Medtronic Ablation Frontiers LLC

Neil Purcell

Jeremy David Dando

John B Horrigan

Jeffrey J Jannicke

Michael E Kapust

A method of producing a multi-lumen elongate body for a medical device. Unlike known methods requiring a solid core of material inserted into each lumen to maintain patency of the lumens during manufacture, the present method obviates the need for a solid core within one or more minor lumens, which saves cost and production complexity. One or more material overlay and mesh overlay steps may be used to produce the multi-lumen elongate body, but only the main lumen may include a solid core therein during all manufacturing steps. The one or more minor lumens may each be defined by a lumen tube having a sufficient stiffness to withstand external pressure during all manufacturing steps without the need for a solid core within.

Multi-lumen device with non collapsable minor lumen

A method and system for manufacturing a multi-lumen device that includes extruding a first layer of material to form an elongate body with a first lumen and a second lumen, the elongate body having a length of at least 100 feet, depositing a mesh layer over the first layer of material along the entire length of the elongate body, and extruding a second layer of material over the mesh layer along at least a portion of the length of the elongate body. The length of at least 100 feet may be considered a first length, the method further comprising cutting the elongate body into a plurality of shortened elongate bodies having a usable length, such as between approximately two feet and approximately six feet.

Methods of manufacturing a multi-lumen device

A method of dimensionally stabilizing a lumen of a multi-lumen device during manufacture wherein one or more minor lumens may contain a fluid that maintains patency of the one or more minor lumens without the need for a solid core within. The at least one second lumen tube may be in fluid communication with a fluid source during the manufacturing process, such as during extrusion and/or mesh overlay steps. Preventing collapse of the one or more minor lumens during manufacture using a fluid instead of a solid core allows the lumens to have any of a variety of shapes and configurations that would be difficult, cost prohibitive, or impossible for a solid core to be used. Also, obviating the need for a solid core within one or more lumens reduces cost and production complexity. The fluid may be a non-compressible liquid or a pressurized gas.

Growing community of inventors

Galway, Ireland

Neil Purcell