thus, by surface treating only surface areas of the inner polymeric layer 68 that are spaced away from the areas of expansion (e.g., the portion of the inner polymeric layer 68 near notches 74 and/or cuts 76), the outer polymeric layer 70 can be adhered to some areas of the inner polymeric layer 68, while other areas of the inner polymeric layer 68 remain free to slide relative to the outer polymeric layer 70, thus allowing for expansion of the diameter of the sheath 66. Thus, areas around or near any notches 74 and/or cuts 76 can experience little to no adhesion between the layers, while other areas of the inner and outer polymeric layers 68, 70 can be adhesively secured or otherwise physically associated with each other.

In some aspects, the structures illustrated in FIGS. 24-26 can be applied to sheaths having a wide variety of inner and outer diameters. Applications can utilize a sheath of the present disclosure with an inner diameter of the inner polymeric layer 68 that is expandable to an expanded diameter of from about 3 Fr to about 26 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, about 25 Fr. The expanded diameter can vary slightly along the length of the sheath 66. For example, the expanded outer diameter at the proximal end of the sheath 66 can range from about 3 Fr to about 28 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, about 25 Fr, while the expanded outer diameter at the distal end of the sheath 66 can range from about 3 Fr to about 25 Fr, including exemplary values of about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, and about 22 Fr. In some aspects, the sheath 66 can expand to an expanded outer diameter that is from about 10% greater than the original unexpanded outer diameter to about 100% greater than the original unexpanded outer diameter, including exemplary values of about 15% greater, about 20% greater, about 25% greater, about 30% greater, about 35% greater, about 40% greater, about 45% greater, about 50% greater, about 55% greater, about 60% greater, about 65% greater, about 70% greater, about 75% greater, about 80% greater, about 85% greater, about 90% greater, and about 95% greater than the original unexpanded outer diameter.

In some aspects, the outer diameter of the sheath 66 gradually decreases from the proximal end of the sheath 66 to the distal end of the sheath 66. For example, in one aspect, the outer diameter can gradually decrease from about 26 Fr at the proximal end to about 18 Fr at the distal end. The diameter of the sheath 66 can transition gradually across substantially the entire length of the sheath 66. In other aspects, the transition or reduction of the diameter of the sheath 66 can occur only along a portion of the length of the sheath 66. For example, the transition can occur along a length from the proximal end to the distal end, where the length can range from about 0.5 inches to about the entire length of sheath 66, including any values between any two foregoing values.

Suitable materials for the inner polymeric layer 68 can have high elastic strength and include materials discussed in connection with other aspects, especially Teflon (PTFE), polyethylene (e.g., high density polyethylene), fluoropolymers, or combinations thereof. In some aspects, the inner polymeric layer 68 has a low coefficient of friction, such as a coefficient of friction of from about 0.01 to about 0.5, including exemplary values of about 0.02, about 0.03, about 0.04, about 0.05, about 0.06, about 0.07, about 0.08 about 0.09, about 0.1, about 0.2, about 0.3, and about 0.4. Some exemplary aspects of a sheath 66 comprise an inner polymeric layer 68 having a coefficient of friction of about 0.5 or less, about 0.4 or less, about 0.3 or less, about 0.2 or less, about 0.1 or less, of about 0.09 or less, about 0.08 or less, about 0.07 or less, about 0.05 or less, about 0.04 or less, about 0.03 or less, about 0.02 or less, or about 0.01 or less.

Likewise, suitable materials for the outer polymeric layer 70 can include any of the discussed above materials and other thermoplastic elastomers and/or highly elastic materials.

The Shore hardness of the outer polymeric layer 70 can be varied for different applications and aspects. Some aspects include an outer polymeric layer with a Shore hardness of from about 25A to about 80A, including exemplary values of about 30A, about 35A, about 40A, about 45A, about 50A, about 55A, about 60A, about 65A, about 70A, and about 75A, or from about 20D to about 40D, including exemplary values of about 22D, about 25D, about 28D, about 30D, about 32 D, about 35D, and about 38D. It is understood that the Shore hardness can be any value between any two foregoing values. In one aspect, the outer polymeric layer can comprise a readily available polyurethane with a Shore hardness of 72A. Yet, in other aspects, a polyethylene inner polymeric layer can be dipped in polyurethane or silicone to create the outer polymeric layer.

The sheath 66 can also include a radiopaque filler or marker, as described above. In some aspects, a distinct radiopaque marker or band can be applied to some portion of the sheath 66. For example, a radiopaque marker can be coupled to the inner polymeric layer 68, the outer polymeric layer 70, and/or can be positioned in between the inner and outer polymeric layers 68, 70.

FIGS. 27A-27E and 28 illustrate section views of various aspects of unexpanded (FIGS. 27A-27E) and expanded (FIG. 28) sheaths 66 according to the present disclosure. The sheath 66 can include a split outer polymeric tubular layer 70 having a longitudinal cut 76 through the thickness of the outer polymeric tubular layer 70 such that the outer polymeric tubular layer 70 comprises a first portion 78 and a second portion 80 separable from one another along the cut 76. An expandable inner polymeric layer 68 is associated with an inner surface 82 of the outer polymeric tubular layer 70, and, in the unexpanded configuration shown in FIG. 27A, a portion of the inner polymeric layer 68 extends through a gap created by the cut 76 and can be compressed between the first and second portions 78, 80 of the outer polymeric tubular layer 70. Upon expansion of the sheath 66, as shown in FIG. 28, first and second portions 78, 80 of the outer polymeric tubular layer 70 have separated from one another, and the inner polymeric layer 68 is expanded to a substantially cylindrical tube. In some aspects, two or more longitudinal cuts 76 can be provided through the thickness of the outer polymeric tubular layer 70. In such aspects, a portion of the inner polymeric layer 68 may extend through each of the longitudinal cuts 76 provided in the outer polymeric tubular layer 70.

In certain aspects, the inner polymeric layer 68 can comprise one or more materials that are elastic and amenable to folding and/or pleating. For example, FIG. 27A illustrates an inner polymeric layer 68 with folded regions 85. As seen in FIGS. 27A-27E, the sheath 66 can be provided with one or more folded regions 85. Such folded regions 85 can be provided along a radial direction and substantially conform to the circumference of the outer polymeric tubular layer 70. At least a portion of the folded regions 85 can be positioned adjacent to the outer surface 83 of the outer polymeric tubular layer 70.

Additionally, as shown in FIGS. 27B and 27E, at least a portion of the folded region or regions 85 can be overlapped by an outer covering, such as outer polymeric covering 81. The outer polymeric covering 81 can be adjacent at least a portion of the outer surface 83 of the outer polymeric tubular layer 70. The outer polymeric covering 81 serves to at least partially contain the folded regions 85 of the inner polymeric layer 68 and can also prevent the folded regions 85 from separating from the outer polymeric tubular layer 70 when, for example, the sheath 66 undergoes bending. In some aspects, the outer polymeric covering 81 can at least partially adhere to the outer surface 83 of the outer polymeric tubular layer 70. The outer polymeric covering 81 can also increase the stiffness and/or durability of the sheath 66.

Additionally, as shown in FIGS. 27B and 27E, the outer polymeric covering 81 may not entirely overlap the circumference of the sheath 66. For example, the outer polymeric covering 81 can be provided with first and second ends, where the ends do not contact one another. In these aspects, only a portion of the folded region 85 of the inner polymeric layer 68 is overlapped by the outer polymeric covering 81.

In some aspects, where a plurality of folded regions 85 is present, the regions can be equally displaced from each other around the circumference of the outer polymeric tubular layer 70. Alternatively, the folded regions can be off-center, different sizes, and/or randomly spaced apart from each other. In certain aspects, while portions of the inner polymeric layer 68 and the outer tubular layer 70 can be adhered or otherwise coupled to one another, the folded regions 85 are not adhered or coupled to the outer tubular layer 70. For example, adhesion between the inner polymeric layer 68 and the outer tubular layer 70 can be highest in areas of minimal expansion.

In one exemplary and unlimiting aspect, the sheath illustrated in FIGS. 27A-28 can comprise a polyethylene (e.g., high density polyethylene) outer polymeric tubular layer 70 and a PTFE inner polymeric layer 68. However, other materials are suitable for each layer, as described above. In certain aspects, suitable materials for use with the outer polymeric tubular layer 70 can include materials having a high stiffness or modulus of strength that can support expansion and contraction of the inner polymeric layer 68.

In some aspects, the outer polymeric tubular layer 70 comprises the same material or combination of materials along the entire length of the outer polymeric tubular layer 70. In alternative aspects, the material composition can change along the length of the outer polymeric tubular layer 70. For example, the outer polymeric tubular layer can be provided with one or more segments, where the composition changes from segment to segment. In one exemplary aspect, the Durometer rating of the composition changes along the length of the outer polymeric tubular layer 70 such that segments near the proximal end comprise a stiffer material or combination of materials, while segments near the distal end comprise a softer material or combination of materials. This can allow for a sheath 66 having a relatively stiff proximal end at the point of introducing a delivery apparatus while still having a relatively soft distal tip at the point of entry into the patient's vessel.

As with other disclosed aspects, in certain aspects, the sheath 66 shown in FIGS. 27A-28 can be provided in a wide range of sizes and dimensions. For example, the sheath 66 can be provided with an unexpanded inner diameter of from about 3 Fr to about 26 Fr., including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, about 25 Fr. In some aspects, the sheath 66 has an unexpanded inner diameter of from about 15 Fr to about 16 Fr. In some other aspects, the unexpanded inner diameter of the sheath 66 can range from about 3 Fr to about 26 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, about 25 Fr at or near the distal end of sheath 66, while the unexpanded inner diameter of the sheath 66 can range from about 3 Fr to about 28 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, and about 25 Fr at or near the proximal end of sheath 66. For example, in one aspect, the sheath 66 can transition from an unexpanded inner diameter of about 16 Fr at or near the distal end of the sheath 66 to an unexpanded inner diameter of about 26 Fr at or near the proximal end of the sheath 66.

The sheath 66 can be provided with an unexpanded outer diameter of from about 3 Fr to about 30 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, about 25 Fr, and about 28 Fr. Yet in other aspects, it can have an unexpanded outer diameter of from about 18 Fr to about 19 Fr. In some aspects, the unexpanded outer diameter of the sheath 66 can range from about 3 Fr to about 28 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, and about 25 Fr at or near the distal end of sheath 66, while the unexpanded outer diameter of the sheath 66 can range from about 3 Fr to about 30 Fr, including exemplary values of about 5 Fr, about 8 Fr, about 10 Fr, about 12 Fr, about 15 Fr, about 18 Fr, about 20 Fr, about 22 Fr, about 25 Fr, and about 28 Fr at or near the proximal end of sheath 66. For example, in one aspect, the sheath 66 can transition from an unexpanded outer diameter of about 18 Fr at or near the distal end of the sheath 66 to an unexpanded outer diameter of about 28 Fr at or near the proximal end of the sheath 66.

In some exemplary aspects, the thickness of the inner polymeric layer 68 can vary from about 0.002 inches to about 0.015 inches, including exemplary values of about 0.003, about 0.004, about 0.005, about 0.006, about 0.007, about 0.008, about 0.009, about 0.01, and about 0.012 inches. In other aspects, expansion of the sheath 66 can result in an expansion of the unexpanded outer diameter of from about 10% or less to about 430% or more. In certain aspects, expansion of the sheath 66 can result in expansion of the unexpanded outer diameter to about 10% or less, to about 9% or less, to about 8% or less, to about 7% or less, to about 6% or less, to about 5% or less, to about 4% or less, to about 3% or less, to about 2% or less, to about 1% or less. In yet other aspects, expansion of the sheath 66 can result in expansion of the unexpanded outer diameter to about 10% or more, about 20% or more, about 30% or more, about 40% or more, about 50% or more, about 60% or more, about 70% or more, about 80% or more, about 90% or more, about 100% or more, about 125% or more, about 150% or more, about 175% or more, about 200% or more, about 225% or more, about 250% or more, about 275% or more, about 300% or more, about 325% or more, about 350% or more, about 375% or more, about 400% or more, or about 425% or more, about 450% or more, about 475% or more, or about 500% or more. As with other illustrated and described aspects, the sheaths shown in FIGS. 27A-28 can be provided with a radiopaque filler and/or a radiopaque tip marker, as described above. The sheath 66 can be provided with a radiopaque tip marker provided at or near the distal tip of the sheath 66. Such a radiopaque tip marker can comprise materials such as those suitable for the radiopaque filler, platinum, iridium, platinum/iridium alloys, stainless steel, other biocompatible metals, or combinations thereof.

FIGS. 29A-29D show section views of other possible configurations of a sheath 66 for introducing a prosthetic device into a patient's vasculature. The sheath 66 comprises a polymeric tubular layer 84 having an inner surface 86 and an outer surface 88. The thickness of the polymeric tubular layer 84 extends from the inner surface 86 to the outer surface 88. As shown in FIGS. 29B-29D, the polymeric tubular layer 84 can be formed with at least a first angular portion 90 of reduced thickness adjacent the inner surface 86 and a second angular portion 92 of reduced thickness adjacent to the outer surface 88, with the second portion 92 at least partially overlapping the first portion 90. FIG. 29A illustrates a similar configuration, where a second portion 92 at least partially overlaps a first portion 90 in a partial coil configuration. In some aspects and as shown in FIG. 29A, the second portion 92, and the first portion 90 of the sheath can have the same thickness.

In some exemplary aspects, the first and second portions 90, 92 are not adhered to one another. In some aspects, and as seen in FIG. 29A, there can be a small gap 94 between the first and second portions 90, 92 that can give the sheath 66 the appearance of having two interior lumens 72, 94. FIGS. 29A-29D illustrate the sheath 66 in unexpanded configurations. In certain aspects, upon expansion of the sheath 66, the ends of the first and second portions 90, 92 abut or are in close proximity to each other to reduce or eliminate any gap between them.

In some aspects, a sheath 66 can comprise a partial slit or scoreline along at least a portion of its length. For example, as shown in FIG. 33, a sheath 66 can comprise an outer polymeric tubular layer 70 over an inner polymeric layer 68. The inner polymeric layer can extend through a cut in the outer polymeric tubular layer 70 to form a folded region 85 on the outer surface of the outer polymeric tubular layer 70, such as also shown in FIG. 27C. The folded region 85 of the inner layer, in some aspects, terminates before the outer polymeric tubular layer 70 (i.e., the outer polymeric tubular layer 70 is longer than the inner layer). As shown in FIG. 33, in these aspects, the sheath 66 can comprise a partial slit or scoreline 77 that can extend from the termination (distal end) 75 of the folded region 85 to the distal end 40 of the sheath 66. In some aspects, scoreline 77 can facilitate expansion of the sheath 66.

Scoreline 77 can be substantially centrally located with respect to the folded region 85. In alternative aspects, scoreline 77 can be positioned in other locations relative to the folded region 85. Also, sheath 66 can comprise one or more scorelines 77. For example, as shown in FIG. 34, one or more scorelines 77 can be peripherally located with respect to the folded region 85. The one or more scorelines 77 can be positioned anywhere around the circumference of the outer polymeric tubular layer 70. In aspects comprising a radiopaque marker 69 as seen in FIG. 33, a scoreline 77 can extend from, for example, the distal end of the radiopaque marker 69 substantially to the distal end 40 of the sheath 66.

FIGS. 35 and 36 illustrate an expandable sheath 100 according to the present disclosure, which can be used with a delivery apparatus for delivering a prosthetic device, such as a tissue heart valve into a patient. In general, the delivery apparatus can include a steerable guide catheter (also referred to as a flex catheter) a balloon catheter extending through the guide catheter, and a nose catheter extending through the balloon catheter (e.g., as depicted in FIG. 1). The guide catheter, the balloon catheter, and the nose catheter can be adapted to slide longitudinally relative to each other to facilitate delivery and positioning of the valve at an implantation site in a patient's body. However, it should be noted that the sheath 100 can be used with any type of elongated delivery apparatus used for implanting balloon-expandable prosthetic valves, self-expanding prosthetic valves, and other prosthetic devices. Generally, sheath 100 can be inserted into a vessel (e.g., the femoral or iliac arteries) by passing through the skin of a patient, such that a soft tip portion 102 at the distal end 104 of the sheath 100 is inserted into the vessel. The sheath 100 can also include a proximal flared end portion 114 to facilitate mating with an introducer housing 101 and catheters mentioned above (e.g., the proximal flared end portion 114 can provide a compression fit over the housing tip and/or the proximal flared end portion 114 can be secured to the housing 101 via a nut or other fastening device or by bonding the proximal end of the sheath to the housing). The introducer housing 101 can house one or more valves that form a seal around the outer surface of the delivery apparatus once inserted through the housing, as known in the art. The delivery apparatus can be inserted into and through the sheath 100, allowing the prosthetic device to be advanced through the patient's vasculature and implanted within the patient.

Sheath 100 can include a plurality of layers. For example, sheath 100 can include an inner layer 108 and an outer layer 110 disposed around the inner layer 108. The inner layer 108 can define a lumen through which a delivery apparatus can travel into a patient's vessel in order to deliver, remove, repair, and/or replace a prosthetic device, moving in a direction along the longitudinal axis X. As the prosthetic device passes through the sheath 100, the sheath locally expands from a first, resting diameter to a second, expanded diameter to accommodate the prosthetic device. After the prosthetic device passes through a particular location of the sheath 100, each successive expanded portion or segment of the sheath 100 at least partially returns to the smaller, resting diameter. In this manner, the sheath 100 can be considered self-expanding in that it does not require the use of a balloon, dilator, and/or obturator to expand.

The inner and outer layers 108, 110 can comprise any suitable materials. Suitable materials for the inner layer 108 include, but are not limited to, polytetrafluoroethylene (PTFE), ethylene tetrafluoroethylene (ETFE), nylon, polyethylene, polyether block amide (e.g., Pebax), and/or combinations thereof. In one exemplary aspect, the inner layer 108 can comprise a lubricious, low-friction, or hydrophilic material, such as PTFE. Such a low coefficient of friction materials can facilitate passage of the prosthetic device through the lumen defined by the inner layer 108. In some aspects, the inner layer 108 can have a coefficient of friction of less than about 0.5, of less than about 0.4, of less than about 0.3, of less than about 0.2, of less than about 0.1, or less than about 0.09, or less than about 0.08, or less than about 0.07. or less than about 0.05. In some aspects, the sheath 100 can include a lubricious liner on the inner surface of the inner layer 108. Examples of suitable lubricious liners can include materials that can further reduce the coefficient of friction of the inner layer 108, such as, for example, and without limitations, PTFE, polyethylene, polyvinylidene fluoride, and combinations thereof. Suitable materials for a lubricious liner also include other materials desirably having a coefficient of friction of about 0.5 or less, about 0.4 or less, about 0.3 or less, about 0.2 or less, about 0.1 or less, about 0.09 or less, about 0.08 or less, about 0.07 or less, about 0.06 or less, or about 0.05 or less.

Suitable materials for the outer layer 110 can include nylon, polyethylene, Pebax, HDPE, polyurethanes (e.g., Tecoflex), and other medical-grade materials. In one aspect, the outer layer 110 can comprise high density polyethylene (HDPE) and Tecoflex (or other polyurethane material) extruded as a composite. In some aspects, the Tecoflex can act as an adhesive between the inner layer 108 and the outer layer 110 and may only be present along a portion of the inner surface of the outer layer 110. Other suitable materials for the inner and outer layers are also disclosed in U.S. Patent Application Publication No. 2010/0094392, which is incorporated herein by reference.

Additionally, in some aspects, the sheath 100 can include an exterior hydrophilic coating on the outer surface of the outer layer 110. Such a hydrophilic coating can facilitate insertion of the sheath 100 into a patient's vessel. Examples of suitable hydrophilic coatings include the Harmony™ Advanced Lubricity Coatings and other Advanced Hydrophilic Coatings available from SurModics, Inc., Eden Prairie, Minn. DSM medical coatings (available from Koninklijke DSM N.V, Heerlen, the Netherlands), as well as other hydrophilic coatings (e.g., PTFE, polyethylene, polyvinylidene fluoride), are also suitable for use with the sheath 100.

Best seen in FIG. 36, the soft tip portion 102 can comprise, in some aspects, low density polyethylene (LDPE) and can be configured to minimize trauma or damage to the patient's vessels as the sheath is navigated through the vasculature. For example, in some aspects, the soft tip portion 102 can be slightly tapered to facilitate passage through the vessels. The soft tip portion 102 can be secured to the distal end 104 of the sheath 100, such as by thermally bonding the soft tip portion 102 to the inner and outer layers of the sheath 100. Such a soft tip portion 102 can be provided with a lower hardness than the other portions of the sheath 100. In some aspects, the soft tip 102 can have a Shore hardness from about 25 D to about 40 D, including exemplary values of about 28 D, about 30 D, about 32 D, about 35 D, and about 38 D. It is further understood that Shore hardness can have any value between any two foregoing values. The tip portion 102 can be configured to be radially expandable to allow a prosthetic device to pass through the distal opening of the sheath 100. For example, the tip portion 102 can be formed with a weakened portion, such as an axially extending scoreline or perforated line that is configured to split and allow the tip portion to expand radially when the prosthetic device passes through the tip portion (such as shown in the aspects of FIGS. 33 and 34).

FIG. 37 shows a cross-section view of the sheath 100 taken near the distal end 104 of the sheath 100, in one aspect. As shown in FIGS. 36 and 37A-B, the sheath 100 can include at least one radiopaque filler or marker, such as a discontinuous, or C-shaped, band 112 positioned near the distal end 104 of the sheath 100. The marker 112 can be associated with the inner and/or outer layers 108, 110 of the sheath 100. For example, as shown in FIG. 37A, the marker 112 can be positioned between the inner layer 108 and the outer layer 110. In alternative aspects, the marker 112 can be associated with the outer surface of the outer layer 110. In some aspects, the marker 112 can be embedded or blended within the inner or outer layers 108, 110. In a still further aspect, the sheath can comprise an outer jacket or an outer cover as described herein. Such exemplary aspects are shown in FIG. 37B, wherein the outer jacket 702 (in some aspects, the outer jacket is an elastic cover) is present. It is understood that the outer jacket can be present along all the length of the sheath, including the distal and proximal end of the sheath (FIG. 37B and FIG. 38B). In yet other aspects, the outer jacket can only be present along a portion of the sheath. It is further understood that the portion of the sheath can comprise any location along the sheath's length.

In certain aspects, wherein the outer jacket is present, it can comprise an inner surface and outer surface. In such aspects, the outer jacket extends at least partially around the outer layer such that the inner surface of the outer jacket overlies the outer surface of the outer layer. In yet further aspects, the outer jacket overlies the outer surface of the outer layer along a circumference of the outer layer along its longitudinal axis.

The C-shaped band 112 can serve as a radiopaque marker or filler to enable visibility of the sheath 100 under fluoroscopy during use within a patient. The C-shaped band 112 can comprise any suitable radiopaque material, such as barium sulfite, bismuth trioxide, titanium dioxide, bismuth subcarbonate, platinum, iridium, and combinations thereof. In one exemplary and unlimiting aspect, the C-shaped band can comprise 90% platinum and 10% iridium. In other aspects, the marker 112 needs not to be a C-shaped band. Other shapes, designs, and configurations are possible. For example, in some aspects, the marker 112 can extend around the entire circumference of the sheath 100. In other aspects, the marker 112 can comprise a plurality of small markers spaced around the sheath 100.

In certain aspects, disclosed herein is a sheath for delivering a medical device, wherein the sheath has a proximal and a distal end and comprises: an expandable inner layer having an inner surface and an outer surface, wherein the inner surface of the expandable inner layer defines a lumen having a longitudinal axis and comprising at least one folded portion having an inner portion and outer portion; an outer layer having an inner surface and an outer surface and extending at least partially around the inner layer such that at least a first portion of the outer surface of the outer layer is positioned adjacent to the inner portion of the at least one folded portion of the inner layer, while a first portion of the inner surface of the outer layer is positioned adjacent to the outer portion of the at least one folded portion of the inner layer; a first polymer disposed between at least a portion of the inner layer and at least a portion of the outer layer, forming an intermediate layer, wherein, the first polymer exhibits a melting temperature from about 30° C. to about 45° C.; and wherein the at least one folded portion is configured to at least partially unfold during application of a radial outward force by passage of a medical device through the lumen of the inner layer. In still further aspects, the first polymer can be disposed between at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer, forming an intermediate layer between the inner portion of the at least one folded portion and the at least first portion of the outer surface of the inner layer. In still further aspects, the first polymer can be disposed between at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer.

In some aspects, the first polymer can be disposed between at least the first portion of the inner surface of the outer layer and the outer portion of the at least one folded portion of the inner layer. In still further aspects, the sheath can further comprise an outer jacket comprising an inner surface and outer surface extending at least partially around the outer layer such that the inner surface of the outer jacket overlies the outer surface of the outer layer. In a certain aspect, the first polymer is disposed between at least a portion of the inner surface of the outer jacket and at least a portion of the outer surface of the outer layer.

In still further aspects, the first polymer can be disposed between the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer along a longitudinal axis of the folded portion. In still other aspects, the first polymer can be disposed along a circumference of the outer surface of the outer layer along its longitudinal axis. FIGS. 38A-B and 39A-B show additional cross sections taken at different points along the sheath 100. FIG. 38A shows a cross-section of a segment of the sheath near the proximal end 106 of the sheath 100, as indicated by a line 38-38 in FIG. 35 without the presence of the outer jacket 702, when FIG. 38B shows a cross-section of a segment of the sheath near the proximal end 106 of the sheath 100, as indicated by line 38-38 in FIG. 35 when the outer jacket 702 is present. In certain aspects where the outer jacket is present, the outer surface of the outer layer of the disclosed sheath can comprise a second portion configured to seal with at least a first portion of the inner surface of the outer jacket at at least a portion of the distal end of the sheath.

In yet other aspects where the outer jacket is present, the outer surface of the outer layer of the disclosed sheath comprises a third portion configured to seal with at least a second portion of the inner surface of the outer jacket at at least a portion of the proximal end of the sheath.

The sheath 100 at the location shown in FIGS. 38A-B can include inner layer 108 and outer layer 110. At this location, near the proximal end of the sheath, the layers 108, 110 can be substantially tubular, without any slits or folded portions in the layers. By contrast, the layers 108, 110 at different locations along the sheath 100 (e.g., at the point indicated by line 39-39 in FIG. 35) can have a different configuration.

FIG. 39A shows a cross section of the sheath without the presence of the first polymer. As shown in FIG. 39A, the inner layer 108 can be arranged to form a substantially cylindrical lumen 116 therethrough. Inner layer 108 can include one or more folded portions 118. In the aspect shown in FIG. 39A, inner layer 108 is arranged to have one folded portion 118 that can be positioned on either side of the inner layer 108. Inner layer 108 can be continuous in that there are no breaks, slits, or perforations in inner layer 108. Outer layer 110 can be arranged in an overlapping fashion such that an overlapping portion 120 overlaps at least a part of the folded portion 118 of the inner layer 108. As shown in FIG. 39A, the overlapping portion 120 also overlaps an underlying portion 122 of the outer layer 110. The underlying portion 122 can be positioned to underlie both the overlapping portion 120 of the outer layer 110, as well as the folded portion 118 of the inner layer 108. Thus, the outer layer 110 can be discontinuous, including a slit or a cut in order to form the overlapping and underlying portions 120, 122. In other words, a first edge 124 of the outer layer 110 is spaced apart from a second edge 126 of the outer layer 110 so as not to form a continuous layer.

In some aspects, the sheath can further comprise a tie layer disposed between at least a second portion of the inner surface of the outer layer and at least a portion of the outer surface of the inner layer, such that it is configured to seal the at least a second portion of the inner surface of the outer layer with the at least a portion of the outer surface of the inner layer. In yet other aspects, the tie layer is disposed between the inner surface of the outer layer and the outer surface of the inner layer along a circumference of the inner layer along its longitudinal axis.

As shown in FIG. 39A, the sheath 100 can optionally include a thin layer of bonding or adhesive material (a tie layer) 128 positioned between the inner and outer layers 108, 110. In one aspect, the adhesive material 128 can comprise a polyurethane material such as Tecoflex, or polymer, copolymer, or terpolymer such as maleic anhydride modified polyolefin, for example, and without limitation, Orevac® (commercially available from Arkema), ethylene acrylic acid copolymer, such as DOW Chemical Primacor®, ethylene acrylate copolymer such as Lotryl® (commercially available from Arkema), ethylene glycidyl methacrylate copolymer, ethylene acrylic esters glycidyl methacrylate terpolymer such as Lotader® (commercially available from Arkema), ethylene acrylic esters maleic anhydride terpolymer such as Lotader® or Orevac® (commercially available from Arkema). In certain aspects, the adhesive material (tie layer) 128 can be positioned on an inner surface 130 (at least a second portion of the inner surface) of at least a portion of the outer layer 110 so as to provide adhesion between selected portions of the inner and outer layers 108, 110. In such exemplary aspects, the tie layer can be configured to seal the at least a second portion of the inner surface of the outer layer with at least a portion of the inner layer. For example, the outer layer 110 can only include a tie layer 128 around the portion of the inner surface 130 that faces the lumen-forming portion of the inner layer 108. In other words, in some aspects, the tie layer 128 can be positioned so that it does not contact the folded portion 118 of the inner layer 108. In other aspects, the tie layer 128 can be positioned in different configurations as desired for that particular application. For example, as shown in FIG. 39A, the tie layer 128 can be positioned along the entire inner surface 130 of the outer layer 110. In an alternative aspect, the tie layer can be applied to the outer surface of the inner liner 108 instead of the inner surface of the outer layer. The tie layer can be applied to all or selected portions of the inner layer; for example, the tie layer can be formed only on the portion of the inner layer that faces the lumen-forming portion of the outer layer and not on the folded portion. The configuration of FIG. 39A allows for radial expansion of the sheath 100 as an outwardly directed radial force is applied from within (e.g., by passing a medical device such as a prosthetic heart valve through the lumen 116). As radial force is applied, the folded portion 118 can at least partially separate, straighten, and/or unfold, and/or the overlapping portion 120 and the underlying portion 122 of the outer layer 110 can slide circumferentially with respect to one another, thereby allowing the diameter of lumen 116 to enlarge.

FIG. 39B shows a cross-section of the sheath comprising a first polymer disposed between the at least the first portion of the outer surface of the outer layer 110 and the inner portion of the at least one folded portion of the inner layer 118, forming an intermediate layer 129 between the inner portion of the at least one folded portion and the at least first portion of the outer surface of the outer layer.

It is, however, understood that the location of the first polymer is not limited by the exemplary sheath shown in FIG. 39B. Additionally, exemplary locations for the first polymer are shown in FIG. 39C-G. For example, FIG. 39C shows the exemplary sheath comprising the first polymer 129 disposed between the outer layer 110 and the folded portion 118 of the inner layer 108. In some exemplary aspects, the first polymer 129 can be disposed between an outer portion of the folded portion 118 and at least a portion of the inner surface 130 of the outer layer 110 that overlaps the folded portion.

In yet other aspects, and as shown in FIG. 39D, the exemplary sheath can comprise the first polymer 129 disposed circumferentially between the inner layer 108 and outer layer 110. For example, as provided in FIG. 39D, the first polymer 129 can be disposed between the outer layer 110 and the folded portion 118 of the inner layer 108 and continue circumferentially between the outer layer 110 and the inner layer 108 (up to the second longitudinally extending edge 124). In some aspects, as shown in FIG. 39E, when the outer jacket 702 is present in the sheath 100, the first polymer 129 can be disposed between the outer surface of the outer layer 110 and the inner surface of the outer jacket 702. For example, the first polymer 129 can extend around all, or a portion, of the circumference of the outer surface of the outer layer 110. FIG. 39F shows aspects where the outer jacket 702 is present, and the first polymer 129 can be disposed between the inner surface of the outer jacket 702 and the outer surface of the outer layer 110, and between the outer layer 110 and the inner layer 108 (i.e., between the outer layer 110 and the folded portion 118 of the inner layer 108, and continue circumferentially between the outer layer 110 and the inner layer 108). As illustrated in FIG. 39F, the first polymer 129 can be disposed between the inner surface of the outer layer 110 and the outer surface of the inner layer 108 around the entire circumference of the sheath. FIG. 39G shows an exemplary configuration that is similar to one disclosed in FIG. 39F with the additional first polymer 129 disposed between at least the first portion of the outer surface of the outer layer 110 and the inner portion/underside of the folded portion 118 of the inner layer 108, forming an intermediate layer 129 between the inner portion of the at least one folded portion 118 and the at least first portion of the outer surface of the outer layer 110.

In another aspect, the folded portion of the disclosed sheath and as shown in FIG. 39B can comprise a first folded edge 131 and a second folded edge 133 and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge 131 is configured to move closer to the second folded edge 133 to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen, and wherein the first polymer is provided between the at least the first portion of the outer surface of the outer layer 110 and an inner surface of the overlapping portion of the folded portion.

Still further, the folded portion can comprise a first folded edge 131 and a second folded edge 133 and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen, the overlapping portion, wherein the outer layer includes a first longitudinally extending edge 126 and a second longitudinally extending edge 124 configured to separate as the sheath expands, the first longitudinal extending edge and an overlapping portion of the outer layer extending over the second longitudinal extending edge when the sheath is not expanded, and wherein the first polymer is provided between the at least the first portion of the outer surface of the outer layer proximate the second longitudinally extending edge and the inner surface of the overlapping portion of the folded portion.

In still further aspects, the sheath as shown in FIGS. 39B-39G can also comprise a tie layer 128. It is understood that the tie layer can be optional, and the aspects where the sheath does not comprise the tie layer are also disclosed. The tie layer can comprise any material disclosed above, for example, and without limitation, it can comprise a polyurethane material such as Tecoflex, or polymer, copolymer, or terpolymer such as maleic anhydride modified polyolefin, for example, and without limitation, Orevac® (commercially available from Arkema), ethylene acrylic acid copolymer, such as DOW Chemical Primacor®, ethylene acrylate copolymer such as Lotryl® (commercially available from Arkema), ethylene glycidyl methacrylate copolymer, ethylene acrylic esters glycidyl methacrylate terpolymer such as Lotader® (commercially available from Arkema), ethylene acrylic esters maleic anhydride terpolymer such as Lotader® or Orevac® (commercially available from Arkema).

In still further aspects, the inner layer can comprise any known in the art and/or disclosed herein, polymers. In still further aspects, the inner layer can comprise polytetrafluoroethylene (PTFE), polyimide, polyetheretherketone (PEEK), polyurethane, nylon, polyethylene, high density polyethylene (HDPE), polyamide, or combinations thereof.

In still further aspects, the expandable inner layer can have a dynamic coefficient of friction of less than about 0.5 against steel as measured according to ASTM D1894, including exemplary values of less than about 0.4, less than about 0.3, less than about 0.2, less than about 0.1, less than about 0.09, less than about 0.08, less than about 0.07, less than about 0.06, less than about 0.05, less than about 0.04, less than about 0.03, less than about 0.02, or less than about 0.01 as measured according to ASTM D1894.

In some of the aspects disclosed herein, the outer layer can comprise PTFE, polyimide, PEEK, polyurethane, nylon, polyethylene, polyamide, polyether block amides, polyether block ester copolymer, thermoset silicone, latex, poly-isoprene rubbers, high density polyethylene (HDPE), Tecoflex, or combinations thereof. In still further aspects, the outer surface of the expandable inner layer can be etched. It is understood that the etched surface can be obtained by any known in the art methods to arrive at the desired results. In certain aspects, the etching can be a solution-based etch or a plasma etch and/or laser ablation.

In one exemplary aspect, the inner layer can comprise PTFE, and the outer layer can comprise a combination of HDPE and Tecoflex. In still other aspects, the inventive sheath can optionally comprise an elastic outer cover. If present, the elastic cover can include any suitable materials, such as any suitable heat shrink materials. Examples include Pebax, polyurethane, silicone, and/or polyisoprene.

In still further aspects, the inner surface of the outer layer comprises a third portion configured to seal with the outer surface of the inner layer at at least a portion of the distal end of the sheath. In yet other aspects, the inner surface of the outer layer can comprise a fourth portion configured to seal with the outer surface of the inner layer at at least a portion of the proximal end of the sheath. In still further aspects, and as described above, when the outer jacket is present, the outer surface of the outer layer can comprise a second portion configured to seal with at least a first portion of the inner surface of the outer jacket at at least a portion of the distal end of the sheath. In still further aspects and when the outer jacket is present, the outer surface of the outer layer can comprise a third portion configured to seal with at least a second portion of the inner surface of the outer jacket at at least a portion of the proximal end of the sheath.

In still further aspects, the first polymer can have a melting temperature between about 30° C. to about 45° C., including exemplary values of about 31° C., about 32° C., about 33° C., about 34° C., about 35° C., about 36° C., about 37° C., about 38° C., about 39° C., about 40° C., about 41° C., about 42° C., about 43° C., and about 44° C. In still further aspects, the first polymer is solid at a temperature below 30° C. It is understood that in such aspects, when the sheath is present in the environment at a temperature of below 30° C., the first portion of the outer surface of the outer layer of the sheath is adhered to the at least one folded portion of the inner layer. In still further aspects, the first polymer is disposed along a circumference of the inner layer along its longitudinal axis.

In still further aspects where the sheath is present in the environment at a temperature from about 30° C. to about 45° C., i.e., within the melting temperature of the first polymer, the intermediate layer can become viscoelastic fluid and can behave as a lubricant between the folded portion and the outer layer. In such aspects, when the sheath is inserted into a body having a temperature of 37° C., the viscoelastic intermediate layer can behave as a lubricant allowing a smooth expansion of the sheath. In further aspects, the sheath can exhibit at least about a 5% reduction in insertion force when inserted into a body having a temperature of 37° C. when compared to a substantially identical reference sheath without the presence of the first polymer. Here is it understood that the insertion force relates to the force needed to insert any delivery apparatus described herein within the body. In still further exemplary aspects, the disclosed sheath having the first polymer disposed as described can exhibit at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50% reduction in insertion force.

In still further aspects, the sheath can require an insertion force that is at least similar to insertion force when other adhesives, such as, for example, NuSil®, are present. Yet, in other aspects, the sheath requires a reduced insertion force when compared to the sheath having an adhesive, such as, for example, NuSil®. In further aspects, the sheath can exhibit at least about a 5% reduction in insertion force when inserted into a body having a temperature of 37° C. when compared to a substantially identical reference sheath having NuSil® as an adhesive. In still further exemplary aspects, the disclosed sheath having the first polymer disposed as described can exhibit at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50% reduction in insertion force in the comparable sheath with the presence of different adhesive materials. It is also understood that when compared with the other commonly used adhesives, the presence of the disclosed herein polymers is preferable as they can melt in the body and do not require any additional preparations. Other adhesives, such as for example, NuSil®, on the other hand, require extensive processing steps, for example, curing for at least 30 min at 90° C. that is both inconvenient and costly.

In still further aspects, when the outer jacket is present, the disclosed sheath can comprise a second polymer and/or a third polymer. In such aspects, the second polymer can exhibit a melting temperature above about 45° C. and can be disposed between the second portion of the outer surface of the outer layer at at least a portion of the distal end of the sheath and the at least a first portion of the inner surface of the outer jacket. It is understood that the difference in the melting point allows the second polymer to stay solid while the first polymer becomes a viscoelastic fluid when the sheath is inserted into a body at a temperature of 37° C. In aspects where the second polymer is solid, it allows the second portion of the outer surface of the outer layer at at least a portion of the distal end of the sheath and the at least a first portion of the inner surface of the outer jacket and prevents the first polymer from being leached out of the sheath into the surrounding environment.

In yet further aspects, the third polymer, when present in the disclosed sheath, can exhibit a melting temperature above about 45° C. and it can be disposed between the third portion of the outer surface of the outer layer at at least a portion of the proximal end of the sheath and the at least a second portion of the inner surface of the outer jacket. It is understood that, again, the difference in the melting points allows the third polymer to stay solid while the first polymer becomes a viscoelastic fluid when the sheath is inserted into a body at a temperature of 37° C. In aspects where the third polymer is solid, a third polymer exhibiting a melting temperature above about 45° C. that is disposed between the third portion of the outer surface of the outer layer at at least a portion of the proximal end of the sheath and the at least a second portion of the inner surface of the outer jacket and prevent the first polymer from being leached out of the sheath into the surrounding environment.

In still further aspects, the first polymer, second polymer, and/or third polymer, while having a different melting point, can comprise the same polymer composition. It is understood that the first, second, and /or third polymer can comprise any polymer suitable for the disclosed operation conditions. In certain non-limiting aspects, the first polymer, second polymer, and/or third polymer can comprise polyethylene glycol (PEG). In exemplary aspects where the first polymer comprises PEG, the first polymer has a molecular weight from about 500 to about 1,500 g/mol, including exemplary values of about 600, about 700, about 800, about 900, about 1,000, about 1,100, about 1,200, about 1,300, and about 1,400 g/mol. In yet other aspects the second and/or the third polymers when comprise PEG, can have a molecular weight from about 1,500 to about 3,500 g/mol, including exemplary values of about 1,600, about 1,700, about 1,800, about 1,900, about 2,000, about 2,100, about 2,200, about 2,300, about 2,400, about 2,500, about 2,600, about 2,700, about 2,800, about 2,900, about 3,000, about 3,100, about 3,200, about 3,300, about 3,400 g/mol. In yet other aspects, the second and/or third polymer can have a composition different from the first polymer. In still further aspects, the second and/or third polymer can comprise polyethylene oxide. It is understood that in such aspects, the second and the third polymer, while required to stay solid at temperatures above 45° C., need not to be rigid and affect the flexibility of the disclosed sheath. It is further understood that the first polymer can have any thickness that can provide for the desired result. In yet other aspects, if present, the second and the third polymers can have any thickness that can ensure sealing between the outer layer and the outer jacket.

In still further aspects, the inner layer can comprise two or more folded portions. In such aspects, the first polymer can be disposed, as described above, between each of the folded portions and the outer layer.

In yet further aspects, the sheath 100, whether with or without the first polymer, is configured to expand from a resting configuration (FIGS. 39A-B and 39E) to an expanded configuration shown in FIG. 40A-C. In the expanded configuration with (FIG. 40B) or without the presence (FIG. 40A) of the first polymer 129, an annular gap 132 can form between the longitudinal edges of the overlapping portion 120 and the underlying portion 122 of the outer layer 110. As the sheath 100 expands ata particular location, the overlapping portion 120 of the outer layer 110 can move circumferentially with respect to the underlying portion 122 as the folded portion 118 of the inner layer 108 unfolds. This movement can be facilitated by the use of a low-friction material for inner layer 108, such as PTFE. This movement can be further facilitated by the presence of the first polymer that forms an intermediate layer that is a viscoelastic fluid at a temperature between (30° C. and 45° C.). This viscoelastic fluid behaves as a lubricant and decreases the friction between the inner layer and the outer layer. In yet other aspects, where the first polymer is present within the folding portion, the presence of the viscoelastic fluid can decrease the friction between the folded parts during the expansion. In further aspects, the improved lubrication results in the reduction of the insertion force when the medical device is inserted into the sheath. In such aspects (not shown in FIG. 40), when the sheath is inserted into the body and is in an expanded configuration, the first polymer is present as a viscoelastic lubricating fluid. The presence of the first polymer, as disclosed above, can reduce the insertion force by at least 5%. Further, the folded portion 118 can at least be partially separated and/or unfold to accommodate a medical device having a diameter larger than that of lumen 116 in the resting configuration. As shown in FIG. 40, in some aspects, the folded portion of the inner layer 108 can completely unfold so that the inner layer 108 forms a cylindrical tube at the location of the expanded configuration. It is further understood that the presence of the first polymer on the outer layer in the expanded configuration can further assist in lubricating the sheath as it moves throughout the vessels of interest.

The sheath 100 can be configured such that it locally expands at a particular location corresponding to the location of the medical device along the length of the lumen 116, and then locally contracts once the medical device has passed that particular location. Thus, a bulge may be visible, traveling longitudinally along the length of the sheath as a medical device is introduced through the sheath, representing continuous local expansion and contraction as the device travels the length of the sheath 100. In some aspects, each segment of the sheath 100 can locally contract after removal of any radial outward (insertion) force such that it regains the original resting diameter of lumen 116. In such aspects, the folded portion and the first polymer return to their original position. In yet further aspects, the first polymer solidifies when the sheath is withdrawn from the body and is at a temperature below 30° C.

In some aspects, each segment of the sheath 100 can locally contract after removal of any radial outward force such that it at least partially returns to the original resting diameter of lumen 116.

The layers 108, 110 of sheath 100 can be configured, as shown in FIG. 39A-G along at least a portion of the length of the sheath 100. In some aspects, the layers 108, 110 can be configured as shown in FIG. 39A-G along the length A (FIG. 35) extending from a location adjacent to the soft tip portion 102 to a location closer to the proximal end 106 of the sheath 100. In this matter, the sheath is expandable and contractable only along a portion of the length of the sheath corresponding to length A (which typically corresponds to the section of the sheath inserted into the narrowest section of the patient's vasculature).

Methods

Methods of making a sheath are also disclosed. Some of the methods disclosed herein comprise providing a mandrel having a first diameter, providing a first tube having a second diameter, the second diameter being larger than the first diameter, mounting the first tube on the mandrel, gathering excess material of the first tube and folding the excess material to one side to form a folded portion of the inner layer. A second tube can then be provided, and the second tube can be cut to form a coiled layer. An adhesive can be applied to at least a portion of the coiled layer, and the coiled layer can be mounted on the first tube such that the adhesive is positioned between the first tube and the coiled layer. The folded portion can be lifted in order to position a portion of the coiled layer under the folded portion.

In yet other aspects, the methods can include applying heat to the first tube, coiled layer, and mandrel so as to thermally fuse the first tube and the coiled layer together. In some aspects, an elastic outer cover can be secured to the outer surface of the coiled layer. In yet other aspects, a soft tip portion can be coupled to a distal end of the expandable sheath to facilitate passing the expandable sheath through a patient's vasculature.

Various methods can be used to produce the sheaths discussed above and below throughout the present disclosure. For example, and without limitation, a method of making the sheath shown in FIGS. 2A-2D can comprise providing a mandrel and applying an inner layer on the mandrel, such as by spray coating or dip coating the mandrel. An intermediate layer, such as a mesh structure, can then be mounted on the inner layer. An outer layer can be applied over the intermediate layer, such as by a second spray coating or dip coating step. Methods can comprise etching or surface treating at least a portion of the inner layer. Also, methods can comprise providing one or more notches and/or cuts in the inner layer and/or the outer layer. Cuts and/or notches can be provided by, for example, laser cutting or etching one or more layers.

In some aspects, in the methods of making the sheaths, such as illustrated in FIGS. 2A-2D, the layers can be pre-formed and mounted on a mandrel and then fused or thermally bonded together. For example, in one aspect, an inner layer is applied to a mandrel. An intermediate layer can be applied to the outer surface of the inner layer. An outer layer can be applied to the outer surface of the intermediate layer. Heat shrink tubing can be applied and the assembly heated, such that the inner layer, the intermediate layer, and/or the outer layer are thermally bonded and compressed together under the heat shrink tubing.

FIG. 30 illustrates a block diagram of the method of producing a sheath, in one aspect, for use with a delivery apparatus in minimally invasive surgery. One or more mandrels can be provided (step 300). The mandrel can be provided with an exterior coating, such as a Teflon® coating, and the mandrel's diameter can be predetermined based on the desired size of the resulting sheath. A liner that will become the inner polymeric layer of the sheath can be made of any material described herein, for example, and without limitation, it can comprise a PTFE or high density polyethylene (HDPE), can be mounted on the mandrel (step 302). The liner can be etched and/or surface treated prior to being mounted on the mandrel, according to conventional etching and surface treatment methods, as described above. FIG. 32A illustrates a section view of a sheath at steps 300 and 302 of FIG. 30. A coated mandrel 96 is inserted within the lumen 72 of the inner polymeric layer 68. The circumference of the inner polymeric layer 68 is larger than the circumference of the mandrel 96, such that an excess portion of the inner polymeric layer 68 can be gathered above the mandrel 96.

A layer of material that will become the outer polymeric tubular layer can be cut or notched through all, substantially all, or a part of the thickness of the layer (step 304). It is understood that the outer layer can comprise any materials described herein without any limitations. In some unlimiting aspects, the outer layer can comprise polyurethane or polyolefin. Such a cut or notch can extend longitudinally along the length of the layer and can extend along substantially the entire length of the outer polymeric tubular layer. In alternative aspects, the cut or notch can be provided along only a portion of the outer polymeric tubular layer. For example, the outer polymeric tubular layer can be cut starting at the distal end of the outer polymeric tubular layer, with the cut ending before the proximal end of the outer polymeric tubular layer. In one aspect, the cut can end at a transition, where the outer diameter of the outer polymeric tubular layer increases or decreases. In one exemplary aspect, the cut or notch can extend longitudinally along about 50%, 55%, 60%, 70%, or 75% of the length of the sheath.

The cut or notched outer polymeric tubular layer can be applied, positioned, adhered, mounted, thermally fused or bonded, dip coated, and/or otherwise coupled to the etched inner liner (step 306). FIG. 32B shows a section view of the sheath at step 306 of FIG. 30, with outer polymeric tubular layer 70 applied to the inner polymeric layer 68 such that a portion of the inner polymeric layer 68 extends between the cut formed between first and second portions 78, 80 of the outer polymeric tubular layer 70.

In alternative aspects, the outer polymeric tubular layer can be notched or cut after being mounted on the inner liner/mandrel assembly. The outer polymeric tubular layer can optionally be provided with a hydrophilic coating and/or provided with additional layers, such as being dip coated with polyurethane. Some portion of the inner liner can protrude through the cut in the outer polymeric tubular layer after such an outer polymeric tubular layer is mounted onto the inner liner/mandrel arrangement. Using, for example, a split tool, the protruding portion of the inner liner can be folded down onto the outer surface of the outer polymeric tubular layer (step 308). In some aspects, the protruding portion of the inner liner is folded down along the entire length of the resulting sheath, while in other aspects, the protruding portion of the inner liner is only present along a portion of the length of the sheath or is only folded down along a portion of the length of the resulting sheath. FIG. 32C shows an exemplary section view of the sheath at step 308 of FIG. 30. A split tool 98 is used to fold the excess portion of inner polymeric layer 68 over a portion of the outer surface 83 of the outer polymeric tubular layer 70. FIG. 32D shows a section view of the sheath after completion of step 308 of FIG. 30. Split tool 98 can then be removed, and folding of the excess portion of the inner polymeric layer 68 can be completed. FIG. 32E shows a section view of an outer covering, such as outer polymeric covering 99, that can be applied such that it overlaps a portion of the folded portion of inner polymeric layer 68. The outer polymeric covering 99 contacts at least a portion of the outer surface 83 of the outer polymeric tubular layer 70. A soft, atraumatic tip can be provided at the distal end of the resulting sheath (step 310). The first polymer is applied between at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer such that it forms an intermediate layer between the inner portion of the at least one folded portion and the at least first portion of the outer surface of the outer layer. In some aspects, the first polymer can be applied in step 309 before mounting the soft tip in step 310. In yet other exemplary aspects, the first polymer can be applied in step 311, after the mounting the soft tip in step 310. In the exemplary aspects shown in FIG. 32C′, the first polymer 79 can be applied between the outer surface of the outer layers 78 and/or 80 and the folded portion overlaying these layers. In such aspects, the first polymer can be applied by any known in the art methods. In some aspects, prior to the step of applying, the first polymer can be provided as a solid or as a viscoelastic fluid. In certain aspects, to ensure proper adhesion between the folded portion and the outer surface of the outer layer, the first polymer, if provided as a solid, is melted to form the viscoelastic fluid prior to the step of applying the first polymer. In still further aspects, the first polymer can be transformed into the viscoelastic fluid by any known in the art methods, for example, and without limitation by heating the polymer in an oven or any other known in the art heater (IR, UV, etc.,) above its melting point. In still further aspects, the first polymer is applied as viscoelastic fluid at a temperature above about 30° C., above about 35° C., above about 40° C., or above about 45° C. It is further understood that the temperature the polymer is exposed to can be chosen based on the specific polymer. In yet further aspects and as it could be readily understood by one of ordinary skill in the art, the upper temperature the polymer is exposed to needs to be controlled to avoid adverse effects on the polymer structure and characteristics as well as adverse effects on the sheath components when it inadvertently exposed to undesired high temperatures.

In still further aspects, the first polymer can be applied as the viscoelastic fluid by any methods known in the art. In certain aspects and without limitation, the first polymer can be applied with a brush. In yet other aspects, it can be applied as a fluid and spread over the desired area with any tool known in the art. Again, the disclosed methods for applying the viscoelastic fluids are only exemplary and non-limiting, and any methods of applying the viscoelastic fluid to any surface can be utilized.

In still further aspects, after the step of applying, the sheath is cooled to a temperature below 30° C. to ensure that the first polymer 79 is solidified and can adhere the folded portion to the outer surface of the outer layer 78 or 80 (as shown in the exemplary aspect of FIG. 32D′).

Additional layers can also be applied if desired. For example, the sheath can also comprise a tie layer, as described above. In such aspects, the tie layer is disposed between at least a second portion of the inner surface of the outer layer and at least a portion of the outer surface of the inner layer, such that it is configured to seal the at least a second portion of the inner surface of the outer layer with the at least a portion of the outer surface of the inner layer. Any described above tie layers can be utilized.

In yet other aspects, the methods described herein comprise positioning an outer jacket comprising an inner surface and outer surface such that it extends at least partially around the outer layer and such that the inner surface of the outer jacket overlies the outer surface of the outer layer.

In still further aspects, the methods described herein comprise the sheath where the inner surface of the outer layer comprises a third portion configured to seal with the outer surface of the inner layer at at least a portion of the distal end of the sheath. In yet other aspects, the methods described herein comprise the sheath where the inner surface of the outer layer comprises a fourth portion configured to seal with the outer surface of the inner layer at at least a portion of the proximal end of the sheath.

In still further aspects, the methods described herein can comprise the sheath where the outer surface of the outer layer comprises a second portion configured to seal with at least a first portion of the inner surface of the outer jacket at at least a portion of the distal end of the sheath. In yet other aspects, the methods described herein comprise the sheath where the outer surface of the outer layer comprises a third portion configured to seal with at least a second portion of the inner surface of the outer jacket at at least a portion of the proximal end of the sheath.

In such aspects, the methods disclosed herein can further comprise a step of applying a second polymer exhibiting a melting temperature above about 45° C. between the second portion of the outer surface of the outer layer at at least a portion of the distal end of the sheath and the at least a first portion of the inner surface of the outer jacket.

In such aspects, the methods disclosed herein can further comprise a step of applying the third polymer exhibiting a melting temperature above about 45° C. between the third portion of the outer surface of the outer layer at at least a portion of the proximal end of the sheath and the at least a second portion of the inner surface of the outer jacket.

In the aspects where the second and/or the third polymers are present, these polymers can be present in the solid or viscoelastic form prior to the application. In still further aspects, during the application step, the second and/or the third polymers are present in the viscoelastic form. In yet other aspects, the second and/or the third polymers, when present as a solid prior to the step of applying, can be transformed into the viscoelastic form by heating above their melting temperature. In still further aspects, the second and/or third polymers can be transformed to the viscoelastic fluid by any known in the art methods, for example, and without limitation by heating the polymer in an oven or any other known in the art heater (IR, UV, etc.,) above its melting point. In still further aspects, the first polymer is applied as viscoelastic fluid at a temperature above about 45° C., or above about 50° C., or above about 55° C. It is further understood that the temperature the second and/or third polymers are exposed to can be chosen based on the specific polymers. In yet further aspects and as it could be readily understood by one of ordinary skill in the art, the upper temperature the second and/or third polymers are exposed to needs to be controlled to avoid adverse effects on the polymer structures and characteristics as well as adverse effects on the sheath components when it inadvertently exposed to undesired high temperatures.

In still further aspects, the second and/or third polymers can be applied as the viscoelastic fluid by any methods known in the art. In certain aspects and without limitation, the second and/or third polymer can be applied with a brush. In yet other aspects, it can be applied as a fluid and spread over the desired area with any tool known in the art. Again, the disclosed methods of application are only exemplary and non-limiting, and any methods of applying the viscoelastic fluid to any surface can be utilized. In still further aspects, the steps of applying the second polymer and the third polymer can occur substantially concurrently. In still further aspects, the steps of applying the first polymer, the second polymer, and the third polymer occur substantially concurrently. As described herein, the first, second, and third polymer can comprise the same or different composition. In still further aspects, the first, the second, and/or the third polymer can have a molecular mass in any of the disclosed above ranges. In still further aspects, it is understood that due to the difference in the melting temperature, if present, the second and/or third polymers remain solid when the sheath is introduced into a body having a temperature of 37° C.

In still further aspects, the sheath formed according to the disclosed methods exhibits at least about a 5% reduction in insertion force when inserted into a body having a temperature of 37° C. when compared to a substantially identical reference sheath without the first polymer.

In still further aspects, a layer of heat shrink tubing, such as, for example, and without limitation, fluorinated ethylene propylene (FEP) heat shrink tubing, can be positioned over the entire assembly (step 312). An appropriate amount of heat is applied, thus shrinking the heat shrink tubing and compressing the layers of the sheath together, such that components of the sheath can be thermally bonded or fused together where desired. Once the components of the sheath have been bonded together, the heat shrink tubing can be removed (step 314). Finally, the proximal end of the sheath can be adhered to or otherwise attached to a housing of a catheter assembly, and the sheath can be removed from the mandrel (step 316). It is understood that the first polymer is applied before step 312.

FIG. 31 illustrates a block diagram of an alternative aspect of a method of making a sheath. An inner liner, comprising any materials described herein, for example, and without limitation, an etched or not etched PTFE or high density polyethylene (HDPE), can be applied to a tapered mandrel, such as a 16 Fr tapered mandrel, and trimmed to an appropriate length (step 200). A second mandrel, such as a 0.070 inches diameter mandrel, can be inserted in the lumen of the inner liner such that the mandrels are arranged side by side in the inner liner (step 202). FIG. 32F shows a section view of a sheath at steps 200 and 202 of FIG. 31. An inner liner or inner polymeric layer 68 is applied on a first tapered mandrel 96. A second mandrel 97 is inserted into the lumen 72 of the inner polymeric layer 68 created by the excess portion of the inner polymeric layer 68, as described.

A notched or cut outer polymeric tubular layer, such as high density polyethylene tubing that has been notched or cut longitudinally, can be slid onto the tapered mandrel and a portion of the inner liner, starting at the distal end of the tapered mandrel (step 204). The second mandrel can then be removed (step 206). FIG. 32G illustrates a perspective view of the sheath at steps 204 and 206 of FIG. 31. A polymeric outer tubular layer 70 having a longitudinal cut is applied over the tapered mandrel 96 and inner polymeric layer 68. The outer tubular layer conforms to the portion of the inner polymeric layer around the tapered mandrel 96, and the portion of the inner polymeric layer 68 around the second mandrel 97 extends through the longitudinal cut in the outer polymeric tubular layer 70.

A split tool can be inserted into the portion of the lumen of the inner liner that was previously occupied by the second mandrel (step 208). The split tool can then be used to form folds and/or pleats in the excess portion of the inner liner, which now extends through the longitudinal cut in the outer polymeric tubular layer (step 210). The first polymer, as described above, is applied (step 213), for example, between the folded portion and the outer surface of the outer portion, as shown in FIG. 39B. However, the first polymer can also be applied, as shown in FIG. 39C-D. The second and the third polymers, as described above, can also be applied. A radiopaque marker band can optionally be applied at the distal end of the sheath (step 212). It is understood that if the radiopaque marker band is present, the first polymer can be applied before or after the application of this band at the distal end of the sheath. It is further understood that the first polymer and, if present, the second and/or third polymers are applied before the heat shrink tubing is applied over the sheath in the next step. Heat shrink tubing, such as FEP heat shrink tubing, can be applied over the entire sheath, and heat can be applied to compress the components of the sheath and bond or fuse them together (step 214). The split tool, heat shrink tubing, and second mandrel can then be removed (step 216). The sheath can then be utilized with a delivery apparatus, such as by bonding the proximal end of the sheath to a polycarbonate housing of a delivery apparatus or catheter assembly (step 218). In still further aspects, an additional step 220 can be optionally present and comprise a step of covering the whole length of the sheath or at least a portion of the sheath with an outer jacket or strain relief.

FIG. 32H illustrates an elevation view of the sheath at step 218 of FIG. 31. The sheath 66, made according to described methods and processes, can be attached or bonded to a housing 101, such as by bonding the proximal end of the sheath 66 to the polycarbonate housing 101.

In another example, disclosed expandable sheaths can be made using a reflowed mandrel process. A mandrel can be provided, with the size of the mandrel defining the inner diameter of the sheath lumen in its resting configuration. A tube of material, such as a PTFE or HDPE tube that will become the sheath's inner liner, can be provided with an inner diameter greater than that of the mandrel (e.g., a 9 mm PTFE tube can be mounted on a 6 mm mandrel). The PTFE or HDPE tube can be mounted on the mandrel and prepared into the final folded configuration by folding the excess material of the tube over to one or both sides. Another HDPE tube that will serve as the outer layer can then be placed over the PTFE or HDPE liner. The first polymer can then be disposed between the folding portion of the inner layer and the outer surface of the outer layer. Additional layers and polymers can also be added. The formed layer assembly can then be thermally fused together. For example, a reflow process can be performed where the assembly is heated to a temperature high enough such that the inner and/or outer layers are at least partially melted and are then fused together as the heat is removed and the assembly cools. It is understood that if this procedure is performed and the assembly is heated above the melting temperature of the first polymer, the second polymer, and/or third polymer is present, the polymers will melt but will re-solidify as the heat is removed, and the assembly cools to form the sheath as disclosed herein.

An elastic cover can be placed over at least part of the fused layers (e.g., over a proximal section of the sheath) and held in place using a thermal process. In some aspects, the same thermal process can bond the layers of the sheath and the elastic cover. In other aspects, a first thermal process can be used to fuse the layers of the sheath, and a second thermal process can be used to secure the elastic cover to the sheath. In some aspects, the elastic cover can be heat shrink tubing that is applied over the expandable sheath and heated to a temperature high enough to cause the tubing to shrink around the sheath. In some aspects, a distal soft tip can then be attached to the shaft of the expandable sheath.

In some aspects, the outer layer can be co-extruded with an adhesive layer or a tie layer. It is understood that any of the adhesive layers or the tie layer can comprise any materials disclosed above. For example and without limitation, the adhesive layer (tie layer) can comprise a polyurethane material such as Tecoflex, or polymer, copolymer, or terpolymer such as maleic anhydride modified polyolefin, for example, and without limitation, Orevac® (commercially available from Arkema), ethylene acrylic acid copolymer, such as DOW Chemical Primacor®, ethylene acrylate copolymer such as Lotryl® (commercially available from Arkema), ethylene glycidyl methacrylate copolymer, ethylene acrylic esters glycidyl methacrylate terpolymer such as Lotader® (commercially available from Arkema), ethylene acrylic esters maleic anhydride terpolymer such as Lotader® or Orevac® (commercially available from Arkema). The tie layer can be disposed at at least a second portion of the inner surface of the outer layer, such that it is configured to seal the at least a second portion of the inner surface of the outer layer with at least a portion of the inner layer. In such aspects, the tie layer will be positioned between the inner and outer layers in the completed sheath. In these aspects, an exemplary outer HDPE tube can be provided with a coating of the tie layer, such as, for example, Tecoflex, on the inner surface. The outer HDPE tube can be slit along the length of the tube to open and flatten it and then cut using a template in some aspects.

For example, for specific applications, portions of the outer layer can be cut and removed using a template. The cut outer HDPE layer can then be placed on the inner layer on the mandrel. In some aspects, only a portion of the outer layer will have the adhesive layer. In these aspects, the sections without the adhesive layer (or tie layer) can only be partially fused to the inner layer. In some aspects, the entire inner surface of the outer layer can have the tie layer disposed on, and the inner surface of the outer layer can be positioned so that it contacts the inner layer on the mandrel. To position the inner and outer layers, as shown in the sheath of FIG. 39A-D, the folded portion of the inner layer can be lifted up, and an edge of the outer layer can be tucked beneath the fold. In still further aspects, these process steps can be done before applying the first polymer between the outer surface of the outer layer and the folder portion.

Sheaths of the present disclosure can be used with various methods of introducing a prosthetic device into a patient's vasculature. One such method comprises positioning an expandable sheath in a patient's vessel, passing a device through the introducer sheath, which causes a portion of the sheath surrounding the device to expand and accommodate the profile of the device, and automatically retracting the expanded portion of the sheath to its original size after the device has passed through the expanded portion. In some methods, the expandable sheath can be sutured to the patient's skin at the insertion site so that once the sheath is inserted the proper distance within the patient's vasculature, it does not move once the implantable device starts to travel through the sheath.

In some aspects, the disclosed expandable sheath can be used with other delivery and minimally invasive surgical components, such as an introducer and loader. In one aspect, the expandable sheath can be flushed to purge any air within the sheath, using, for example, flush port 103 (FIG. 35). An introducer can be inserted into the expandable sheath, and the introducer/sheath combination can be fully inserted into vasculature over a guiding device, such as a 0.35″ guidewire. In certain aspects, the seam formed by the intersection of the folded portion of the inner layer and the overlapping portion of the outer layer can be positioned such it is oriented downward (posterior). Once the sheath and introducer are fully inserted into a patient's vasculature, in some aspects, the expandable sheath can be sutured in place at the insertion site. In this manner, the expandable sheath can be substantially prevented from moving once positioned within the patient.

The introducer can then be removed, and a medical device, such as a transcatheter heart valve, can be inserted into the sheath, in some instances, using a loader. Such methods can additionally comprise placing the tissue heart valve in a crimped state on the distal end portion of an elongated delivery apparatus and inserting the elongated delivery device with the crimped valve into and through the expandable sheath. Next, the delivery apparatus can be advanced through the patient's vasculature to the treatment site, where the valve can be implanted.

Typically, the medical device has a greater outer diameter than the diameter of the sheath in its original configuration. The medical device can be advanced through the expandable sheath towards the implantation site, and the expandable sheath can locally expand to accommodate the medical device as the device passes through. The radial force exerted by the medical device can be sufficient to locally expand the sheath to an expanded diameter (e.g., the expanded configuration) just in the area where the medical device is currently located. Once the medical device passes a particular location of the sheath, the sheath can at least partially contract to the smaller diameter of its original configuration. The expandable sheath can thus be expanded without the use of inflatable balloons or other dilators. Once the medical device is implanted, the sheath and any sutures holding in place can be removed. In some exemplary aspects, the sheath is removed without rotating it.

EXEMPLARY ASPECTS

In view of the described processes and compositions, hereinbelow are described certain more particularly described aspects of the disclosures. These particularly recited aspects should not, however, be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language and formulas literally used therein.

EXAMPLE 1: A sheath for delivering a medical device, wherein the sheath has a proximal and a distal end and comprises: an expandable inner layer having an inner surface and an outer surface, wherein the inner surface of the expandable inner layer defines a lumen having a longitudinal axis and comprising at least one folded portion having an inner portion and outer portion; an outer layer having an inner surface and an outer surface and extending at least partially around the inner layer such that at least a first portion of the outer surface of the outer layer is positioned adjacent to the inner portion of the at least one folded portion of the inner layer, while a first portion of the inner surface of the outer layer is positioned adjacent to the outer portion of the at least one folded portion of the inner layer; a first polymer disposed between at least a portion of the inner layer and at least a portion of the outer layer, forming an intermediate layer, wherein, the first polymer exhibits a melting temperature from about 30° C. to about 45° C.; and wherein the at least one folded portion is configured to at least partially unfold during application of a radial outward force by passage of a medical device through the lumen of the inner layer.

EXAMPLE 2: The sheath of any examples herein, particularly example 1, wherein the first polymer is disposed between the at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer.

EXAMPLE 3: The sheath of any examples herein, particularly examples 1 or 2, wherein the first polymer is disposed between at least the first portion of the inner surface of the outer layer and the outer portion of the at least one folded portion of the inner layer.

EXAMPLE 4: The sheath of any examples herein, particularly examples 1-3, wherein the sheath further comprises an outer jacket comprising an inner surface and outer surface extending at least partially around the outer layer such that the inner surface of the outer jacket overlies the outer surface of the outer layer.

EXAMPLE 5: The sheath of any examples herein, particularly example 4, wherein the first polymer is disposed between at least a portion of the inner surface of the outer jacket and at least a portion of the outer surface of the outer layer.

EXAMPLE 6: The sheath of any examples herein, particularly examples 2-5, wherein the first polymer disposed between the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer along a longitudinal axis of the folded portion.

EXAMPLE 7: The sheath of any examples herein, particularly examples 1-6, wherein the sheath further comprises a tie layer disposed between at least a second portion of the inner surface of the outer layer and at least a portion of the outer surface of the inner layer, such that it is configured to seal the at least a second portion of the inner surface of the outer layer with the at least a portion of the outer surface of the inner layer.

EXAMPLE 8: The sheath of any examples herein, particularly example 7, wherein the tie layer is disposed between the inner surface of the outer layer and the outer surface of the inner layer along a circumference of the inner layer along its longitudinal axis.

EXAMPLE 9: The sheath of any examples herein, particularly examples 1-8, wherein the expandable inner layer has a dynamic coefficient of friction of less than 0.4 against steel as measured according to ASTM D1894.

EXAMPLE 10: The sheath of any examples herein, particularly examples 1-9, wherein the expandable inner layer comprises a fluoropolymer.

EXAMPLE 11: The sheath of any examples herein, particularly examples 1-10, wherein the expandable inner layer comprises polytetrafluoroethylene (PTFE).

EXAMPLE 12: The sheath of any examples herein, particularly examples 1-11, wherein the outer surface of the expandable inner layer is etched.

EXAMPLE 13: The sheath of any examples herein, particularly examples 1-12, wherein the expandable inner layer is high density polyethylene (HDPE).

EXAMPLE 14: The sheath of any examples herein, particularly examples 1-13, wherein the inner surface of the outer layer comprises a third portion configured to seal with the outer surface of the inner layer at at least a portion of the distal end of the sheath.

EXAMPLE 15: The sheath of any examples herein, particularly examples 1-14, wherein the inner surface of the outer layer comprises a fourth portion configured to seal with the outer surface of the inner layer at at least a portion of the proximal end of the sheath.

EXAMPLE 16: The sheath of any examples herein, particularly examples 4-15, wherein the outer surface of the outer layer comprises a second portion configured to seal with at least a first portion of the inner surface of the outer jacket at at least a portion of the distal end of the sheath.

EXAMPLE 17: The sheath of any examples herein, particularly examples 4-16, wherein the outer surface of the outer layer comprises a third portion configured to seal with at least a second portion of the inner surface of the outer jacket at at least a portion of the proximal end of the sheath.

EXAMPLE 18: The sheath of any examples herein, particularly examples 1-17, wherein the first polymer is solid at a temperature below about 30° C. and adheres the first portion of the outer surface of the outer layer to the inner portion of the at least one folded portion of the inner layer.

EXAMPLE 19: The sheath of any examples herein, particularly examples 1-18, wherein the intermediate layer is a viscoelastic fluid at a temperature from 30° to about 45° C. and is a lubricant.

EXAMPLE 20: The sheath of any examples herein, particularly examples 1-19, wherein the sheath exhibits at least about 5% reduction in insertion force when inserted into a body having a temperature of 37° C. when compared to a substantially identical reference sheath without the first polymer.

EXAMPLE 21: The sheath of any examples herein, particularly examples 16-20, further comprising a second polymer exhibiting a melting temperature above about 45° C. that is disposed between the second portion of the outer surface of the outer layer at at least a portion of the distal end of the sheath and the at least a first portion of the inner surface of the outer jacket.

EXAMPLE 22: The sheath of any examples herein, particularly examples 17-21, further comprising a third polymer exhibiting a melting temperature above about 45° C. that is disposed between the third portion of the outer surface of the outer layer at at least a portion of the proximal end of the sheath and the at least a second portion of the inner surface of the outer jacket.

EXAMPLE 23: The sheath of any examples herein, particularly examples 21-22, wherein the first polymer, second polymer, and third polymer comprise the same composition.

EXAMPLE 24: The sheath of any examples herein, particularly examples 21-22, wherein the first polymer, second polymer, and third polymer comprise polyethylene glycol (PEG).

EXAMPLE 25: The sheath of any examples herein, particularly example 24, wherein the first polymer has a molecular weight from about 500 to about 1,500 g/mol.

EXAMPLE 26: The sheath of any examples herein, particularly example 24, wherein the second polymer and/or third polymer has a molecular weight from about 1,500 to about 3,500 g/mol.

EXAMPLE 27: The sheath of any examples herein, particularly examples 1-26, wherein the inner layer comprises two or more folded portions.

EXAMPLE 28: The sheath of any examples herein, particularly examples 1-27, wherein the folded portion comprises a first folded edge and a second folded edge and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen.

EXAMPLE 29: The sheath of any examples herein, particularly examples 2-28, wherein the folded portion comprises a first folded edge and a second folded edge and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen, the overlapping portion, wherein the outer layer includes a first longitudinally extending edge and a second longitudinally extending edge configured to separate as the sheath expands, the first longitudinal extending edge and an overlapping portion of the outer layer extending over the second longitudinal extending edge when the sheath is not expanded, wherein the first polymer is provided between the at least the first portion of the outer surface of the outer layer proximate the second longitudinally extending edge and the inner surface of the overlapping portion of the folded portion.

EXAMPLE 30: A method of making a sheath comprising: providing a sheath comprising: an expandable inner layer having an inner surface and an outer surface, wherein the inner surface of the expandable inner layer defines a lumen having a longitudinal axis and comprising at least one folded portion having an inner portion and outer portion; and an outer layer having an inner surface and an outer surface and extending at least partially around the inner layer such that at least a first portion of the outer surface of the outer layer is positioned adjacent to the inner portion of the at least one folded portion of the inner layer, while a first portion of the inner surface of the outer layer is positioned adjacent to the outer portion of the at least one folded portion of the inner layer; applying a first polymer between at least a portion of the inner layer and at least a portion of the outer layer, thereby forming an intermediate layer, wherein, the first polymer exhibits a melting temperature from about 30° C. to about 45° C. and wherein the at least one folded portion is configured to at least partially unfold during application of a radial outward force by passage of a medical device through the lumen of the inner layer.

EXAMPLE 31: The method of any examples herein, particularly example 30, wherein the first polymer is applied between the at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer.

EXAMPLE 32: The method of any examples herein, particularly example 30 or 31, wherein the first polymer is applied between the at least the first portion of the inner surface of the outer layer and the outer portion of the at least one folded portion of the inner layer.

EXAMPLE 33: The method of any examples herein, particularly examples 30-32, further comprises positioning an outer jacket comprising an inner surface and outer surface such that it extends at least partially around the outer layer and such that the inner surface of the outer jacket overlies the outer surface of the outer layer.

EXAMPLE 34: The method of any examples herein, particularly example 33, wherein the first polymer is applied between at least a portion of the inner surface of the outer jacket and at least a portion of the outer surface of the outer layer.

EXAMPLE 35: The method of any examples herein, particularly examples 30-34, wherein prior to the step of applying, the first polymer is provided as a solid or as a viscoelastic fluid.

EXAMPLE 36: The method of any examples herein, particularly example 35, wherein the first polymer is applied as a viscoelastic fluid at a temperature above about 30° C.

EXAMPLE 37: The method of any examples herein, particularly examples 30-36, wherein after the step of applying the sheath, is cooled to a temperature below 30° C.

EXAMPLE 38: The method of any examples herein, particularly examples 30-37, wherein the sheath further comprises a tie layer disposed between at least a second portion of the inner surface of the outer layer and at least a portion of the outer surface of the inner layer, such that it is configured to seal the at least a second portion of the inner surface of the outer layer with the at least a portion of the outer surface of the inner layer.

EXAMPLE 39: The method of any examples herein, particularly examples 30-38, wherein the expandable inner layer has a dynamic coefficient of friction of less than 0.4 against steel as measured according to ASTM D1894.

EXAMPLE 40: The method of any examples herein, particularly examples 30-39, wherein the expandable inner layer comprises a fluoropolymer.

EXAMPLE 41: The method of any examples herein, particularly examples 30-40, wherein the expandable inner layer comprises polytetrafluoroethylene (PTFE).

EXAMPLE 42: The method of any examples herein, particularly examples 30-41, wherein the outer surface of the expandable inner layer is etched.

EXAMPLE 43: The method of any examples herein, particularly examples 30-42, wherein the expandable inner layer is high density polyethylene (HDPE).

EXAMPLE 44: The method of any examples herein, particularly examples 30-43, wherein the inner surface of the outer layer comprises a third portion configured to seal with the outer surface of the inner layer at at least a portion of the distal end of the sheath.

EXAMPLE 45: The method of any examples herein, particularly examples 30-44, wherein the inner surface of the outer layer comprises a fourth portion configured to seal with the outer surface of the inner layer at at least a portion of the proximal end of the sheath.

EXAMPLE 46: The method of any examples herein, particularly examples 30-45, wherein the outer surface of the outer layer comprises a second portion configured to seal with at least a first portion of the inner surface of the outer jacket at at least a portion of the distal end of the sheath.

EXAMPLE 47: The method of any examples herein, particularly examples 30-46, wherein the outer surface of the outer layer comprises a third portion configured to seal with at least a second portion of the inner surface of the outer jacket at at least a portion of the proximal end of the sheath.

EXAMPLE 48: The method of any examples herein, particularly examples 30-47, wherein the sheath exhibits at least about 5% reduction in insertion force when inserted into a body having a temperature of 37° C. when compared to a substantially identical reference sheath without the first polymer.

EXAMPLE 49: The method of any examples herein, particularly examples 45-47, further comprising applying a second polymer exhibiting a melting temperature above about 45° C. between the second portion of the outer surface of the outer layer at at least a portion of the distal end of the sheath and the at least a first portion of the inner surface of the outer jacket.

EXAMPLE 50: The method of any examples herein, particularly examples 46-48, further comprising applying a third polymer exhibiting a melting temperature above about 45° C. between the third portion of the outer surface of the outer layer at at least a portion of the proximal end of the sheath and the at least a second portion of the inner surface of the outer jacket.

EXAMPLE 51: The method of any examples herein, particularly examples 46-49, wherein the first polymer, second polymer, and third polymer comprise the same composition.

EXAMPLE 52: The method of any examples herein, particularly examples 46-50, wherein the first polymer, second polymer, and third polymer comprise polyethylene glycol (PEG).

EXAMPLE 53: The method of any examples herein, particularly example 51, wherein the first polymer has a molecular weight from about 500 to about 1,500 g/mol.

EXAMPLE 54: The method of any examples herein, particularly example 51, wherein the second polymer and/or third polymer has a molecular weight from about 1,500 to about 3,500 g/mol.

EXAMPLE 55: The method of any examples herein, particularly examples 30-54, wherein the inner layer comprises two or more folded portions.

EXAMPLE 56: The method of any examples herein, particularly examples 46-55, wherein the steps of applying the second polymer and the third polymer occur substantially concurrently.

EXAMPLE 57: The method of any examples herein, particularly examples 46-55, wherein the steps of applying the first polymer, the second polymer, and the third polymer occur substantially concurrently.

EXAMPLE 58: The method of any examples herein, particularly examples 30-57, wherein the folded portion comprises a first folded edge and a second folded edge and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen.

EXAMPLE 59: The method of any examples herein, particularly examples 31-58, wherein the folded portion comprises a first folded edge and a second folded edge and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen, wherein the outer layer includes a first longitudinally extending edge and a second longitudinally extending edge configured to separate as the sheath expands, the first longitudinal extending edge and an overlapping portion of the outer layer extending over the second longitudinal extending edge when the sheath is not expanded, wherein the step of applying a first polymer to the at least one folded portion comprises applying the first polymer between the at least the first portion of the outer surface of the outer layer proximate the second longitudinally extending edge and the inner surface of the overlapping portion of the folded portion.

In view of the many possible aspects to which the principles of the disclosed disclosure can be applied, it should be recognized that the illustrated aspects are only some examples of the disclosure and should not be taken as limiting the scope of the disclosure. Rather, the scope of the disclosure is defined by the following claims. We, therefore, claim as our disclosure all that comes within the scope and spirit of these claims.

Claims

1. A sheath for delivering a medical device, wherein the sheath has a proximal and a distal end and comprises: an expandable inner layer having an inner surface and an outer surface, wherein the inner surface of the expandable inner layer defines a lumen having a longitudinal axis and comprising at least one folded portion having an inner portion and outer portion;an outer layer having an inner surface and an outer surface and extending at least partially around the inner layer such that at least a first portion of the outer surface of the outer layer is positioned adjacent to the inner portion of the at least one folded portion of the inner layer, while a first portion of the inner surface of the outer layer is positioned adjacent to the outer portion of the at least one folded portion of the inner layer;a first polymer disposed between at least a portion of the inner layer and at least a portion of the outer layer, forming an intermediate layer,wherein the first polymer exhibits a melting temperature from about 30° C. to about 45° C.; andwherein the at least one folded portion is configured to at least partially unfold during application of a radial outward force by passage of a medical device through the lumen of the inner layer.

2. The sheath of claim 1, wherein the first polymer is disposed between the at least the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer.

3. The sheath of claim 1, wherein the first polymer is disposed between at least the first portion of the inner surface of the outer layer and the outer portion of the at least one folded portion of the inner layer.

4. The sheath of claim 1, wherein the sheath further comprises an outer jacket comprising an inner surface and outer surface extending at least partially around the outer layer such that the inner surface of the outer jacket overlies the outer surface of the outer layer.

5. The sheath of claim 4, wherein the first polymer is disposed between at least a portion of the inner surface of the outer jacket and at least a portion of the outer surface of the outer layer.

6. The sheath of claim 2, wherein the first polymer disposed between the first portion of the outer surface of the outer layer and the inner portion of the at least one folded portion of the inner layer along a longitudinal axis of the folded portion.

7. The sheath of claim 1, wherein the sheath further comprises a tie layer disposed between at least a second portion of the inner surface of the outer layer and at least a portion of the outer surface of the inner layer, such that it is configured to seal the at least a second portion of the inner surface of the outer layer with the at least a portion of the outer surface of the inner layer.

8. The sheath of claim 7, wherein the tie layer is disposed between the inner surface of the outer layer and the outer surface of the inner layer along a circumference of the inner layer along its longitudinal axis.

9. The sheath of claim 1, wherein the expandable inner layer comprises a fluoropolymer, high density polyethylene (HDPE), or a combination thereof.

10. The sheath of claim 1, wherein the outer surface of the expandable inner layer is etched.

11. The sheath of claim 1, wherein the inner surface of the outer layer comprises a third portion configured to seal with the outer surface of the inner layer at at least a portion of the distal end of the sheath and/or a fourth portion configured to seal with the outer surface of the inner layer at at least a portion of the proximal end of the sheath.

12. The sheath of claim 4, wherein the outer surface of the outer layer comprises a second portion configured to seal with at least a first portion of the inner surface of the outer jacket at at least a portion of the distal end of the sheath and/or a third portion configured to seal with at least a second portion of the inner surface of the outer jacket at at least a portion of the proximal end of the sheath.

13. The sheath of claim 2, wherein the first polymer is solid at a temperature below about 30° C. and adheres the first portion of the outer surface of the outer layer to the inner portion of the at least one folded portion of the inner layer.

14. The sheath of claim 1, wherein the intermediate layer is a viscoelastic fluid at a temperature from 30° C. to about 45° C. and is a lubricant.

15. The sheath of claim 1, wherein the sheath exhibits at least about 5% reduction in insertion force when inserted into a body having a temperature of 37° C. when compared to a substantially identical reference sheath without the first polymer.

16. The sheath of claim 12, further comprising a second polymer exhibiting a melting temperature above about 45° C. that is disposed between the second portion of the outer surface of the outer layer at at least a portion of the distal end of the sheath and the at least a first portion of the inner surface of the outer jacket and/or a third polymer exhibiting a melting temperature above about 45° C. that is disposed between the third portion of the outer surface of the outer layer at at least a portion of the proximal end of the sheath and the at least a second portion of the inner surface of the outer jacket.

17. The sheath of claim 1, wherein the first polymer comprises polyethylene glycol (PEG) having a molecular weight from about 500 to about 1,500 g/mol.

18. The sheath of claim 16, wherein the second polymer and/or third polymer comprises polyethylene glycol (PEG) having a molecular weight from about 1,500 to about 3,500 g/mol.

19. The sheath of claim 1, wherein the folded portion comprises a first folded edge and a second folded edge and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, and wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen.

20. The sheath of claim 2, wherein the folded portion comprises a first folded edge and a second folded edge and an overlapping portion extending circumferentially between the first and second folded edges, the overlapping portion comprising an overlap in a radial direction of at least two thicknesses of the inner layer, wherein the first folded edge is configured to move closer to the second folded edge to shorten the overlapping portion at a local axial location during application of a radial outward force by passage of the medical device and wherein shortening of the overlapping portion corresponds with a local expansion of the lumen, the overlapping portion,wherein the outer layer includes a first longitudinally extending edge and a second longitudinally extending edge configured to separate as the sheath expands, the first longitudinal extending edge and an overlapping portion of the outer layer extending over the second longitudinal extending edge when the sheath is not expanded, andwherein the first polymer is provided between the at least the first portion of the outer surface of the outer layer proximate to the second longitudinally extending edge and the inner surface of the overlapping portion of the folded portion.