U.S. patent application number 09/343917 was filed with the patent office on 2001-09-20 for method of shaping structures with an overcoat layer including female urinary catheter.
Invention is credited to CONWAY, ANTHONY J., CONWAY, PHILIP J., FRYAR, RICHARD D. JR..
Application Number | 20010022411 09/343917 |
Document ID | / |
Family ID | 27569586 |
Filed Date | 2001-09-20 |
United States Patent
Application |
20010022411 |
Kind Code |
A1 |
CONWAY, ANTHONY J. ; et
al. |
September 20, 2001 |
METHOD OF SHAPING STRUCTURES WITH AN OVERCOAT LAYER INCLUDING
FEMALE URINARY CATHETER
Abstract
A method of shaping polymeric structures by coating a support
structure with a bond-preventing agent to attain a particular shape
and subsequently coating the shaped structure of the
bond-preventing agent with a polymeric bonding composition is
provided. Such shaped polymeric structures can have one or more
cavities which can be fluid-filled or gel-filled. Also provided is
a hand-actuating retention female urinary catheter having an inner
tube and an outer overcoat layer encircling the tube with an
elastomeric collar with a shroud. A cavity containing a fluid is
interposed between the tube and the overcoat layer. The cavity
includes a balloon portion and a reservoir portion. The shroud
encircles the reservoir section to inhibit the ballooning of the
reservoir section when the reservoir section is squeezed to force
fluid from the reservoir portion to the balloon portion through the
sleeve portion of the cavity. The overcoat layer and the collar
with a shroud are made of soft resilient material.
Inventors: |
CONWAY, ANTHONY J.;
(CHATFIELD, MN) ; CONWAY, PHILIP J.; (CHATFIELD,
MN) ; FRYAR, RICHARD D. JR.; (CHATFIELD, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Family ID: |
27569586 |
Appl. No.: |
09/343917 |
Filed: |
June 30, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09343917 |
Jun 30, 1999 |
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08892325 |
Jul 14, 1997 |
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08892325 |
Jul 14, 1997 |
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08285026 |
Aug 2, 1994 |
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5670111 |
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08285026 |
Aug 2, 1994 |
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07827936 |
Jan 29, 1992 |
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5360402 |
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07827936 |
Jan 29, 1992 |
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07809281 |
Dec 13, 1991 |
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5261896 |
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07809281 |
Dec 13, 1991 |
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07489462 |
Mar 6, 1990 |
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07489462 |
Mar 6, 1990 |
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07487422 |
Mar 1, 1990 |
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5098379 |
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07487422 |
Mar 1, 1990 |
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07462832 |
Jan 10, 1990 |
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5137671 |
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Current U.S.
Class: |
264/221 ;
264/303; 264/304; 264/317 |
Current CPC
Class: |
A61M 25/0009 20130101;
A61L 29/085 20130101; A61L 29/06 20130101; B29C 41/22 20130101;
A61M 25/0017 20130101; B29C 2791/001 20130101; B29C 41/14 20130101;
A61M 25/1027 20130101; A61M 2210/1092 20130101; A61M 25/1036
20130101; B29K 2083/00 20130101; A61M 25/0045 20130101; C08L 83/04
20130101; A61M 2025/0062 20130101; B29L 2031/7542 20130101; A61M
2025/1075 20130101; B29K 2083/005 20130101; A61M 2025/0056
20130101; A61M 2025/1031 20130101; A61L 29/06 20130101; A61M
2205/0238 20130101; A61M 25/10 20130101; A61M 25/1011 20130101 |
Class at
Publication: |
264/221 ;
264/303; 264/304; 264/317 |
International
Class: |
B29C 033/40; B29C
033/64; B29C 041/14 |
Claims
What is claimed is:
1. A method of shaping a structure having an overcoat layer, said
method comprising: (a) forming a shaped structure of a
bond-preventing agent; and (c) subsequently coating the shaped
structure of a bond-preventing agent with a liquid composition to
form a shaped overcoat layer, wherein the shape of the overcoat
layer results from the shape of the shaped structure of a
bond-preventing agent.
2. The method of claim 1 wherein the shaped structure includes a
first section, a second section, and a third section, said second
section interconnecting and disposed between said first and third
sections, said second section having a larger transverse
cross-sectional area than that of said first and that of said third
section.
3. The method of claim 1 further comprising replacing the
bond-preventing agent with a fluid after forming the overcoat layer
so as to form a fluid-filled cavity encircled by said overcoat
layer.
4. The method of claim 1 wherein the shaped structure of a
bond-preventing agent is formed by providing an inner piece and
shaping a residual coating of the bond-preventing agent on an outer
surface of the inner piece to a desired shape, wherein said coating
of said bond-preventing agent has a varying thickness on different
portions of an outer surface of said inner piece.
5. The method of claim 4 wherein the step of shaping a residual
coating of a bond-preventing agent comprises coating portions of an
outer surface of said inner piece with a bond-preventing agent in a
plurality of dipping steps, wherein the inner piece is immersed
into the bond-preventing agent to a desired depth for a desired
length of time, and subsequently removed therefrom, wherein the
desired depth and the desired length of time for each of the
plurality of dipping steps is prescribed so that a residual coating
of bond-preventing agent remains on portions of the inner piece
following said plurality of dipping steps, said residual coating
having varying thickness as a result of variation between the depth
of any two of said plurality of dipping steps and the speed the
bond-preventing agent is removed from the inner piece.
6. The method of claim 5 wherein the step of coating with a
bond-preventing agent includes stripping the inner piece, wherein
the inner piece is immersed in a stripping fluid to a desired depth
for a desired length of time following any of said plurality of
dipping steps in order to remove at least a portion of the
bond-preventing agent from the outer surface of the inner
piece.
7. The method of claim 6 wherein the stripping fluid is removed
from the inner piece at a varying speed in a dipping step effective
to strip a portion of the bond-preventing agent to result in a
gradually varying thickness in the coating of the bond-preventing
agent on the inner piece.
8. The method of claim 4 wherein the step of subsequently coating
includes dipping the inner piece and the residual coating of
bond-preventing agent in the polymeric bonding composition.
9. The method of claim 4 wherein a portion of the shaped structure
of a bond-preventing agent is not coated with the polymeric bonding
composition to result in a polymeric structure having an inner
piece integrally connected to an outer piece at one end of said
inner piece, said outer piece encircling at least a portion of said
inner piece to define a recess in cooperation with said inner piece
at said attached end, wherein peripheral portion of the outer piece
is not attached to the inner piece.
10. The method of claim 4 wherein the inner piece is made by
dipping a mandrel in a liquid composition.
11. The method of claim 10 wherein the liquid composition is a
polymeric bonding composition and the liquid composition for the
step of subsequent coating is a polymeric bonding composition.
12. The method of claim 11 wherein the polymeric bonding
compositions contain uncured silicone rubber.
13. A method of shaping a structure having an overcoat layer, said
method comprising: (a) dipping a mandrel in a first liquid
composition to result in a coating on the mandrel; (a) coating
portions of an outer surface of said coating on the mandrel with a
bond-preventing agent in a plurality of dipping steps to form a
residual coating of a desired shape; and (c) subsequently coating
the shaped residual coating of the bond-preventing agent with a
second liquid composition to form a shaped overcoat layer, wherein
the shape of the overcoat layer results from the shape of the
shaped structure of a bond-preventing agent.
14. The method of claim 13, wherein the coating on the mandrel is
immersed into the bond-preventing agent to a desired depth for a
desired length of time, and subsequently removed therefrom, wherein
the desired depth and the desired length of time for each of the
plurality of dipping steps is prescribed so that a residual coating
of bond-preventing agent remains on portions of the inner piece
following said plurality of dipping steps, said residual coating
having varying thickness as a result of variation between the depth
of any two of said plurality of dipping steps and the speed the
bond-preventing agent is removed from the inner piece.
15. The method of claim 13, wherein the first liquid composition is
a polymeric bonding composition.
16. The method of claim 15, wherein the second liquid composition
contains uncured silicone rubber.
17. The method of claim 13, wherein the second liquid composition
is a polymeric bonding composition.
18. The method of claim 13 wherein the structure having an overcoat
layer has mutiple cavities encircled by the overcoat layer.
19. A method of shaping a structure having an overcoat layer on an
inner structure with a lumen, said method comprising: (a) dipping a
mandrel in a first polymeric bonding composition to result in a
coating on the mandrel; (a) coating portions of an outer surface of
said coating on the mandrel with a bond-preventing agent in a
plurality of dipping steps to form a residual coating of a desired
shape by immersing the coating on the mandrel into the
bond-preventing agent to a desired depth for a desired length of
time, and subsequently removed therefrom, wherein the desired depth
and the desired length of time for each of the plurality of dipping
steps is prescribed so that a residual coating of bond-preventing
agent remains on portions of the inner piece following said
plurality of dipping steps, said residual coating having a varying
thickness as a result of variation between the depth of any two of
said plurality of dipping steps and the speed the bond-preventing
agent is removed from the inner piece; (c) subsequently coating at
least a portion of the shaped residual coating of the
bond-preventing agent with a second polymeric bonding composition
to form a shaped overcoat layer, wherein the shape of the overcoat
layer results from the shape of the shaped structure of a
bond-preventing agent; and (d) subsequently replacing the
bond-preventing agent coated by the second polymeric bonding
composition with a fluid.
20. The method of claim 19 wherein the fluid is mineral oil.
21. A hand-actuated retention catheter, comprising: a tube having
outer and inner surfaces, the inner surface defining an inner
lumen, an overcoat layer encircling the tube, the overcoat layer
having interior and exterior surfaces, a cavity interposed between
the tube and the overcoat layer, said cavity encircling the tube
and being defined by portions of the outer surface of the tube in
cooperation with portions of the interior surface of the overcoat
layer, a fluid within the cavity, a restriction means and a means
for limiting the lateral ballooning of the reservoir section;
wherein the overcoat layer includes an expandable, resilient
balloon section proximate a distal end, a fluid reservoir section
proximal thereto, and a catheter sleeve section interconnecting
said balloon section and said reservoir section, each of the
sections corresponds to a corresponding section of the catheter;
the cavity including a balloon portion, a fluid reservoir portion,
and a catheter sleeve portion thereof interconnecting said balloon
portion and said reservoir portion; the catheter sleeve section of
the overcoat layer defines a narrowing in cavity through which
fluid passing from the fluid reservoir portion and the balloon
portion thereof must pass; the restriction means encircling the
sleeve section to restrict the flow of fluid from the balloon
portion to the reservoir portion of the cavity, and the means for
limiting lateral ballooning encircling the reservoir section to
limit the lateral ballooning thereof.
22. The catheter of claim 21 wherein the restricting means is a
restrict collar and the means for limiting lateral ballooning is a
cylindrical shroud.
23. The catheter of claim 22 wherein the collar and the shroud are
unitarily and integrally connected.
24. The catheter of claim 22 wherein the collar and the shroud are
made of silicone rubber.
25. The catheter of claim 21 wherein the restriction means and the
means for limiting lateral ballooning are capable of being removed
from the catheter by being pulled to slip along the catheter in the
proximal direction.
26. The catheter of claim 21 wherein the tube and the overcoat are
made with a silicone rubber.
27. The catheter of claim 26 wherein the silicone rubber overcoat
has 20-40 durometer hardness and a wall thickness of 0.1-1 mm.
28. The catheter of claim 26 further comprising a stylet, a portion
of which is removably disposed in the inner lumen of the tube for
urging the catheter during deployment thereof.
29. A method of catheterizing a patient, comprising: urging a
hand-actuated retention catheter into a body passageway from a
space exterior thereto, said catheter comprising a tube having
outer and inner surfaces, the inner surface defining an inner
lumen, an overcoat layer encircling the tube, the overcoat layer
having interior and exterior surfaces, a cavity interposed between
the tube and the overcoat layer, a fluid within the cavity, and a
restriction collar with a shroud; said cavity encircling the tube
and being defined by portions of the outer surface of the tube in
cooperation with portions of the interior surface of the overcoat
layer, wherein the overcoat layer includes an expandable, resilient
balloon section, a fluid reservoir section proximal thereto, and a
catheter sleeve section interconnecting said balloon section and
said reservoir section, each of such sections corresponds to a
corresponding section of the catheter; the overcoat layer being
joined to the outer surface of the tube at distal and proximal ends
of the cavity; the cavity including a balloon portion, a fluid
reservoir portion, and a catheter sleeve portion thereof
interconnecting said balloon portion and said reservoir portion;
wherein the catheter sleeve section of the overcoat layer defines a
narrowing in cavity through which fluid passing from the fluid
reservoir portion and the balloon portion thereof must pass; the
collar being encircling the sleeve section to restrict flow in the
sleeve portion of the cavity and the shroud encircling the
reservoir section to limit the lateral ballooning thereof;
compressing the shroud-encircled reservoir section to force fluid
through the sleeve portion to the balloon portion of the cavity;
and subsequently removing the collar with the shroud from the
catheter to enable withdrawal of the catheter from the body
passageway.
30. The method of claim 28 wherein the step of urging the catheter
is a result of pushing a stylet inserted into the lumen of the
inner tube.
Description
CROSS-REFERENCE TO OTHER APPLICATIONS
[0001] The present application is a continuation-in-part
application of co-pending U.S. patent application Ser. No.
07/827,936, filed Jan. 29, 1992, which is a continuation-in-part
application of co-pending U.S. patent application Ser. No.
07/809,281, filed Dec. 13, 1991, which is a continuation-in-part of
co-pending U.S. patent application Ser. No. 07/489,462, filed Mar.
6, 1990, which is a continuation-in-part application of co-pending
U.S. patent application Ser. No. 07/487,422, filed Mar. 1, 1990,
which is a continuation-in-part application of co-pending U.S.
patent application Ser. No. 07/462,832, filed Jan. 10, 1990, the
disclosures of which are each incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to methods of making shaped
structures with an overcoat layer. The present invention also
relates to making polymeric structures such as cannulas and
catheters. In addition, the present invention also relates to
urinary catheters and most particularly to female urinary
catheters.
BACKGROUND OF THE INVENTION
[0003] Many structures, for example, hoses, condoms, gloves,
cannulas, catheters, and the like, are made of a polymeric material
(e.g., latex, silicone). Such polymeric structures may have various
shapes, e.g., sections with different diameters, contours, etc. In
addition, various cavities might be present in the structures, some
of which might contain fluids of various types. A traditional way
to form such structures is by adhesively affixing parts together so
that the outer coat can attain the desired shape. However, these
traditional methods do not lend themselves to mass production and
are labor intensive. Some shapes are extremely difficult if not
impossible to make by traditional adhesive methods. likewise,
traditional methods of making shaped structures of nonpolymeric
substances, such as inorganic materials, with cavities therein
sometimes have similar difficulties.
[0004] An example of a shaped polymeric structure is a catheter.
Most catheters are cannulas or tube like devices which are inserted
into a portion of a person's body in order to transport fluids,
such as liquids, gases, and sometimes semisolid material, in or out
of that particular portion of the body. For instances, urinary
catheters are used to transport urine collected in the bladder out
of the body via the urinary tract. Other types of catheters such as
gastronomy devices, transport fluids into and out of various
segments of the gastrointestinal system, primarily the stomach.
[0005] In order to provide a means of retaining the catheter within
the body, inflatable bag catheters were introduced many years ago.
Subsequently, Foley (U.S. Pat. No. 3,409,016) taught an elongated
catheter having a secondary lumen for inflating a retention balloon
at a distal end of the catheter once the distal end is positioned
within the body. Generally, the "distal end" is the end of the
catheter that is first introduced into the body when the catheter
is being positioned within the body and the "proximal end" is the
end opposite the distal end. Such catheters are now generally
referred to as "Foley" catheters out of respect for the
contribution made by Dr. Foley. Because of the variation in needs
of patients, improvements on Dr. Foley's contribution to the
catheter art are continually being made. These improvements
sometimes result in cannulas or catheters that have shapes quite
different from that of the device originally designed by Dr.
Foley.
[0006] Traditionally, Foley catheters are made by a process which
includes slipping a band of cured rubber over a double lumen latex
rubber tubing and affixing the band on the double lumen tubing by
dipping the band and the tubing in a suspension of latex to form an
outer layer. The cost of manufacturing traditional Foley catheters
has been influenced by the need to use a significant amount of hand
labor to make the devices, especially the silicone rubber Foley
catheters. Moreover, in many cases where a polymeric structure such
as a catheter is to have a cavity filled with fluid, traditional
manufacturing methods can not be used. It will be appreciated that
using such traditional methods to make catheters that have a
variety of shapes and sizes of cavities between the tubing and the
outer layer would add significantly to the cost of production and
pose limitations on the variety of catheters that can be made.
Reducing the amount of hand labor in the manufacture of such
devices may reduce the cost of such devices so as to provide a more
affordable product to the consumer and to render such a product
more competitive in the market place.
[0007] The same problem of high labor cost and limitation of the
variety of shapes is similarly encountered in the manufacture of
other shaped structures such as gastronomy devices, condom, and
hoses. The present invention provides a method of making polymeric
structures which offers substantial advantages over traditional
manufacturing methods. In addition, the present invention provides
a simple, easily applied, comfortable disposable catheter for
incontinent females.
SUMMARY OF THE INVENTION
[0008] Method of Making Polymeric Structures The present invention
relates to making a shaped structure by coating at least a portion
of a shaped structure of a bond-preventing agent with a liquid
composition, e.g. a polymeric bonding composition such as one that
contains uncured silicone rubber, to attain an overcoat layer of a
desired shape. The shaped structure of a bond-preventing agent can
be formed by coating over an outer surface of a support structure,
for example, a mandrel or a tube, to form a residual coating of a
particular shape.
[0009] One embodiment of the present invention relates to dipping a
mandrel in a liquid composition, such as polymeric composition to
form an inner piece (or structure) over a surface of a mandrel,
applying and shaping a residual coating of a bond-preventing agent
over the outer surface of the inner piece, and coating at least a
portion of the structure resulting from the previous steps with a
liquid composition to form a shaped structure having an overcoat on
an inner piece.
[0010] Another embodiment of the present invention relates to a
method of making a polymeric structure in accordance with one of
the above methods wherein a fluid-filled cavity is formed between
an inner polymeric layer and an outer polymeric layer.
[0011] Yet another embodiment of the present invention relates to a
method of making a polymeric structure in accordance with one of
the above methods wherein an outer polymeric layer only partially
encapsulates an inner polymeric layer such that only one end of the
outer polymeric layer is attached to the polymeric structure. This
method might be utilized to form a polymeric structure having an
umbrella-like structure.
[0012] It will be appreciated that shaped structures of varying
shapes can be formed by the present invention. The shaped
structures formed by the present invention might be hollow,
liquid-filled, gel-filled, etc. and/or might include a solid piece
as well as combinations thereof.
[0013] The coating of the bond-preventing agent can have a varying
thickness on different portions of an outer surface of the inner
piece. The coating of the bond-preventing agent remaining on the
inner piece before the coating of the liquid composition is herein
referred to as the "residual coating." The shape of the overcoat
layer results from the varying thicknesses of the residual coating
of the bond-preventing agent.
[0014] In one embodiment, the forming of residual coating of
varying shapes can be done by coating portions of an outer surface
of the inner piece with a bond-preventing agent in a plurality of
dipping steps by immersing the inner piece into the bond-preventing
agent to a desired depth for a desired length of time and
subsequently removing the inner piece from the bond-preventing
agent. The desired depth and the desired length of time for each of
the plurality of dipping steps is selected so that a residual
coating of bond-preventing agent of desired thickness and shape
remains on portions of the inner piece following the plurality of
dipping steps. The residual coating has a specific shape as a
result of the variation between the depth of any two of the
plurality of dipping steps, the number of dipping steps, the length
of time between any two of the plurality of dipping steps, and the
varying speeds of withdrawal from the liquids in dip tanks. By
appropriate coating and stripping sequence, the bond-preventing
agent can be sculpted to result in desired, symmetrical shapes much
as the shapes achievable using a lathe. The sculpted residual
coating can have varying thickness, curves, and angles, and
therefore a specific, desired shape. By subsequently coating the
residual coating of bond-preventing agent, which coats the inner
piece, with a polymeric bonding composition, a shaped overcoat
layer is formed wherein the shape of the overcoat layer results
from the varying shapes of the residual coating. Also, other shaped
structures, such as a bullet-shaped, molded, solid polymeric tip
can be added to the inner piece before the formation of the
overcoat layer to attain a desirable shape for a particular part of
the shaped structure with the polymeric overcoat. As used herein,
two structures of similar shapes but having unequal ratios of
dimensions in the two structures are considered to have different
shapes. For example, annular cylinders with the same inside
diameter and length but different outside diameters are not
considered to have the same shape. As used herein, the residual
coating is still considered "a residual coating" even if it is not
continuous over two or more portions of the inner piece as long as
the coating is not radially separated into layers by a different
intervening substance.
[0015] In one embodiment, the step of coating the inner piece with
the bond-preventing agent can include a step of stripping the inner
piece by immersing the inner piece in a stripping fluid to a
desired depth for a desired length of time following any of the
plurality of dipping steps in order to remove at least a portion of
the bond-preventing agent from the outer surface of the inner
piece. After the stripping step, the inner piece can be dipped into
the bond-preventing agent again to form another coat of the
bond-preventing agent on a selected portion of the inner piece if
desired. The portion of the inner piece that has been stripped can
be dipped in a bond-preventing agent to form a coating. If desired,
to form a particular shape, both the stripped portion of the inner
piece and a portion of the bond-preventing agent coating that
remains on the inner piece can be dipped into the bond-preventing
agent. The thickness of the bond-preventing agent coating can be
increased by repeating the dipping and removal steps.
[0016] In one embodiment the inner piece might be a simple
cylindrical mandrel. Such a mandrel can be used for making, for
example, a polymeric hose or tube. In another embodiment, the inner
piece can be a polymeric tube. Such a polymeric tube can either be
purchased or formed by a process that comprises dipping a mandrel
in a polymeric bonding composition. Such a polymeric tube typically
can have a closed tip at one end.
[0017] In an alternate embodiment, a method of mass producing
polymeric structures is provided. This method comprises providing a
plurality of mandrels, each mandrel having the aforementioned
elements; coating portions of an outer surface of the mandrel with
a bond-preventing agent in a plurality of dipping steps by
immersing the mandrel into the bond-preventing agent to a desired
depth for a desired length of time and removing therefrom,
stripping portions of the bond-preventing agent by dipping in a
stripping agent, and alternately dipping and stripping to achieve
the desired shape, and then coating the mandrel, now at least
partially coated with the bond-preventing agent, with a polymeric
bonding composition to form a shaped overcoat layer.
[0018] The present invention enables the production of structures,
such as polymeric structures, with a great reduction of hand labor,
which not only is costly, but also contribute to inconsistent
results. The present invention can be adapted to produce structures
of a wide variety of sizes and shapes by varying the thickness of
the residual coating of the bond-preventing agent. The variation of
the thickness of the residual coating of the bond-preventing agent
can be designed to result in a structure with an overcoat of a
specific shape. Because of the variation of need for different
types of structures, e.g., simple Foley balloon catheters for
placement in the urinary tract, balloon catheters with cavities
containing bactericidal agents, catheters with cylindrical sleeve
with a lubricant, and the like, a variety of shapes are needed for
such structures.
[0019] The present invention also provides the advantage of
obviating the need to machine a solid (such as metallic) mandrel of
a specific shape for making a structure with overcoat of that
specific shape. Moreover, often such mandrels cannot be used to
make overcoat layers of complex shapes. For example, once a
polymeric overcoat layer is formed on a mandrel with a shape as
that of the inner tube and the coating of bond-preventing agent
shown in FIG. 11A, it is very difficult to remove the overcoat
layer from the mandrel. Although injection molding using very
expensive cavity molds may be used to make structures with overcoat
layers, the resulting overcoat layer has "part lines" where the
mold is opened to allow removal of the molded structure. Such
shortcomings can be overcome by using the method of the present
invention.
[0020] In the making of polymeric structures using the method of
the present invention, the outside dimensions (e.g. diameter) can
be made with more consistency than in similar products made by
traditional manufacturing methods, such as affixing balloon
portions to the outer surface of a tube by hand. The method of the
present invention makes possible the highly automated process of
fabricating polymeric structures with shaped gel-filled, liquid
filled cavities, especially those with a soft, outer, elastomeric
layer that can conform to the contour of a surface in contact
therewith.
Female Catheter
[0021] The present invention further relates to a female catheter
having an inner tube and an outer layer encircling the tube. In an
embodiment of a female catheter of the present invention, a cavity
is interposed between the tube and overcoat layer. A fluid is
contained in the cavity. The cavity is enlarged at two spaced apart
locations along the inner tube so as to form a balloon portion and
a reservoir portion connected by a sleeve section. The sleeve
portion is in fluid communication with the balloon and reservoir
portions such that fluid is capable of flowing between these
portions whereby the size of the balloon and reservoir portions can
vary depending on the amount of fluid in each of the portions. The
reservoir portion at a proximal end of the catheter is normally in
an enlarged state although it is readily compressible into a
compressed state. The overcoat has reservoir, sleeve, and balloon
sections corresponding to the respective portions of the
cavity.
[0022] In one embodiment of the invention, a collar encircles the
sleeve section of the overcoat to restrict fluid flow between the
various portions of the cavity through the sleeve portion and a
shroud encircles the reservoir section of the overcoat to limit
lateral ballooning thereof when the reservoir section is compressed
by forces not completely enveloping the reservoir section.
[0023] In another embodiment of the invention, a female catheter as
described above further includes a removable stiff plastic stylet
inserted into the inner tube to facilitate insertion of the
catheter.
[0024] The present invention provides a simple, comfortable,
disposable female catheter which can be manually inserted by
incontinent females and is hand-actuated to achieve retention in a
body passageway.
[0025] In using one embodiment of the present invention, a distal
end of the catheter is inserted into the urethral tract by exerting
force on the stylet. Upon emergence into the bladder of the first
balloon section at the distal end of the catheter, the fluid in the
reservoir portion of the cavity can be forced through the sleeve
portion into the balloon portion by compressing the reservoir
section of the overcoat layer to inflate the balloon section, thus
retaining the catheter in the body passageway. The sleeve section
of the catheter can be made to conform to the urethral tract walls
providing a leak proof fit. It will be appreciated, that the
catheter can allow the inner drain tube to twist and move within
the soft outer layer. An elastomeric shroud encircles the reservoir
section of the overcoat to limit the lateral ballooning thereof. An
elastomeric collar restricts the sleeve section to prevents fluid
from being forced back from the balloon portion to the reservoir
portion of the cavity during normal activities of the user.
[0026] This catheter has the advantage that a limited amount of
fluid is confined in the cavity, and therefore the balloon cannot
be overinflated. The utilization of a stylet facilitates the
insertion of the catheter. The length of the catheter can be
designed such that as the reservoir section of the catheter is
proximate the outside entrance of the urethra, the balloon section
is disposed in the bladder proximate the entrance to the urethra
effective to prevent fluid communication between the urethra and
the bladder. The catheter can be made with soft material. Because
the overcoat layer of the catheter gently conforms to the urethral
wall, irritation to the body tissue is greatly reduced, thus
lowering the risk of infection. Further, when the catheter is to be
withdrawn, the restriction on the sleeve section can be easily
removed by pulling the shroud and the collar from the catheter.
Therefore, the retention catheter can be easily inserted,
positioned, and withdrawn by the patient without the aid of a
health professional.
[0027] In one embodiment, the fluid in the catheter is mineral oil.
The mineral oil migrates to an outer surface of a silicone rubber
outer layer to provide a lubricated, low friction surface.
[0028] The present invention, its advantages and other objects
obtained by its use are also illustrated by the drawings, and the
accompanying descriptive material, in which the preferred
embodiments of the present invention are described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] In the drawings, in which like and primed reference numerals
indicate corresponding parts throughout the several views,
[0030] FIG. 1 is a transverse schematic view of a retention
catheter made in accordance with the present invention in
cross-section;
[0031] FIG. 2 is a transverse schematic view of a tube in partial
cross-section which can be used to make the retention catheter
shown in FIG. 1;
[0032] FIG. 3 is a side view of a mandrel for making an embodiment
of the retention catheter of the present invention;
[0033] FIG. 4 is a cross-sectional view of the mandrel shown in
FIG. 3 when secured on a moveable pallet, and following the
addition of a coating of a polymeric bonding composition to the
mandrel;
[0034] FIG. 5 is a cross-sectional view similar to that shown in
FIG. 4 but after the addition of a coating of a removable
bond-preventing agent to a portion of the outer surface of the
tube;
[0035] FIG. 6 is a view similar to that shown in FIG. 5, but after
the addition of an additional thickness of the removable
bond-preventing agent to the outer surface of the tube;
[0036] FIG. 7 is a transverse schematic view of the tube shown in
FIGS. 4-6, but showing only the removable bond-preventing agent in
cross-section and only after a portion thereof has been removed
from the outer surface of the tube;
[0037] FIG. 8 is a transverse schematic view similar to that shown
in FIG. 7, but after an additional coating of removable
bond-preventing agent has been added to the outer surface of the
tube;
[0038] FIG. 9 is a transverse schematic view similar to that shown
in FIG. 8, but after a further thickness of removable
bond-preventing agent is added to the outer surface of the
tube;
[0039] FIG. 10 is a transverse schematic view similar to that shown
in FIG. 9, but after a portion of the removable bond-preventing
agent on the outer surface of the tube is removed;
[0040] FIG. 11A is a transverse schematic view similar to that
shown in FIG. 10, but showing an overcoat layer on the removable
bond-preventing agent in cross-section on the outer surface of the
tube;
[0041] FIG. 11B is a view similar to FIG. 11A except that the
bond-preventing agent has been generally replaced by mineral
oil;
[0042] FIG. 12 is a schematic illustration of apparatus used to
automate the production of retention catheters in accordance with
the present invention similar to that shown in FIG. 1;
[0043] FIGS. 13A, 13B and 13C are flow charts disclosing steps of
methods of manufacturing retention catheters in accordance with the
present invention;
[0044] FIG. 14 is a schematic representation of the automated
controls for the apparatus shown in FIG. 12, used to automate the
production of retention catheters made in accordance with the
present invention;
[0045] FIG. 15 is a transverse schematic view similar to that shown
in FIG. 11B, but showing another embodiment with transition
portions in the distal ends of balloon section and the reservoir
section;
[0046] FIG. 16 is a transverse schematic view similar to that shown
in FIG. 15, but showing another embodiment with transition portions
in both proximal and distal ends of the balloon section and the
reservoir section;
[0047] FIG. 17 is a transverse schematic view of showing a
cross-section of a catheter of FIG. 1 when being inserted in an
urethral tract of a patient, prior to the balloon section emerging
into the bladder;
[0048] FIG. 18 is a view similar to that shown in FIG. 17, but
showing the balloon section of the catheter having emerged into the
bladder and is being inflated;
[0049] FIG. 19 is a transverse schematic view of another embodiment
of an retention catheter in accordance of the present invention,
similar to the view of FIG. 1;
[0050] FIG. 20 is a cross-sectional view of the retention catheter
shown in FIG. 19 as seen generally from the line 20-20 thereof;
[0051] FIG. 21 is an isometric view of another embodiment of a
shaped structure made by the method according to the present
invention; and
[0052] FIG. 22 is a cross-sectional view of yet another embodiment
of a shaped structure made by the method according to the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0053] The present method can be used to make many different shaped
structures with a shaped overcoat. Various structures, ranging from
simple structures, such as hoses, balloons, and the like, to more
complex-shaped structures, such as condoms, urinary catheters with
many portions of different geometries, and the like, can be made in
with the method of the present invention.
[0054] In a preferred embodiment, the method of shaping a structure
having a polymeric overcoat layer can be accomplished by first
shaping a structure of bond-preventing agent and then coating the
shaped structure of a bond-preventing agent with a polymeric
bonding composition to form a shaped overcoat layer. The shaped
structure of a bond-preventing agent can be formed by coating the
outer surface of an inner piece, such a mandrel or a tube with a
bond-preventing agent to result in a residual coating with a
desired shape. The coating of the bond-preventing agent can have a
varying thickness on different portions of an outer surface of the
inner piece, which results in a particular shape in the shaped
structure having a polymeric overcoat. The inner piece, if it has a
lumen, is preferably made by a dipping process. Similarly, the
residual coating and the overcoat layer are preferably made by
respective dipping steps in appropriate liquid materials.
[0055] An embodiment of a female urinary catheter in accordance
with of the principle of the present invention is shown in FIG. 1.
The catheter can be made with the above method or by other
appropriate methods. This catheter 5 has an inner lumen 8 defined
by an inner surface 10 of a tube 12. An overcoat layer 14 encircles
the tube 12 to define a cavity 16. The cavity 16 contains a fluid
18 and has a fluid reservoir portion (or simply "reservoir
portion") 22 and a balloon portion 24 interconnected by a catheter
sleeve portion (or simply "sleeve portion") 26 such that fluid 18
can pass between the fluid reservoir portion 22 and the balloon
portion 24 via the catheter sleeve portion 26.
[0056] Such a catheter is a "hand-actuated retention catheter" and
is useful in that a restriction means such as a restriction disc,
clamp, elastomeric collar, or elastomeric collar 50 with a shroud
51, can be used to encircle the sleeve portion 26 to restrict fluid
from flowing from the balloon portion 24 to the reservoir portion
22 after the balloon portion has been expanded by squeezing the
reservoir section of the overcoat (or "squeeze bulb") by hand, thus
maintaining the balloon portion 24 in an expanded state to retain
the catheter in the desired location in a body passageway. The
restriction means is preferably an elastomeric collar 50 with a
shroud 51 for limiting the lateral bulging of the squeeze bulb when
the squeeze bulb 30 is compressed, for example, between the thumb
and the index finger. The restriction means can be loosened or
removed to allow fluid to flow from the balloon portion when
desired, thus deflating the balloon portion 24 to facilitate
removal of the catheter from the body passageway. Preferably, the
catheter 5 further includes a stylet for deploying the catheter in
the urinary tract.
Method of Making Polymeric Shapes
[0057] To illustrate the application of the present method to
forming a shaped, polymeric structure, the embodiment of making a
female urinary catheter in accordance of the present invention is
described in the following. This embodiment of a female urinary
catheter (see FIG. 1) has various portions with different
diameters. Referring now to FIG. 2, a resilient, polymeric tube 12
with a closed end, preferably a silicone rubber tube 12, is to be
formed first. Although the preferred material for the tube 12 is
medically acceptable, silicone rubber, it is to be appreciated that
other suitable, medically acceptable polymeric materials may be
used. A silicone rubber tube can be made by dipping a mandrel in a
polymeric dispersion containing uncured silicone rubber to form a
coating and then curing the coating. The uncured silicone rubber
for making the tubing is preferably one that will result in a
silicone rubber of 50-70 durometer.
[0058] Referring now also to FIGS. 3-14, mandrels 62, preferably
made of a metal or alloy such as stainless steel or aluminum, are
used for forming the catheter of the present invention. The
mandrels are preferably coated with a polymer having low surface
energy, such as tetrafluroethylene (e.g., TEFLON) so that the
completed catheters can be readily removed from the mandrels. FIG.
12 provides a schematic representation of a preferred mechanized
catheter production line 81 which is virtually fully automated.
FIGS. 13A-C highlights various steps of the automated method which
is described below. The mechanized production line 81 includes one
or more pallets 64 having a plurality of elongated mandrels 62 each
having a generally round or blunt end distal to the pallet. The
mandrel 62 preferably has an enlarged section corresponding to a
connector portion (or an end piece) 80 proximate the pallet. The
end piece 80 can have a transition portion that provides a gradual
transition from the wider, proximal end of the end piece to the
narrower, inner tubing of the catheter if desired. The moveable
pallet 64 is attached to a transport mechanism 82 which can move
the pallet to a position over one of a plurality of dip tanks
84,86,88,90,92,94,96. Each of the respective dip tanks will contain
a fluid in which mandrels 62 are immersed when the respective dip
tank is raised. By dipping in the fluids in these dip tanks, a
polymeric tube, shaped residual coating of a bond-preventing agent,
and a polymeric overcoat layer are formed on the mandrel to result
in a shaped, completed structure.
[0059] Movement of the pallet 64 is preferably controlled by an
output from a computer control mechanism 83, illustrated
schematically in FIG. 14, which are directed to the transport
mechanism 82. Each of the respective dip tanks 84,86,88,90,92,94,96
are raised and lowered by associated lift mechanisms. The lift
mechanisms are also preferably controlled by outputs from the
computer control mechanism 83. Each of the lift mechanisms includes
a speed control capable of modulating the rate at which the
respective dip tank is raised and lowered so that the speed at
which the respective mandrels are immersed into and withdrawn from
the respective fluid within the respective dip tank can be varied,
either continuously or intermittently, and either during one
dipping or between different dippings. The computer control
mechanism 83 also receives inputs from depth sensors within each of
the respective dip tanks. The depth sensors, preferably ultrasonic
depth sensors, are capable of providing an input to the computer
control mechanism 83 which enables the computer control mechanism
to determine when the mandrels 62 are immersed to a desired depth
in the respective dip tank. Timers are also provided for each of
the respective dip tanks in order to provide inputs to the computer
control mechanism 83 so that the computer control mechanism 83 can
determine when a desired period of time has elapsed. A computer
program is provided which moves the pallet along the mechanized
production line 81 and raises and lowers the respective dip tanks
at predetermined times, at predetermined rates of speed, and to
predetermined locations and/or heights to enable the mechanized
production line 81 to produce a plurality of completed catheters 4
by dipping the mandrels in various dip tanks of fluids. In
alternate embodiments, the mechanized production line 81 may have a
series of pallets (not shown) which are moved along an alternate
transport mechanism (not shown) in series.
[0060] After a retention catheter is made, preferably, it is
tested. During the testing of the completed retention catheter 5, a
removable cylindrical support device 98 is secured around the
catheter sleeve section 34 of the overcoat layer 14 interposed
between the balloon section 32 and the reservoir as shown in FIG.
11B, to minimize any potential expansion of the catheter sleeve
section 34. During testing, the balloon section 32 is expanded and
stretched. The step of testing the balloon section 32 helps to
create a retention catheter which has a readily expandable balloon
section, as opposed to the catheter sleeve section 34 which does
not expand as readily upon compression of the fluid reservoir
section 30. In addition, the balloon section can be inherently more
readily expandable than the sleeve section due to its preferably
larger diameter. After testing, the elastomeric collar 50 with a
shroud 51 connected thereto is secured onto the catheter 5 by
slipping the distal end 42 of the catheter 5 through the collar 50
until the collar encircles the catheter 5 on the catheter sleeve
section 34 of the overcoat layer 14 just distal to the squeeze bulb
30 and the shroud encircles the squeeze bulb. In this way, when the
squeeze bulb 30 is squeezed by the user, the shroud prevent the
squeeze bulb from significantly stretching the portion of the
reservoir section of the overcoat not being compressed to cause
lateral ballooning (or bulging) thereof.
[0061] If desired, the polymeric tube can also be provided by
either forming from a suitable tubing (e.g. medically adaptable
silicone rubber tubing) purchased or made by an extrusion process
known to those skilled in the art. The tubing can be cut to length,
have a tip secured thereon, and then be secured to support rods,
which can be attached to the pallet. The tip can be affixed to the
tube, for example, by using an appropriate adhesive.
[0062] In the Applicants' use of the preferred methods of the
present invention, production can be almost completely automated.
Sets of polymeric structures such as catheters 5 can be
manufactured simultaneously. In such preferred automated
manufacturing process, the preferred pallet 64 has 400
TEFLON-coated stainless steel mandrels 62 attached to the pallet in
20 rows of 20 mandrels, wherein each of the mandrel 62 is about 1
inch (2.54 cm) from each adjacent mandrel.
[0063] Referring to FIGS. 4-10, in a preferred embodiment of the
present method wherein the manufacturing process is automated for
mass production of catheters, 400 of TEFLON-coated stainless steel
mandrels are mounted vertically on a moveable pallet 64. The pallet
64 is then moved via a transport mechanism 82 (see FIG. 12) over a
series of dip tanks 84,86,88,92,94,96 as follows in one of these
embodiments:
[0064] (A) The pallet 64 is transported to over a first tank 84,
which contains a polymeric bonding composition (e.g., an uncured
silicone dispersion, for example, a mixture of uncured silicone
rubber in toluene that is made by dispersing DOW CORNING Q7-4850 in
the solvent (i.e., toluene). The tank 84 is then raised to immerse
the mandrels in the uncured silicone dispersion to a depth to cover
substantially the whole length of the mandrel such that the uncured
silicone rubber dispersion covers the mandrel up to the level of
dash line M. The dip tank 84 is then lowered and the outer surface
of the mandrel from the distal end up to the dash line M in FIGS.
3-4 is coated with a layer of the uncured silicone rubber
dispersion, which is allowed to air-dry for the solvent to
evaporate for about 8 minutes. The dipping step is repeated several
times to obtain a desirable thickness of uncured silicone rubber
coating corresponding to a desired cured silicone rubber thickness.
The thickness of the inner tube is preferably about 0.89 mm (0.035
inch), plus or minus 0.1 mm (0.004 inch). The thickness of cured
silicone rubber coating on the mandrel is selected such that the
completed catheter can be deployed in the body by urging the
catheter up the urethra (as shown in FIG. 17 below) with a stylet
inserted in the inner tube of the catheter and bearing or biasing
against the tip of the inner tube without puncturing the inner
tube. When the tank is lowered for the last time, the coating is
allowed to air-dry for several minutes, preferably 10 minutes.
[0065] (B) The pallet 64 is then advanced to a dip tank (not shown)
containing hot USP petrolatum heated to about 210.degree. F.
(99.degree. C.) and the uncured silicone rubber coating on the
mandrel is cured by dipping in the hot petrolatum for about 0.5
hour and the removed therefrom. Preferably, the cured silicone
rubber coating on the mandrel is subsequently dipped in a volatile
organic solvent such as toluene to remove all the petrolatum before
the next dipping step. Alternatively, the curing can be done by
removing the coated mandrels from the transport mechanism and
placing them in a hot-air oven (220.degree. F. or 104.degree. C.)
for about 0.5 hours to cure the uncured silicone rubber for forming
an inner (or intermediate tube). After curing the silicone rubber,
the pallet is again secured to the transport mechanism. "An
intermediate tube" as used herein refers to a polymeric tube which
can be coated with coating of a bond-preventing agent and overcoat
layer to form a catheter. Alternatively, the individual mandrels
can be placed in the oven separately. Another alternative is to
heat the pallet with the mandrels and uncured silicone rubber
coating in an oven designed for the whole pallet unit without
removing the pallet from the transport mechanism in the production
line.
[0066] (C) The pallet 64 is then moved and stopped over a second
tank 86, which contains a bond-preventing agent 66, such as a
petroleum jelly or petrolatum, preferably a liquid petrolatum
mixture at about 125.degree. F. (about 52.degree. C.). The mixture
will include Perfecta.TM. Petrolatum USP (from Sonneborn
Petrolatums, Sonneborn Div., Witco Chemical Corp., New York, N.Y.).
The tank is raised so as to immerse the intermediate tubes 3 into
the petrolatum to such a depth (up to dashed line A shown in FIGS.
5 and 6) that the petrolatum coats the first, second, third and
fourth portions 20a, 20b, 20c and 20d of the outer surface 20 of
the intermediate tubes 3. The dip tank 84 is then lowered and these
portions of the outer surface 20 are coated with a first coating 75
of petrolatum. The tubes 3 are allowed to air-dry and cool for
about 30-60 seconds, and the dip tank is raised again and the tubes
3 are immersed again to the same depth. This is repeated 10-15
times until the first coating 75 is built up to a desired thickness
(referred to as coating 76 in the drawing, see FIGS. 5 and 6). The
desired thickness of the first coating 76 on the tube 3 corresponds
to the desired thickness of the reservoir portion 22 of the cavity.
Preferably, this thickness is about 1 cm to 2 cm (0.4 in to 0.8
inch) such that the resulting reservoir section of the completed
catheter will not be inadvertently drawn into the urethra.
[0067] (D) The pallet 64 is then automatically advanced and stopped
over a third dip tank 88 which contains hot USP petrolatum heated
to about 180.degree. F. (about 82.degree. C.). The third dip tank
88 is raised so as to immerse the intermediate tubes 3 into the
super-heated petrolatum for 1 minute so that the super-heated
petrolatum comes up to dashed line B and into contact with the
first coating 76 on the second, third and fourth portions 20b, 20c
and 20d of the outer surfaces 20 of the intermediate tubes 3 from
the prior dipping step. The third dip tank 88 is then lowered. This
dipping step causes the coating 76 of petrolatum from the prior
dipping step to be largely removed (or stripped) from the second,
third and fourth portions 20b, 20c and 20d of the outer surface 20
of the intermediate tubes 3, as shown in FIG. 7. Some residual
petrolatum may remain on these portions of the outer surface 20.
However, most of the petrolatum is removed from them. The time of
dwelling and/or the rate of withdrawal of the mandrels from the
stripping fluid can be varied to effect a gradual reduction of the
diameter of the distal portion of the first coating 76 remaining on
the mandrel, thereby forming a transition portion in the second
portion. For example, the time of dwelling of the proximal part of
the first coating 76 on the 20b portion of the surface 20 in the
stripping fluid can be less than the time of dwelling of the more
distal part of the same portion to allow more time to strip the
distal portion. This can be accomplished, for example, by lowing
the dip tank from the dash line B at a decreasing rate for a
distance desired for the transition portion.
[0068] (E) The pallet 64 is then automatically advanced and stopped
over a fourth dip tank 90 containing a liquid petrolatum mixture
identical to that in the second dip tank 86, except that the
temperature is about 135.degree. F. (about 57.degree. C.). The
fourth dip tank 90 is then raised so as to immerse the intermediate
tubes 3 into the petrolatum mixture to the same depth as they were
immersed in the super-heated petrolatum in the third dip tank 88.
In the case where there is a transition portion on the coating
remaining on the intermediate tube after the stripping step, the
tank is raised to a depth so as to just immerse the distal end of
the transition portion. The tank 90 is then lowered, leaving a
coating 77 (referred to as the second coating to distinguish from
the first coating) of petrolatum on the second, third and fourth
portions 20b, 20c and 20d of the outer surface 20, as shown in FIG.
8. If desired, this step can be repeated a few times to build up
the thickness of the second coating to have an outside diameter
generally corresponding to the diameter of the urethra. The tubes
are then immersed again up to the dashed line C and a third coating
78 is created over the third and fourth portions 20c and 20d of the
outer surface 20 (as shown in FIG. 9). Preferably, the dipping step
is repeated to build up the the third coating 78 to that it is
somewhat thicker than the second coating 77 but thinner than the
first coating 76.
[0069] (F) The pallet 64 is then automatically advanced and stopped
over a fifth dip tank 92 containing hot USP petrolatum like that in
the third dip tank 86. The fifth dip tank 92 is raised and the
tubes 3 are immersed in the super-heated petrolatum up to the
dashed line D for about 30 seconds. The fifth dip tank is then
lowered and the third coating 78 of petrolatum is removed from the
fourth portion 20d of the outer surface 20, as shown in FIG. 10. As
before, if desired, a transition portion can be formed by lowering
the dip tank 92 gradually or at a decreasing rate once the dip tank
has been raised to the desired position. In addition, if desired,
part of the residual coatings remaining on the intermediate tube
can be further shaped by mechanically removing some of the
coatings, for example, by using a knife-like device to sculpture
specific shapes thereon.
[0070] (G) The pallet 64 is then automatically advanced and stopped
over a sixth dip tank 94 containing a volatile organic solvent such
as toluene, xylene, or the like, effective to remove all of the
bond-preventing agent therefrom so that there will be no
interference with the subsequent bonding of silicone rubber to the
intermediate tube. The fifth tank 94 is then raised to immerse the
intermediate catheters 3 in the organic solvent up to dashed line D
(or up to the distal end of the transition portion in the portion
20d below the dash line D if a transition portion is present) so as
to remove any remaining petrolatum 66 on the fourth portion 20d of
the outer surface 20. The intermediate catheter tubes 3 now have
three bands 76, 77 and 78 of semi-solid petrolatum around the axial
circumference of each of the intermediate tubes 3, as shown in FIG.
10.
[0071] (H) The tank 64 is then lowered, and the organic solvent is
allowed to evaporate from the outer surface 20 for about 15
minutes. The pallet 64 is then automatically advanced to a seventh
dip tank 96 containing a hexamethyl disiloxane silicone rubber
dispersion which is effective to minimize any disruption of the
integrity of the petrolatum coatings 76, 77 and 78 remaining on the
intermediate tubes 3. Although the present retention catheter 5 can
be constructed of any suitable, medically acceptable, polymeric
material, medical grade silicone rubber is preferred. The silicone
rubber of the sleeve overcoat preferably is soft, with a hardness
of about 20 to 40 durometer, more preferably about 30 durometer. It
will be appreciated that such a silicone rubber polymeric must be
fully cured prior to sale or use. The overcoat layer can have a
thickness of about 0.1 mm to 1 mm, preferably about 0.35 mm plus or
minus 0.06 mm (0.0175 inch plus or minus 0.0025 inch). The
preferred uncured silicone rubber dispersion is a very soft uncured
silicone rubber dissolved in weak solvent that will not attack
petroleum jelly. An effective uncured silicone rubber dispersion
for making the present invention is a 25-75 mixture of uncured
silicone rubber in hexamethyl disiloxane. This mixture is made of
GE 603015 LIQUID SILICONE RUBBER and hexamethyl disiloxane. Another
example of such an uncured silicone rubber dispersion is Dow
Corning Q7-4720 in hexamethyl disiloxane. The seventh dip tank 94
is then raised to immerse essentially the entire length of the
intermediate tube 3 in the silicone mixture. This step is
preferably subsequently repeated 4-6 times at 8-minute intervals to
allow time for significant solvent evaporation. When the tank 96 is
lowered for the last time, the overcoat layer 14 is allowed to dry
and the solvent is allowed to evaporate for about 30 minutes,
preferably about an hour. If transition portions are provided on
the distal portions of the first coating (in second portion 20b)
and the third coating (in fourth portion 20d) as described
hereinabove, the resulting completed catheter will have features
shown in FIG. 15, which shows a transition portion of a balloon
section and a transition portion of a reservoir section.
[0072] (I) In a preferred embodiment of the present method, the
pallet 24 is advanced to yet another dip tank (not shown) similar
to the others, but containing hot USP petrolatum, heated to about
210.degree. F. (about 99.degree. C.). The tubes 3 are completely
immersed in the hot petrolatum for 1 hr to cure the uncured
silicone rubber and form the completed intermediate catheters 4
shown in FIG. 11A, and the tank (not shown) is then lowered.
[0073] (J) The completed intermediate catheters 4 are then removed
from the pallets and further cured in hot air at 220.degree. F.
(about 104.degree. C.) for about an hour and a half (1.5 hrs).
[0074] (K) After the completion of the heat cure, the intermediate
catheters 4 are allowed to cool before forming an eyelet 40 each
thereon to form the completed retention catheter 5. Preferably, the
intermediate catheters are soaked in hot mineral oil at 250.degree.
F. (121.degree. C.) for 24-48 hours. The intermediate catheters 4
are then removed from the oil and preferably cleaned.
[0075] (L) The completed catheters 5 are finished by punching the
fluid conduit access opening or eyelet 40 in the exterior surface
36 of each catheter such that the opening communicates with the
fluid conduit lumen 8 in a location below or distal to the balloon
section 32. In a device not used for draining fluid, such is a
device used for blocking a passageway, for example, for stopping
fluid leakage therethrough, such an eyelet may not be needed.
[0076] (M) If not previously soaked in mineral oil, the completed
catheters 5 are then soaked for preferably 24 to 48 hrs in a hot
bath of mineral oil at 250.degree. F. (about 121.degree. C.). The
mineral oil will generally replace the petrolatum 66 in the cavity
16 after this period of time, and will remain a fluid 18 at room
temperature. The mineral oil has a significantly lower viscosity
than petrolatum at room temperature. A different fluid such as
water, sterile saline, glycerin, polyethylene glycol, gas (e.g.,
air) and the like, or appropriate mixtures thereof may also be
substituted for the mineral oil/petrolatum fluid in alternate
embodiments by removing most of the latter fluid, and then
inserting the former by an appropriate means.
[0077] (N) The expandable balloon section 32 is then tested and
stretched, and then an elastomeric collar 50 with a shroud 51 is
put into place over the sleeve section 34 and the reservoir section
30 of the overcoat by slipping over the distal portion of the
catheter from the distal end. The completed catheters 5 are
packaged and then sterilized prior to shipment.
[0078] The above process of shaping the preferred embodiment of a
hand-actuated catheter is summarized in the flow diagrams in FIGS.
13A, 13B and 13C. The automated method that Applicants claim can
permit completed catheters 5 to be manufactured at the rate of
about 1,600 catheters per hour. Because little handwork is
involved, the catheters 5 produced will be consistent, of very high
quality, and less costly to produce than comparable prior art
catheters. The exterior surface 36 is believed to be smoother and
softer than the exterior surface of hand-glued balloons.
[0079] The method of the present invention can be used to make
structures having an overcoat layer encircling an inner piece
wherein the size of the cavity and the number of cavities can be
different from the embodiments described hereinabove. The cavities
can be isolated from each other or one or more of the cavities can
be connected together to have fluid communication. For example, the
cavity defined between an overcoat and the inner tube can have
sections with different sizes (such as fluid reservoirs, sleeve
cavities, balloons as in the embodiment described hereinabove).
Some of the cavities may also be linked by fluid communication
means that is not defined between the overcoat layer and the inner
tube. These variations affects the shape of the final structure
with the overcoat layer, e.g., a catheter. Also, any structure or
object, e.g. a conical tip, affixed to the inner piece, e.g., a
tube, will also affect the shape of the final structure when the
overcoat layer is shaped.
[0080] The method can be used to make structures having transition
portions on both ends. One embodiment of the process for making a
transition portion gradually narrowing distally has been described
hereinabove. Transition portions on the proximal ends can be made
by immersing the inner piece, e.g., intermediate tube, to a lesser
depth in the bond-preventing agent in each succeeding,
thickness-building dipping step during the multiple-dipping process
in the formation of the residual coating (e.g. the first and the
third coating of the bond-preventing agent of FIG. 10). By this
method, the proximal ends of the first and third coatings narrow
gradually in the proximal direction. By providing such transition
portions, structures with various portions of different size can be
made to have gradual change rather than abrupt change in shape, for
example, a female urinary catheter as shown in FIG. 16.
[0081] As previously stated, the present method can be used to make
structures that contain a fluid, such as mineral oil. Furthermore,
if desired, the completed shaped structure can be a hollow
structure, such as a hollow or air-filled balloon. In this case,
the inner piece can be pulled from the overcoat layer and the
bond-preventing agent or liquid (such as mineral oil) can be
squeezed out of the inside cavity of the completed shaped
structure. The inner piece can be pulled from the overcoat layer if
the inner piece is not in direct contact with the overcoat, as in
the case wherein a coating of bond-preventing agent is disposed
between the inner piece and the overcoat layer over all the area of
the overcoat layer. In another embodiment, the inner piece is
coated with a release layer such as TEFLON so that an overcoat
layer is not irremovably bonded to it. If desired, the
bond-preventing agent can be left in the cavity enclosed by the
overcoat layer. As previously stated, the present method can be
used to make a simple structure such as a condom. This can be done
by a process which includes dipping a mandrel in a bond-preventing
for form the shaped structure of bond-preventing agent and coating
this structure with a polymeric bonding composition. Depending on
the polymeric composition used, a curing step may or may not be
necessary. The mandrel and the bond-preventing agent can be removed
from the completed condom with appropriate methods.
[0082] Therefore, based on the present invention, one can make
structures, such as hoses, balloons, condoms, cannulas, catheters,
and the like, with one or more sections with different diameters,
lengths, or shapes. For example, a hollow structure with a
polymeric overcoat of a shape shown in FIG. 21, which has a hollow
disc 202 interconnecting and disposed between a first tubular
structure 204 and a second tubular structure 206 can be made.
Another example is a generally umbrella-shaped polymeric structure
as shown in FIG. 22. This generally umbrella-shaped structure 210
has, for example, a cylindrical inner piece (or shaft) 212 (which
can be a rod or a tube) and a bowl-shaped outer piece (or hood) 214
integrally connected to an end of the inner piece. The hood
encircles the shaft at least partially (e.g., the distal portion or
entire length) and defines a recess 216 in cooperation with the
shaft at the distal end of the shaft. The periphery of the hood is
not attached to the shaft. This structure can be made by a method
that includes first forming a cylindrical polymeric inner piece
(which can be made by injection molding or by coating a mandrel to
form a tube and filling the tube with polymeric material to form a
rod), coating the cylindrical inner piece with a residual coating
of bond-preventing agent, stripping away the distal portion of the
residual coating of bond-preventing agent up to the end of the
cylindrical inner piece, and subsequently coating the distal
portion of the cylindrical inner piece and the residual coating
with a polymeric bonding composition without completely
encapsulating or covering the proximal portion of the residual
coating. By varying detailed steps of the method, other structures
with recesses of various shapes can be formed.
Female Urinary Catheter
[0083] The female urinary catheter of the present invention is a
hand-actuated retention catheter which is similar to the
hand-actuated retention catheter disclosed in U.S. patent
application Ser. No. 07/827,936, filed Jan. 29, 1992, the method of
making, characteristics, and use of which are incorporated by
reference herein. The preferred embodiment (shown in FIG. 1) of the
hand-actuated retention catheter 5 of the present invention
comprises a tube 12 having outer surface 20 and inner surface 10
and an overcoat layer 14. The tube 12 has an inner lumen 8 which is
defined by the inner surface 10 of the tube. The overcoat layer 14
encircles the tube 12 and has interior and exterior surfaces. A
cavity 16 is interposed between the tube 12 and the overcoat layer
14. This cavity 16 also encircles the tube 12 and is defined by
portions of the outer surface 20 of the tube 12 in cooperation with
portions of the interior surface of the overcoat layer 14. This
cavity 16 preferably contains a fluid 18, although it can contain a
soft, moldable semisolid such as petroleum jelly, or the like, or a
combination thereof instead. The overcoat layer 14 includes an
expandable, resilient balloon section 32 proximate a distal end, a
reservoir (or bulbous) section 30 proximal thereto, and a catheter
sleeve section 34 disposed therebetween. The sleeve section 34
interconnects the balloon section 32 and the reservoir section 30.
The overcoat layer 14 is joined to the outer surface 20 of the tube
12 at the distal and proximal ends of the cavity 16 (i.e., above
and below the cavity) along the tube. The cavity 16 also includes a
balloon portion 24, a reservoir portion 22, and a catheter sleeve
portion 26 that interconnects the balloon portion and the reservoir
portion. The catheter sleeve section 34 of the overcoat layer
defines a narrowing in cavity through which fluid passes if made to
flow between the balloon portion 24 to the reservoir portion 22.
Each of the sections can be cylindrical in shape, or a transition
portion that narrows gradually can be provided on one or both ends
of the balloon section and/or the reservoir section to facilitate
smooth insertion and withdraw of the catheter into the body. The
balloon section of the overcoat and the balloon portion of the
cavity are of a size such that when the balloon is expanded, it is
effective to prevent withdrawal of the balloon section into the
urethra in contact with the catheter. Disposed on the sleeve
section 34 proximate the squeeze bulb 30 is an elastomeric collar
50 with a shroud 51, which encloses the squeeze bulb. The shroud 51
is preferably, but not necessarily, unitary and integral with the
collar 50. The shroud 51 can be connected with the outer edge of
the collar 50 such that they resemble a cylindrical cap with an end
disc having an opening in the center of the end disc. In another
embodiment (not shown), the shroud can be separate from the collar
and the shroud can have an ellipsoid shape with open ends which
have diameters larger than that of the sleeve section 34 to
generally conform to the shape of the reservoir section 30.
[0084] The collar 50 presses radially inward on the sleeve so that
fluid is prevented from flowing from the balloon portion of to the
reservoir portion of the cavity during normal, everyday activities
of the user. However, when the catheter is being deployed, the
fluid can be deliberately forced past the sleeve section of the
cavity by squeezing the squeeze bulb, thus forcing the inside
diameter of the collar to slightly increase. In this manner, the
balloon section is expanded (i.e. inflated) to retain the catheter
in the body passageway.
[0085] Preferably, the collar 50 and shroud 51 are made of a
material soft and resilient enough such that when desired, they can
be readily pulled along the catheter over the reservoir section.
Preferably, the shroud 51 is generally cylindrical with an inside
diameter of about the outside diameter of the squeeze bulb so that
it can be readily slipped over the squeeze bulb 30 during assembly
of the catheter. When a force is not being applied from an external
source, as by compressing with a thumb and a finger, preferably the
shroud does not compress the squeeze bulb. Without the shroud 51,
when the squeeze bulb 30 is squeezed to force the fluid from the
reservoir portion 22 to the balloon portion 24 through the sleeve
portion 26 of the cavity, for example, as when being compress
between the thumb and index finger of an user, because of the
resistance to fluid flow caused by the restricting collar, the
squeeze bulb 30 has a tendency to balloon or bulge out in a
direction perpendicular to the direction of the applied compression
force, i.e. generally lateral to the axis of the catheter. This is
because when compressing forces are not applied in an enveloping
manner on the squeeze bulb, the fluid in the squeeze tends to
balloon out at the locations with the least compressing force. Such
lateral ballooning in the squeeze bulb 30 decreases the efficiency
of the squeezing action and make it relatively difficult to expand
the balloon portion 24 of the cavity. A shroud 51 encircling the
squeeze bulb 30 inhibits he lateral ballooning of the squeeze bulg
as it is being squeezed, thus directing the compressing force of
the squeezing action to force the fluid to increase the inside
diameter of the collar. In this way, fluid is passed to expand the
balloon portion 24. The shroud 51 is preferably constructed of a
silicone rubber which is soft and pliable and has a thickness
making it relatively less stretchable than the overcoat layer on
the squeeze bulb 30 and the balloon section 32 so that the shroud
can inhibit the lateral ballooning of the squeeze bulb 30 when the
squeeze bulb is compressed to force fluid past the sleeve section
restricted by the collar 50. The elastomeric collar and shroud can
be made with the same silicone rubber material that is used for
constructing the inner polymeric tube 12 or the overcoat layer 14.
The elastomeric collar and shroud can be made with conventional
methods such as injection-molding, or if preferred, with an
overcoat-shaping method through dipping in a polymeric material
similar to that described above.
[0086] The female urinary catheter described hereinabove can be
used in the following fashion. Referring to FIGS. 17-18, first, an
elongated, stiff, but slightly flexible stylet 104 is removably
inserted into the catheter 5 through the opening at the connector
or end piece 80. Such a stylet is preferably made with plastic and
has a diameter slightly smaller than the inside diameter of the
inner tube of the catheter for easy insertion and withdrawal. The
stylet preferably has a round or blunt distal end 106 and a
proximal end having a generally flat end portion 108 generally
perpendicular to the elongated part of the stylet. If desired, the
flat end portion can extend with its plane parallel to the axis of
the stylet. The proximal end portion 108 of the stylet can also be
of a shape (e.g., bulb-shaped) for a person's hand to comfortably
press thereon to urge the stylet into the catheter and bear against
the tip of the catheter. The length of the stylet is slightly
longer than the length of the catheter such that when inserted all
the way inside a catheter with the distal end of the stylet bearing
against the tip of the catheter, the proximal end portion 108 of
the stylet 104 is outside and proximal to the end piece 80 of the
catheter 5.
[0087] The tip of the catheter is then inserted into the urethral
tract 120. By generally pressing on the proximal end portion 108 of
the stylet, the balloon section of the catheter is slowly urged
into the urethral tract. The catheter is slowly advanced into the
urethra until the balloon section 32 reaches and emerges into the
space inside the bladder 128 and the squeeze bulb (or reservoir
section) 30 of the catheter reaches the external opening of the
urethra.
[0088] Referring to FIG. 18, after the balloon section 32 emerges
from the urethra, the squeeze bulb 30, encircled by the shroud 51,
is squeezed, for example, between a thumb and an index finger, to
force the fluid 18 from the reservoir portion 22 into the balloon
portion 24 through the sleeve portion 26. Strong enough forces are
applied (the directions of application are shown by the arrows P
and Q) to overcome the compression force by the collar 50 so that
fluid can pass through the sleeve portion 26 to inflate the balloon
section of the overcoat 32. The shroud 51 inhibits any significant
ballooning of the squeeze bulb 30 in a direction perpendicular to
the applied forces P and Q. The collar 50 prevents fluid that has
been previously forced out of the reservoir portion of the cavity
from flowing back thereinto, thus maintaining the balloon portion
24 in an expanded state to retain the catheter in the desired
location in a body passageway. The urethral (or sleeve) section 34
of the catheter can softly conform to the wall of urethral tract to
provide a gentle leak-proof fit. The stylet 104 is then withdrawn
from the catheter 5 by grasping the catheter to maintain it in
place as the stylet is gently pulled out of the catheter.
Alternatively, the stylet 104 can be withdrawn before the balloon
portion 24 is expanded. The end piece 80 of the catheter is
connected to a connector tube which leads to a bag for holding
urine.
[0089] To remove the catheter from the body, the shroud 51 can be
grasped by hand and gently pulled while the sleeve section 34 of
the catheter is firmly held so that the collar 50 with shroud 51 is
slipped proximally over the reservoir section 30. If the collar 50
and the shroud 51 are separate, the collar can be similarly removed
by pulling. Subsequently, the sleeve portion 26 of the cavity, no
longer being restricted by the collar 50, allows the fluid to
freely return from the balloon portion 24 to the reservoir portion
22, thus deflating the balloon portion to facilitate the removal of
the catheter from the body passageway.
[0090] The catheter of the present invention can be made so that
the enclosed cylindrical sleeve cavity contains a lubricant. An
example of lubricant effective for lubricating the sliding of the
overcoat on the surface of inner tube and reduction of friction is
petrolatum or liquid soap. The lubricant and the method of
incorporating the lubricant into the cavity as disclosed in U.S.
Pat. No. 5,098,379 (Conway et al.) are incorporated by reference
herein.
[0091] The female catheter can also include bactericidal agents.
One embodiment is to incorporate the bactericidal agents into the
polymeric matrix of at least a portion of the overcoat layer of the
cannula or catheter. The polymeric matrix preferably includes cured
silicon rubber. The bactericidal agent and the method of
incorporating such bactericidal agent into the matrix of the
overcoat layer as disclosed in U.S. Pat. No. 5,261,896 (Conway et
al.) are incorporated by reference herein. Another method of
providing bactericidal effect by the catheter is to incorporate
bactericidal agents in the substance, such as a lubricant,
contained in the cavity defined by the overcoat layer and the inner
tube with a means provided for the diffusion of the bactericidal
agents out of the cavity. The bactericidal agents and the method of
incorporating these agents into the catheter as disclosed in U.S.
Pat. No. 5,269,770 (Conway et al.) are incorporated by reference
herein.
[0092] Another embodiment is a catheter (as shown in FIGS. 19-20)
having channel 27 in the wall of the inner tube that provides fluid
communication between the balloon cavity 24" and the reservoir
cavity 22" (the features of the primed numbers in FIGS. 19-20
correspond to the features of corresponding numbers in FIG. 1). The
reservoir cavity 22" has a cylindrical narrow portion 26" distal
thereto extending toward but not communicating with the reservoir
cavity 22". The channel enters the balloon portion 24" of the
cavity at an opening 25 and enters the cylindrical, narrow portion
26" of the reservoir cavity at an opening 23. Such an inner tube
can be made by injection molding. Another embodiment is a catheter
similar to the retention catheter described hereinabove in FIG. 1
with the differences that the balloon section of the catheter has a
much larger geometry (i.e., diameter) than that shown in FIG. 1. If
preferred, catheters with more than one cavity wherein the cavity
has one or more portions of different diameters can be made with
the method of the present invention.
[0093] A catheter of the present invention can also be packaged in
a vapor barrier pack (such as metal foil or plastic) with a stylet
inserted in the catheter to reduce the loss of fluid. Such a
package can be sold as a kit commercially.
[0094] It is to be understood that even though numerous
characteristics and advantages of the present invention have been
set forth in the foregoing description, together with details of
the structure and function of the invention, the sequence or order
of the specific steps, or the actual compositions, solvents,
temperatures, environmental conditions and the like employed for
each step, it will be appreciated the disclosure is illustrative
only, and that changes may be made in detail, especially in matters
of shape, size, arrangement of parts or sequence or elements of
events within the principles and spirit of the invention. For
example, in making a shaped structure with the method of the
present invention, the liquid composition for forming the inner
piece can be a nonpolymeric material such as a composition
containing an inorganic dispersion such as clay or a molten metal
such as lead. Likewise, the liquid composition for coating the
bond-preventing agent need not be polymeric.
* * * * *