Medical balloons are widely used in medical procedures. Typically, an uninflated medical balloon is inserted into a body space. When the medical balloon is inflated, the volume of the medical balloon expands, and the body space is similarly expanded.
In procedures such as angioplasty, the medical balloon may be used to open a collapsed or blocked artery. A typical medical balloon includes a central barrel portion between tapered or conical portions. The medical balloon may be provided in a non-compliant form by including one or more fiber layers.
In the past, the fibers used in such balloons have typically been made of synthetic materials, such as UHMW polyethylene fiber. However, such synthetic fibers are not found in nature, and thus are costly to manufacture. Synthetic fibers may also lack superior adhesion characteristics in some applications.
Accordingly, a need is identified for a medical balloon that overcomes any or all of the foregoing limitations and possibly others that have yet to be identified.
According to a first aspect of the disclosure, a medical balloon includes a base balloon layer and at least one cellulose fiber applied to the base balloon layer.
In one embodiment, the base balloon layer includes first and second tapered portions and a barrel portion therebetween. The at least one cellulose fiber may extend over the first and second tapered portions and the barrel portion of the base balloon layer. The at least one cellulose fiber may extend substantially parallel to a longitudinal axis of the base balloon layer, and/or may extend radially around the base balloon layer. For example, in one particular embodiment, the at least one cellulose fiber comprises a single continuous fiber extending substantially parallel to a longitudinal axis of the base balloon layer and radially around the base balloon layer.
The medical balloon may further include at least one silk fiber. The at least one cellulose fiber may further comprise silk proteins. The at least one cellulose fiber may comprise cellulose nano fibers, such as hydro-dynamically focused cellulose nano fibers.
The at least one cellulose fiber may be attached to the base balloon layer by an adhesive. The at least one cellulose fiber may be attached to an outer surface of the base balloon layer. An outer layer may also be applied over the at least one cellulose fiber.
According to a further aspect of the disclosure, a medical balloon comprises a base balloon having a longitudinal axis and at least one longitudinal fiber extending along the base balloon substantially parallel to the longitudinal axis, the at least one longitudinal fiber comprising cellulose.
In one embodiment, including at least one hoop fiber extends over the at least one longitudinal fiber, the at least one hoop fiber comprising cellulose. The at least one longitudinal fiber and at least one hoop fiber may form part of a single continuous fiber. The at least one longitudinal fiber may further comprise silk proteins, and the medical balloon may further include at least one silk fiber. The at least one longitudinal fiber may comprise cellulose nano fibers, such as hydro-dynamically focused cellulose nano fibers. The at least one longitudinal fiber may be attached to the base balloon by an adhesive.
A further aspect of the disclosure pertains to a method of forming a medical balloon. The method comprises the step of applying at least one cellulose fiber applied to a base balloon layer.
In one embodiment, the applying step comprises applying the at least one cellulose fiber along a longitudinal axis of the base balloon. The applying step may comprise wrapping the cellulose fiber around the base balloon. The applying step may comprise adhesively attaching the at least one cellulose fiber to the base balloon.
The above and further advantages of the disclosure may be better understood by referring to the following description in conjunction with the accompanying drawings in which:
The dimensions of some of the elements may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element. Further, sometimes reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. Moreover, some of the items depicted in the drawings may be combined into a single function.
In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the present invention. The disclosed embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, or structures may not have been described in detail so as not to obscure the present invention.
The principles and operation of systems and methods of the disclosure may be better understood with reference to the drawings and accompanying descriptions. The invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
Certain features of the invention that are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
With reference to
The diameter 116 of an inflated fiber-reinforced medical balloon 10 in accordance with the one embodiment may be about ten millimeters, but may vary depending on the application. The length of an inflated fiber-reinforced medical balloon 10 in accordance with one embodiment may be about eight centimeters. A balloon 10 with a length 118 of 2-200 centimeters or more is possible. The inclination angle of a tapered or cone portion 108 of an inflated fiber-reinforced medical balloon 10 in accordance with the disclosed embodiment may be about twenty degrees.
It will be recognized by those having skill in the art that the fiber-reinforced balloon 10 could be made in a wide variety of diameters 116 and lengths and with a variety of inclinations at the tapered or cone portion 108 of the balloon 10, without limitation.
The fiber-reinforced medical balloon 10 may include a base layer 100 formed of a thin polymer material and a first layer 12 of thin, elongated inelastic fibers 13, which may extend longitudinally. The balloon 10 may include a second layer 14 made up of one or more thin, elongated fibers 15, which may extend transversely (termed “hoop” fibers). Additional fiber layers may be included, if desired.
An outer layer 16 over the fiber layer(s) 12, 14 (or others, if present) may be included. This outer layer 16 may comprise a polymer. The polymer may be applied in film form (blow-molded, extruded, or otherwise) or applied as a solution, such as by spraying.
Each fiber 13 is typically fixed relative to other fibers in the first fiber layer 12 and other fibers in the balloon 10. The thin inelastic fibers 13 of the first fiber layer 12 may be characterized by a high tensile strength, which provide superior burst strength. The fiber-reinforced balloon 10 may also resist abrasion, cuts, and punctures. It may be recognized that enhanced structural integrity may result from the fiber reinforcement.
With further reference to
The base layer 100 is typically formed of a thin film polymeric material, or other suitable materials with high strength relative to film thickness. Polymers and copolymers that can be used for the base layer 100 include the conventional polymers and copolymers used in medical balloon construction, such as, but not limited to, polyethylene, (PET), polycaprolactam, polyesters, polyethers, polyamides, polyurethanes, polyimides, ABS, nylons, copolymers, polyester/polyether block copolymers, ionomer resins, liquid crystal polymers, and rigid rod polymers. The base layer 100 may typically be formed as a blow-molded balloon of a polymer material, such as for example a polyamide, such as nylon.
The base layer 100 may comprise a polymer, which has been cured into the shape of a balloon, may be formed. This base layer 100 of a cured polymer may form the inner polymeric wall of the fiber reinforced balloon. With reference to
A removable balloon similar to base layer 100 may be used as the mandrel 122. The mandrel 122 may be made from a variety of materials. The mandrel 122 may be made in the shape of the interior wall of the desired finished balloon. The mandrel 122 may be made of collapsible metal or polymeric bladder, foams, waxes, low-melting metal alloys, and the like. Once the composite balloon is developed and laminated, the mandrel 122 (i.e., base layer 100) may be removed by melting, dissolving, fracturing, compressing, pressurizing, or other suitable removal techniques.
With reference to
One or more fibers 13 are applied to the base layer 100 to form a first fiber layer 12, as shown in
In a disclosed embodiment, the fibers 13 of the first fiber layer 12 are ribbon-shaped, where the width of the fiber is larger than the thickness of the fiber. The fibers 13 may be flat so that the fiber has a rectangular cross-section. The fibers 13 used in the initial layer of fibers 12 may all be fibers 13 made of the same material and the same shape. Fibers 13 made from different materials may be used in the initial fiber layer 12. Fibers 13 made in different shapes may be used in the initial fiber layer 12. Fiber 13, which has been flattened on a roll mill may be used to form the first fiber layer 12. To the flattened fiber 13 is applied an adhesive, such as the 1-MP adhesive. The fibers 13 may be arranged as 30 longitudinal fibers, each substantially equal in length to the length of the balloon 10.
The fibers 13 of the initial fiber layer 12 may be arranged so that each fiber 13 is substantially parallel to the long axis of the balloon 10. The density of the fibers 13 in the initial fiber layer 12 is determined by the number of fibers 13 or fiber winds per inch and the thickness of the fibers 13. In a disclosed embodiment of the first fiber layer 12 having longitudinally-placed fibers 13, a fiber density of generally about 15 to 30 fibers 13 having a fiber thickness of about 0.0005 to 0.001 inch and placed equidistant from one another provide adequate strength for a standard-sized fiber-reinforced medical balloon 10. Each of the fibers 13 is substantially equal in length to the balloon 10. The first fiber layer 12 may prevent longitudinal extension of the completed fiber-reinforced balloon 10.
In accordance with a disclosed embodiment, a second fiber layer 14 made with one or more high-strength inelastic fibers 15 is positioned along circumference of the balloon 10, as shown in
The fibers 15 of the second fiber layer 14 may be inelastic fiber, typically made of an inelastic fibrous material. An inelastic fiber is a member of a group of fibers that have very minimal elasticity or stretch in a given range of pressures. Some fibrous materials are generally classified as inelastic although the all fibrous material may have a detectable, but minimal elasticity or stretch at a given pressure. The fibers 15 of the second fiber layer 14 may be high-strength fibers, typically made of a high-strength fibrous material.
In a disclosed embodiment, the fibers 15 of the second fiber layer 14 are ribbon-shaped, where the width of the fiber is larger than the thickness of the fiber. The fibers 15 may be flat so that the fiber has a rectangular cross-section. The fibers 15 used in the second layer of fibers 14 may all be fibers 15 made of the same material and the same shape. Fibers 15 made from different materials may be used in the second fiber layer 14. Fibers 15 made in different shapes may be used in the second fiber layer 14. Fiber 15 which has been flattened on a roll mill may be used to form the second fiber layer 14. To the flattened fiber 15 is applied a thin coat of an adhesive, such as the 1-MP adhesive. The fibers 15 may be arranged as a second fiber layer 14 may have a fiber density of 54 wraps per inch.
The fibers 15 of the second fiber layer 14 may be perpendicular to or substantially perpendicular to the fibers 13 placed longitudinally to form the first fiber layer 12. This transverse placement of the first fiber layer 12 and the second fiber layer 14 allows for maximum radial stability of the fiber-reinforced balloon 10. The placement of the fiber layers 12, 14 distributes the force on the balloon surface equally, creating pixelized pressure points of generally equal shape, size, and density.
The fibers 13 of the first fiber layer 12 may be the same as or different from the fiber 15 of the second fiber layer 14. Specifically, the fibers 15 of the second fiber layer 14 may be made of a different material or materials than the fibers 13 of the first layer 12. The fibers 15 of the second layer 14 may be shaped differently from the fibers 13 of the first fiber layer 12. The characteristics of the fibers or combination of fibers used for the first or second fiber layers may be determined from the specific properties required from the resulting fiber-reinforced balloon 10.
With respect to the fiber density of the second fiber layer 14, in accordance with the disclosed embodiment, fiber 15 having a thickness of about 0.0005 to 0.001 inch and arranged in parallel lines with about 50 to 80 wraps per inch provides generally adequate strength. A single fiber 15 may form the second fiber layer 14, with the fiber 15 wound in a generally parallel series of circumferential continuous loops.
With reference to
With reference to
With reference to
In accordance with another embodiment, the fibers 47 of the first fiber layer 46 may be positioned parallel to a line at a thirty-degree angle to a line parallel to the longitudinal axis of the balloon 10. In accordance with another embodiment, the fibers 47 of the first fiber layer 46 may be positioned parallel to a line at a forty-five-degree angle to a line parallel to the longitudinal axis of the balloon 10. It will be apparent to those having skill in the art that the fibers 47 may be placed at any appropriate angle.
The fibers 49 of the second fiber layer 48 lie parallel to the circumference of the balloon 10. With reference to
The fiber 44 of the second fiber layer 43 may be positioned parallel to a line at a twenty-degree angle to a line parallel to the circumference of the balloon 10. In accordance with one embodiment, the fiber 44 of the second fiber layer 43 may be positioned parallel to a line at a thirty-degree angle to a line parallel to the circumference of the balloon 10. In accordance with one embodiment, the fiber 44 of the second fiber layer 43 may be positioned parallel to a line at a forty-five-degree angle to a line parallel to the circumference of the balloon 10. It will be apparent to those skilled in the art that the fibers 44 may be placed at any appropriate angle.
The fibers 42 of the first fiber layer 41 and the fibers 44 of the second fiber layer 43 are positioned perpendicularly relative to each other. With reference to
Referring to
Turning to
As illustrated in
The fibers 13 of the first fiber layer 12 and/or the fibers 14 of the second fiber layer 15, (or any other fibers disclosed herein, such as the fibers 47 of the first fiber layer 46 and fibers 49 of the second fiber layer 48) may comprise natural materials, such as cellulose. Specifically, any or all of these fibers may comprise one or more of: (1) cellulose nano fibers (fibrils); (2) cellulose nano fibers combined with silk fibers; or (3) cellulose nano fibers combined with silk proteins. Advantageously, the fibers 13 or 15 may thus comprise naturally available, as compared to synthetic, materials, which can reduce the cost of manufacturing or use without sacrificing strength or crimpability.
The cellulose-based fibers or fibrils may be formed using a process called hydrodynamic focusing. This involves forming a fiber from cellulose nano fibers by feeding them into a water channel that squeezes/condenses the fibers into an aligned, well packed and extremely strong fiber material. Such fibers may have stiffness of 60-70 Gpa with tensile break of 1015 MPa, and have superior properties of adhesion as compared to synthetic fibers.
Summarizing, this disclosure may relate to the following items:
1. A medical balloon comprising:
2. The medical balloon of item 1, wherein the base balloon layer includes first and second tapered portions and a barrel portion therebetween.
3. The medical balloon of item 1 or item 2, wherein the at least one cellulose fiber extends over the first and second tapered portions and the barrel portion of the base balloon layer.
4. The medical balloon of any of items 1-3, wherein the at least one cellulose fiber extends substantially parallel to a longitudinal axis of the base balloon layer.
5. The medical balloon of any of items 1-4, wherein the at least one cellulose fiber extends radially around the base balloon layer.
6. The medical balloon of item 1, wherein the at least one cellulose fiber comprises a single continuous fiber extending substantially parallel to a longitudinal axis of the base balloon layer and radially around the base balloon layer.
7. The medical balloon of any of items 1-6, further including at least one silk fiber.
8. The medical balloon of any of items 1-7, wherein the at least one cellulose fiber further comprises silk proteins.
9. The medical balloon of any of items 1-8, wherein the at least one cellulose fiber comprises cellulose nano fibers.
10. The medical balloon of any of items 1-8, wherein the at least one cellulose fiber comprises hydrodynamically focused cellulose nano fibers.
11. The medical balloon of any of items 1-8, wherein the at least one cellulose fiber is attached to the base balloon layer by an adhesive.
12. The medical balloon of any of items 1-8, wherein the at least one cellulose fiber is attached to an outer surface of the base balloon layer.
13. The medical balloon of any of items 1-12, wherein an outer layer, such as a polymer film or spray coating, is applied over the at least one cellulose fiber.
14. A medical balloon comprising:
15. The medical balloon of item 14, further including at least one hoop fiber over the at least one longitudinal fiber, the at least one hoop fiber comprising cellulose.
16. The medical balloon of item 15, wherein the at least one longitudinal fiber and at least one hoop fiber form part of a single continuous fiber.
17. The medical balloon of any of items 14-16, wherein the at least one longitudinal fiber further comprises silk proteins.
18. The medical balloon of any of items 14-17, further including at least one silk fiber.
19. The medical balloon of any of items 14-18, wherein the at least one longitudinal fiber comprises cellulose nano fibers.
20. The medical balloon of any of items 14-19, wherein the at least one longitudinal fiber is formed of hydro-dynamically focused cellulose nano fibers.
21. The medical balloon of any of items 14-20, wherein the at least one longitudinal fiber is attached to the base balloon by an adhesive.
22. A method of forming a medical balloon, comprising:
23. The method of item 22, wherein the applying step comprises applying the at least one cellulose fiber along a longitudinal axis of the base balloon.
24. The method of item 22 or item 23, wherein the applying step comprises wrapping the cellulose fiber around the base balloon.
25. The method of any of items 22-24, wherein the applying step comprises adhesively attaching the at least one cellulose fiber to the base balloon.
As used herein, the following terms have the following meanings:
“A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.
“About,” “substantially,” or “approximately,” as used herein referring to a measurable value, such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of +/−20% or less, including +/−10% or less, +/−5% or less, +/−1% or less, and +/−0.1% or less of and from the specified value, in so far such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier “about” refers is itself also specifically disclosed.
“Comprise”, “comprising”, and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.
Although the invention has been described in conjunction with specific embodiments, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it embraces all such alternatives, modifications, and variations that fall within the appended claims' spirit and scope. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, the identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present disclosure.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/082,077, the disclosure of which is incorporated by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/051640 | 9/23/2021 | WO |
Number | Date | Country | |
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63082077 | Sep 2020 | US |