HK1139032A - Methods for securing strand ends and the resulting devices - Google Patents

Description

Method for securing wire ends and device formed thereby

Cross Reference to Related Applications

This application claims priority to U.S. provisional patent application No. 60/862,456 filed on.10/2006, day 22, the entire contents of which are hereby incorporated by reference.

Technical Field

The present invention relates generally to methods and structures for securing a wire (e.g., wire) end of a device adapted for placement within an anatomical structure, and devices formed thereby. Examples of such devices include braided, self-expanding stents (stents).

Background

Examples of devices formed from one or more wires and adapted to be inserted into an anatomical structure are disclosed in U.S. patent nos. 6,007,574, 6,419,694, and 7,018,401 and U.S. patent application publication nos. US 2005/0049682 and US 2006/0116752, which are incorporated herein by reference.

Disclosure of Invention

Some embodiments of the method of the invention comprise the steps of: securing a coupling structure to a first strand end portion of a device shaped for insertion into an anatomical structure; and securing the coupling structure to the second strand end portion of the device; wherein the first strand end portion and the second strand end portion are substantially aligned, the coupling structure is not a strand of the device, and the device comprises one or more strands comprising nickel and titanium. In some embodiments, the length of the linker structure is less than 25%, 24%, 23%, 22%, 21%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, or 0.1% of the length of the device; this may be applied to each joint structure used. The coupling structure may be shaped to have a passageway before it is secured to the first strand end portion and the second strand end portion, and may be placed in direct contact with the first strand end portion and the second strand end portion before securing. The device may be a stent (e.g., a stent woven from a plurality of wires), or any other medical device suitable for use in treating a patient, such as a filter or occluder (occluder). The device may be self-expanding. The device may have two or more device ends (e.g., two ends of a straight stent or three ends of a bifurcated stent), and each device end may be characterized by or defined by wire bends (strand bends), wherein the wire bends of a particular device end are at least similar (e.g., substantially similar) in shape to each other and in some cases to all of the wire bends of all device ends, such that one device end looks very similar to the other device end or ends. The number of coupling structures used may correspond to the number of strands (e.g., wires) used to form the device, and these coupling structures may be positioned axially in-line (parallel to the longitudinal axis of the device), or may be axially offset relative to one another and positioned around the periphery of the device. The securing may be accomplished by welding (e.g., laser welding) the coupling structure to the first strand end portion to form a first welded region and welding the coupling structure to the second strand end portion to form a second welded region. The two lands may be separated from each other without being connected by any other land. In some embodiments the two strand end portions are in direct contact with each other, while in other embodiments the two strand end portions are not in direct contact with each other. The wire end portions may be substantially aligned with one another (end-to-end) or may be positioned in a side-by-side relationship (which may be characterized as overlapping). In some embodiments, the coupling structure is a separate piece of material from the first strand end portion and the second strand end portion that is disposed in direct contact with both strand end portions prior to the initiation of the weld when the securing is performed using the weld. In some embodiments, some or all of the securing steps result in securing a particular half of a particular strand to (a) only one other strand or (b) only the other half of the same strand. In some embodiments, the coupling structure is positioned below the strand that intersects the coupling structure. In some embodiments, all of the joint structures used are positioned in this same manner. In some embodiments, neither the coupling structure nor the strand end portions secured to the coupling structure are subjected to a finishing step after the securing is complete. In some embodiments, the device is woven from a plurality of wires so as to create wire intersections that define obtuse angles that increase when the device is axially compressed in an unconstrained state, and each device opening (excluding those openings that are proximal to the longitudinal channel or passages of the device) is defined by at least three wire intersections, where each wire intersection is defined by two intersecting wire portions. In some embodiments, the coupling structure located closest to a particular end of the device (the "device end") is spaced apart from all device ends (even on the portion of the coupling structure closest to the device end) in a direction substantially parallel to the longitudinal axis of the device (e.g., along a line) by at least one strand intersection (in some embodiments, by at least two strand intersections; in some embodiments, by at least three strand intersections; in some embodiments, by at least four strand intersections; in some embodiments, by at least five strand intersections).

Some embodiments of the method comprise the steps of: welding a coupling structure to a first strand end portion of a device shaped for insertion into an anatomical structure; and welding the coupling structure to a second strand end portion of the device; wherein the coupling structure is not a strand of the device, and the device includes one or more strands comprising nickel and titanium.

The device may have one or more wires and be shaped for insertion into an anatomical structure. In some embodiments, the present devices include a coupling structure secured to two different strand end portions that are substantially aligned with each other; wherein the two different strand end portions comprise nickel and titanium, and the coupling structure is not a strand of the device. In some embodiments, the present devices include a coupling structure welded to two different strand end portions; wherein the two different strand end portions comprise nickel and titanium, and the coupling structure is not a strand of the device. The device may be a stent, or any other medical device suitable for use in treating a patient, such as a filter or occluder. The number of coupling structures used may correspond to the number of strands (e.g., wires) that the device has, and the coupling structures may be positioned axially in-line (parallel to the longitudinal axis of the woven device), or the coupling structures may be axially offset relative to one another and positioned around the periphery of the device. Each pair of strand end portions secured (e.g., welded) to a particular coupling structure may be substantially aligned with one another or may be arranged in a side-by-side relationship with one another (which may be characterized as overlapping). In some embodiments, the length of the linker structure is less than 25%, 24%, 23%, 22%, 21%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, or 0.1% of the length of the device; this may be applied to each joint structure used. The coupling structure may be shaped to have a passageway before it is secured to the first and second strand end portions, and may be placed in direct contact with the first and second strand end portions before securing (e.g., welding) is performed. The device may be a stent (e.g., a stent woven from a plurality of wires), or any other medical device suitable for use in treating a patient, such as a filter or occluder. The device may be self-expanding. The device may have two or more device ends (e.g., two ends of a straight stent or three ends of a bifurcated stent), and each device end may feature or be defined by a wire bend turnaround portion, wherein the wire bend turnaround portions of a particular device end are at least similar (e.g., substantially similar) in shape to each other and in some cases to all of the wire bend turnaround portions of all device ends, such that one device end is visually very similar to the other device end or ends. The number of coupling structures used may correspond to the number of strands (e.g., wires) used to form the device, and the coupling structures may be positioned axially in-line (parallel to the longitudinal axis of the device), or the coupling structures may be axially offset relative to one another and positioned around the periphery of the device. The coupling structure may be secured to the first strand end portion by a weld that forms a first weld region and to the second strand end portion by a weld that forms a second weld region, and the first and second weld regions are not directly connected to each other by another weld region. The two welding areas can be separated from each other without being connected by any other welding area. In some embodiments the two strand end portions are in direct contact with each other, while in other embodiments the two strand end portions are not in direct contact with each other. In some embodiments, the coupling structure is a separate piece of material from the first strand end portion and the second strand end portion that is disposed in direct contact with both strand end portions prior to the initiation of welding when the coupling structure is secured to the strand end portions using welding. In some embodiments, a particular half of a particular strand of the device is secured to (a) only one other strand or (b) only the other half of the same strand. In some embodiments, the coupling structure is positioned below the strand that intersects the coupling structure. In some embodiments, all of the joint structures used are positioned in this same manner. In some embodiments, neither the coupling structure nor the strand end portion secured to the coupling structure requires finishing after securing. In some embodiments, the device is woven from a plurality of wires so as to create wire intersections that define obtuse angles that increase when the device is axially compressed in an unconstrained state, and each device opening (excluding those openings that are proximal to the longitudinal channel or passages of the device) is defined by at least three wire intersections, where each wire intersection is defined by two intersecting wire portions. In some embodiments, the coupling structure located closest to a particular end of the device (the "device end") is spaced apart from all device ends (even on the portion of the coupling structure closest to the device end) in a direction substantially parallel to the longitudinal axis of the device by at least one strand intersection (in some embodiments, by at least two strand intersections; in some embodiments, by at least three strand intersections; in some embodiments, by at least four strand intersections; in some embodiments, by at least five strand intersections).

Any embodiment of any of the methods and apparatus of the present invention may consist of, or consist essentially of, the recited steps and/or features, rather than, comprise, contain, or have the recited steps and/or features.

Details relating to these embodiments and other embodiments are described below.

Drawings

The following drawings are by way of example only and are not limiting. The same reference numerals do not necessarily denote the same structures. Rather, the same reference numerals may be used to denote similar features or features having similar functions. For the sake of clarity of the drawings, not every feature of the various embodiments is labeled in every drawing showing the embodiment.

Fig. 1 shows an embodiment of a portion of a device being shaped for insertion into an anatomical structure and in a stage of formation where the free wire end is at one end of the device. In the top central portion of the figure, a hook is shown that is holding the device on an underlying surface. The hook is not an integral part of the device.

Fig. 2 shows an embodiment of a portion of a device being shaped for insertion into an anatomical structure and being in a stage of formation where half of the free wire ends have been woven back while the other half remains at one end of the device.

Fig. 3 shows an example of a portion of the device after completion of the weaving shown in fig. 1 and the back weaving shown in fig. 2, and including a coupling structure equal in number to the number of strands used to form the device. Specifically, one joint structure has been laser welded to each of six different pairs of substantially aligned wire ends of the device (for a total of six joint structures).

Fig. 4A and 4B show an embodiment of a portion of other apparatus similar to that shown in fig. 3.

Fig. 5 shows the structure of the device ends of a device similar to the devices shown in fig. 3 and 4 (and the similarity of the wire bend turns defining these device ends).

Fig. 6 shows an example of a portion of an apparatus having a coupling structure that is axially aligned and that each secures two strand end portions in overlapping relation.

Fig. 7 shows an example of a portion of an apparatus having a coupling structure that is axially aligned and that each secures two strand end portions that are substantially aligned.

Fig. 8 shows an example of a portion of a device similar to that shown in fig. 6, except that adjacent joint structures are spaced apart from each other around the periphery of the device. Wherein two of the joint structures that are farthest from an observer are labeled.

Fig. 9 shows an example of a portion of a device similar to that shown in fig. 7, except that adjacent joint structures are spaced apart from one another around the periphery of the device.

Fig. 10A shows a coupling structure secured to two strand end portions that are substantially aligned.

Fig. 10B shows a coupling structure secured to overlapping strand end portions.

Fig. 10C shows another embodiment of a coupling structure secured to two strand end portions that are substantially aligned.

FIGS. 11A and 11B are schematic views showing examples of different arrangements of joint structures for a device (e.g., a woven stent).

Fig. 12 shows an embodiment of a laser welding system that can be used to form the apparatus shown in fig. 2-9.

Fig. 13 is a table providing examples of the inner diameter, outer diameter, and length dimensions of a nitinol coupling structure of a nitinol wire size of a particular diameter that can be used for a six-wire braided stent of a particular size, in addition to providing examples of setup parameters for a LASAG welding system described below (where scfh represents standard cubic feet per hour).

Fig. 14A is a detail view showing a weld of a particular size created by the welding process that secures the coupling structure shown to the strand shown.

Fig. 14B is a table containing example values of the dimensions shown in fig. 14A, as well as parameters of other aspects of a stent formed according to the methods of the present invention.

Detailed Description

The terms "comprising" (and any form of "comprising", such as "comprises" in the singular and "comprising" in the present participle form), "having" (and any form of "having", such as "having" in the singular and "having" in the present participle form), "containing" (and any form of "containing", such as "containing" in the singular and "containing" in the present participle form), and "including" (and any form of "including", such as "including" in the singular and "including" in the present participle form, are open linking verbs. Thus, an apparatus or method that "comprises," "has," "contains," or "includes" one or more components or steps possesses those one or more components or steps, but is not limited to possessing only those one or more components or steps. Likewise, a component of a device or a step of a method that "comprises," "has," "contains," or "includes" one or more features possesses those one or more features, but is not limited to possessing only those one or more features. Further, a structure shaped in a certain way should be understood as being shaped in at least that way, but can also be shaped in other ways not illustrated.

Any embodiment of any of the methods and apparatus of the present invention may consist of, or consist essentially of, the recited steps and/or features, rather than, comprise, contain, or have the recited steps and/or features. Thus, as an example, although some embodiments of the method of the present invention include the steps of: welding a coupling structure to a first strand end portion of a device shaped for insertion into an anatomical structure; and welding the coupling structure to a second strand end portion of the device; wherein the coupling structure is not a strand of the device and the device comprises one or more strands comprising nickel and titanium, but other embodiments consist essentially of or consist of: welding a coupling structure to a first strand end portion of a device shaped for insertion into an anatomical structure; and welding the coupling structure to a second strand end portion of the device; wherein the coupling structure is not a strand of the device, and the device includes one or more strands comprising nickel and titanium.

The terms "a" and "an" are defined as one or more than one unless otherwise indicated explicitly in the disclosure. The terms "substantially" and "about" are defined as at least close to (and including) a particular value or condition (preferably within 10% of the particular value or condition, more preferably within 1% of the particular value or condition, and most preferably within 0.1% of the particular value or condition).

The method of the present invention may be used to secure two unsecured wire ends of a device shaped for insertion into an anatomical structure. The initial process for forming the device may include a braiding process (such as the braiding methods disclosed in U.S. patent nos. 6,792,979 and 7,048,014, which are incorporated by reference), or any other type of process capable of producing at least two unsecured wire ends. One suitable braiding machine that may be used is "Steeger 24 Carrier Horizontal Fine Wire Carrier Braider HS 140-24-IH" manufactured by "Steeger USA" (Stebadburg, N.C.). The device may be formed from one or more wires, and the device may have a variety of configurations, such as a stent (e.g., a stent having two ends or a multi-legged stent having more than two ends), an occluder, or a filter. The wire end may be secured by a coupling structure that includes a passage (e.g., a thin tube) into which the wire end can be inserted from an opposite end and welded (e.g., laser welded) to the end of the wire inserted into the passage. However, the joint structure need not surround the wire end like a thin tube. Alternatively, in other embodiments, the coupling structure may include a flat strip or a contoured strip, such as a portion of a thin tube, attached to the strand end. Further, while laser welding is described below as the preferred method of joining, other methods may be used including, but not limited to, electron beam welding, resistance welding, tungsten inert gas welding, metal inert gas welding, crimping (crimping), thermal welding, thermal expansion joining (bridging), and adhesive bonding.

The coupling structure may be made of the same material as the strand end portions coupled to the coupling structure (e.g., a nickel-titanium coupling structure may be used to couple two nickel-titanium wire end portions together), or may be made of one or more different materials (e.g., a stainless steel coupling structure may be used to couple two nickel-titanium wire end portions together).

In embodiments where the device is braided from nickel-titanium wire (nickel-56.0% by weight of the total composition; titanium-the balance of the total composition), after the initial braiding process is complete, the device (if desired, with a mandrel on which it is formed) may be heat treated according to the data in table 1 below:

TABLE 1

Diameter of support (mm)	Temperature setting (. degree. C.) of the furnace	Heat treatment time (minutes)
			4.0	525	5
5.0	535	5
			6.0	510	10
7.0	520	10
			8.0	510	13
9.0	520	13
			10.0	530	13

When the device is heat treated in this manner, the device may have free wire ends on some or all of the device ends. Fig. 1 shows one embodiment of a device (device 100) having one or more wires and shaped for insertion into an anatomical structure. The device 100 is a stent, and the device 100 is woven from six wires (wires) having twelve half wires 10 according to the method disclosed in U.S. patent No.7,018,401. There is no free wire end on the device end of the device 100, not shown. Each half-wire is only fixed (see fig. 3) to another half-wire (which may belong to the same wire or a different wire).

After this heat treatment, the apparatus may be quenched directly in deionized water until cooled. The free wire end of the device can then be woven back as needed, and then baked according to the data in table 1 and quenched directly in deionized water until cool. Fig. 2 shows device 100 after half of the twelve loose ends have been back-braided.

Next, one or more coupling structures (e.g., coupling structures comprising nickel and titanium, such as nickel 55.8% by weight of the total composition and titanium the balance of the total composition) may be attached to the strand end of the braided device at any desired location along the length of the device. The device may be loaded onto a mandrel prior to positioning the coupling structure to enable accurate setting of the inner diameter of the device. Once the coupling structure has been positioned as desired, the coupling structure may be secured to the strand end portion using any suitable method, such as laser welding (which will be described in greater detail below). Fig. 3-4B illustrate an embodiment of device 100 in which coupling structure 20 has been placed in contact with a pair of strand end portions, respectively, and then welded to those strand end portions according to a laser welding process described below. Fig. 5 shows two device ends 102, 104 of a device 100 formed by the weaving, back-weaving, and joint structure securing methods shown in fig. 1-4B and 6-9 for making the device, and shows that the device ends 102, 104 (device end 104 being the device end closest to the joint structure used) are each defined by a strand bight portion 40 (not all strand bight portions 40 are labeled), where the strand bight portions 40 have substantially similar shapes.

As shown in fig. 3 and 4A, in some embodiments, the coupling structure closest to a particular device end (e.g., the rightmost coupling structure 20 shown in these figures) may be spaced apart from the device end by at least one strand intersection or a plurality of strand intersections. In the embodiment shown in these figures, the rightmost coupling structure 20 shown in the figures is spaced from the device end shown in the figures by at least three strand intersections (indicated by circles labeled 30) taken along line 40, which line 40 is substantially parallel to the longitudinal axis 50 of the device 100. The right-most coupling structure 20 is spaced from the illustrated device end by at least one device opening 45 or a plurality of device openings 45; specifically, spaced from the illustrated device end by at least three device openings 45 (the device openings 45 have been outlined elsewhere in the figure to show that this type of opening (which may also be characterized as a mesh opening) is defined by wire intersections, specifically, the other device openings are defined by four wire intersections except for the last row of device openings, which are defined by only three wire intersections (thus, all device openings of such a device 100 shown in the figure are defined by at least three wire intersections)). Additionally, the rightmost coupling structure 20 forms a fourth strand intersection 30 from the illustrated device end along line 40 and is positioned below the strand of device 100 that intersects coupling structure 20. Each coupling structure 20 of the other coupling structures 20 is also individually positioned below the strands of device 100 that intersect with each coupling structure 20. Prior to fixation, the strand end that is fixedly attached to a particular coupling structure may be cut (as desired) so that the strand end is positioned substantially centrally under the strand that is to pass through the coupling structure; thus, the center of the tab construction will be located substantially at the intersection point defined by the tab construction portions, which is applicable to the tab construction shown in fig. 3-4B.

The coupling structures used (the number of coupling structures preferably being equal to the number of strands for the stent) may be axially aligned as with coupling structures 20 shown in fig. 3, 4A, 4B, 6, and 7, or may be axially spaced from one another and positioned around the periphery of the device as with coupling structures 20 shown in fig. 8 and 9. The cutting machine for cutting the ends of the wire may be of the type known under the trademark EremCutting machines of the type 576TX (cemented carbide cutters) or 503ETST (oblique head cemented carbide cutters), which are available from Cooper Hand Tools (Cooper Industries, LLC). For the small size of the device, a microscope may be used during cutting of the wire end and deployment of the coupling structure.

Fig. 10A-10C show examples of coupling structures for joining or connecting two wire ends (which may be wire ends of different wires or wire ends of the same wire) and examples of arrangements of wire end portions secured by such coupling structures. Fig. 10A shows coupling structure 20 secured to strand end portions 12, 14 in a butt joint or butt-joint configuration; this arrangement allows the wire end portions 12, 14 to be substantially aligned with each other. Coupling structure 20 is secured to strand end portion 12 by a weld that forms first weld region 22, and coupling structure 20 is secured to strand end portion 14 by a weld that forms second weld region 24. As shown, the first land 22 is not connected to the second land 24 by another land; the two weld areas are spaced apart and separated from each other. Furthermore, although in other embodiments the two strand end portions are in direct contact with each other, the two strand end portions shown in this figure are not in direct contact with each other (with a slight gap between their ends). The coupling structure 20 shown in fig. 10A has a passageway that exists prior to securing the coupling structure to either of the two wire ends and is sized to receive one wire of the device.

Fig. 10B shows coupling structure 20 secured to strand end portions 12, 14 in a lap joint or lap configuration; the structure may also feature an overlap. Thus, the two wire end portions are positioned to the side of each other rather than end-to-end. Although a slight gap is shown between the two wire end portions in this embodiment, in other embodiments, there may be direct side-to-side contact between them. The two welding zones 22, 24 have the same characteristics as the welding zone in the embodiment of fig. 10A: i.e. the two welding areas 22, 24 are not connected to each other by means of another welding area; they are spaced apart and separated from each other. Although the two welds forming the two weld zones shown schematically in fig. 10B are each directed to only one strand end portion, the two welds may also each be applied to both strand end portions, as are the welds forming the weld zones shown in fig. 6. Coupling structure 20 of the type shown in fig. 10B has a passageway that exists prior to securing the coupling structure to either of the two strand ends and that is sized to receive two strands of a device.

Fig. 10C shows another embodiment of one of the joint structures of the present invention, namely, joint structure 20 ', which joint structure 20' is fixed to first wire end 12 and second wire end 14 by two welds forming first weld region 22 and second weld region 24. The joint structure 20' has no passages; alternatively, the coupling structure 20' is formed as a portion of a tubular structure (e.g., a strip having an arc, although in other embodiments the strip is flat).

Fig. 11A is a schematic view showing the joint structure 20 for a specific device being axially aligned. Fig. 11B shows that the joint construction 20 may be arranged helically, which is a way of offsetting the joint constructions 20 axially and circumferentially (e.g. at 60 ° intervals) relative to each other.

For braided stents made from nitinol (e.g., a wire containing 56.0% nickel by weight of the total composition and the balance titanium by weight of the total composition), a joint structure made from the same type of nitinol (e.g., a nitinol containing 55.8% nickel by weight of the total composition and the balance titanium by weight of the total composition) may be used to join the ends of different strands by laser welding (e.g., pulse laser welding). An example of a suitable laser welding system is shown in fig. 12 and includes a LASAG pulsed Nd: YAG (neodymium: yttrium aluminum garnet) "EasyWelder" laser system selected from the SLS 200 series (LASAG, switzerland).

For stents made from six nitinol wires (nickel-56.0% by weight of the total composition; titanium-the balance of the total composition), six nitinol structures (nickel-55.8% by weight of the total composition; titanium-the balance of the total composition) may be used. The table in fig. 13 provides examples of the inner diameter, outer diameter, and length dimensions of a nitinol coupling structure of a specific diameter nitinol wire size that can be used for a specific size of six-wire braided stent, and also provides examples of the setup parameters for the LASAG welding system described above (scfh stands for standard cubic feet per hour).

The following briefly describes how the joint structure is secured to the paired wire ends of a heat treated (heat treated according to the above method) nickel titanium stent woven from six wires by using the above-described at least semi-automated (and in other embodiments fully automated) process of the LASAG welding system:

the stent has been partially back-woven (e.g., hand-woven), meaning that 6 of the 12 wire ends have been back-woven into the stent;

starting from any suitable wire crossing (e.g., the fourth or fifth wire crossing from a wire end that has been woven back), cutting the wire end as described above such that the ends of the wires contact under the crossing wires;

the coupling structure is loaded onto the wire ends and centered about the crossing wire while the stent is loaded onto the mandrel to enable precise setting of the stent's inner diameter;

securing the attachment region of the stent to the mandrel by a spring-loaded clamp to prevent relative movement between the stent and mandrel and to enable precise setting of the inner diameter of the stent and to maintain proper placement of the wire ends within the joint structure;

further, placing the mandrel with the holder mounted and secured therein in a laser welding system and aligning the first joint structure with the horizontal crosshair on a viewing screen of the system;

invoking a welding program for a specific size of a stent to be welded (examples are provided below); and

prompting an operator to align the crosshair with an upper left corner of the joint. Once aligned, the operator presses the start button, thereby forming a left weld. The system then moves and prompts the operator to align the crosshair to the top right corner of the joint. Once aligned, the operator presses the start button, thereby forming a right weld. The system then moves to the top left corner of the second joint and repeats the process. This will continue until all 12 welds are completed.

The dimensions of weld zone 24 of a particular joint structure 20 of one of the inventive arrangements (specifically, woven stents such as those shown in fig. 1-4B) are shown in fig. 14A, and example values for these dimensions are given in fig. 14B. Table 2 below provides example values for the dimensions of the tubular joint construction corresponding to the "joint construction number" given in fig. 14B:

TABLE 2

Joint structure number	Joint design inner diameter (inch)	Joint structure outside diameter (inch)	Joint structure length (inch)
				-01	0.0070	0.0100	0.070
-02	0.0070	0.0100	0.080
				-03	0.0075	0.0105	0.100
-04	0.0085	0.0120	0.120
				-05	0.0085	0.0120	0.150

Unless otherwise specified, the tolerances for the values in fig. 14B are as follows: x. ± 1; x ═ 5; 25. XX ═ ± · 25; XXX ═ 125. Unless otherwise specified, the tolerances for the values in table 2 are as follows: x ═ ± 030; -XX ═ 010; XXX ═ 005.

Thus, in the first example of the behavior of fig. 14B, a particular stent having an inner diameter of 4.0mm and a length of 40mm made from a 0.006 inch diameter nitinol wire (such as the wire described above) can be made from a 0.0070 inch inner diameter, a 0.0100 inch outer diameter, and a 0.070 inch length tubular joint structure (No. -01) with the dimensions A, B, C of the weld zone produced by laser welding securing the joint structure to one of the designated wires being 0.010 inch a, 0.005 inch B, and 0.010 inch C, respectively.

The following routines, written in industry standard NC (numerical code), can be used as the program for the above-described LASAG welding system for forming butt joints by using the above-described joint structure to obtain nickel titanium stents (formed by using the above-described nickel titanium alloy) of various sizes as previously described in the respective routines:

4mm internal diameter support

(ii) a Welding procedure for 4mm bore stent

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.25, respectively; pulse width 0.25ms

C108Q 200; peak power 200W

C111Q 120; scale value of A120

M51; laser monitoring is normal

(ii) a Moving the laser to the normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.656; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal (inter) movement

X-.040 Y.037; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.040 Y.037; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.040 Y.037; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.040 Y.037; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.040 Y.037; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a V. end of program +

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.008Y-. 004; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.058 Y.0045; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.008Y-004; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

5mm internal diameter support

(ii) a Welding procedure for 5mm inner diameter support

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.25, respectively; pulse width 0.25ms

C108Q 200; peak power 200W

C111Q 120; scale value of A120

M51; laser monitoring is normal

(ii) a Moved to a normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.656; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal movement

X-.040 Y.041; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.040 Y.041; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.040 Y.041; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.040 Y.041; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.040 Y.041; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.010Y-. 004; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.055Y.0045; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.010Y-004; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

6mm internal diameter support

(ii) a Welding procedure for 6mm inner diameter support

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.3, respectively; pulse width 0.3ms

C108Q 300; peak power 200W

C111Q 100; scale value of 100A

M51; laser monitoring is normal

(ii) a Moved to a normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.6716; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal movement

X-.060 Y.045; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.060 Y.045; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.060 Y.045; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.060 Y.045; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.060 Y.045; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.010Y-. 005; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.075Y.005; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.010Y-. 005; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

7mm internal diameter support

(ii) a Welding procedure for 7mm inner diameter support

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.3, respectively; pulse width 0.3ms

C108Q 300; peak power 200W

C111Q 100; scale value of 100A

M51; laser monitoring is normal

(ii) a Moved to a normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.6716; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal movement

X-.060 Y.049; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.060 Y.049; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.060 Y.049; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.060 Y.049; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.060 Y.049; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.010Y-. 005; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.075Y.005; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.010Y-. 005; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

Support with 8mm inner diameter

(ii) a Welding procedure for 8mm inner diameter support

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.3, respectively; pulse width 0.3ms

C108Q 300; peak power 200W

C111Q 100; scale value of 100A

M51; laser monitoring is normal

(ii) a Moved to a normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.6544; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal movement

X-.067 Y.053; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.067 Y.053; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.067 Y.053; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.067 Y.053; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.067 Y.053; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.010Y-. 006; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.095Y.006; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.010Y-. 006; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

9mm internal diameter support

(ii) a Welding procedure for 9mm inner diameter support

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.3, respectively; pulse width 0.3ms

C108Q 300; peak power 200W

C111Q 100; scale value of 100A

M51; laser monitoring is normal

(ii) a Moved to a normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.6716; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal movement

X-.067 Y.057; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.067 Y.057; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.067 Y.057; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.067 Y.057; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.067 Y.057; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.010Y-. 006; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.095Y.006; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.010Y-. 006; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

10mm internal diameter support

(ii) a Welding procedure for 10mm inner diameter support

M61; laser remote control

(ii) a Welding parameters

C101Q 10; frequency 10HZ

C102Q0.3, respectively; pulse width 0.3ms

C108Q 300; peak power 200W

C111Q 100; scale value of 100A

M51; laser monitoring is normal

(ii) a Moved to a normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

Z-2.6716; adjusting focus

(ii) a Welding six joints

M26H 152; door reset

M98P 2; go to subroutine 1-first splice

F4; fast feed for internal movement

X-.067 Y.061; back to the relative origin

M98P 2; go to subroutine 1-second splice

F4; fast feed for internal movement

X-.067 Y.061; back to the relative origin

M98P 2; go to subroutine 1-third splice

F4; fast feed for internal movement

X-.067 Y.061; back to the relative origin

M98P 2; go to subroutine 1-fourth splice

F4; fast feed for internal movement

X-.067 Y.061; back to the relative origin

M98P 2; go to subroutine 1-fifth junction

F4; fast feed for internal movement

X-.067 Y.061; back to the relative origin

M98P 2; go to subroutine 1-sixth junction

(ii) a Returning to normal operating position

G90; absolute coordinates

F50; feed rate

X3.93Y-4.6; positioning fixture and components

M25H 152; door of opening machine

M02; end of digital code

(ii) a Joint welding subprogram

O2; welding procedure

F1; feed rate

G05Q 1; intermittently jog/move to upper left corner

G91; incremental coordinates

M8; open air

G4F.5; stay for 0.5 second

X0.010Y-. 006; angular offset from joint

M71; laser machining with simultaneous feed

X is 0.015; left weld line of 0.015

M70; stopping laser processing

X0.095Y.006; to the right upper corner

G05Q 1; intermittently slow/adjust to the upper right corner

X-0.010Y-. 006; offset from the upper right corner of the joint

M71; laser machining with simultaneous feed

X-0.015; welding seam is 0.015

M70; stopping laser processing

M9; stopping qi

M99; return to

***

It should be understood that the methods and apparatus formed by the methods of the present invention are not intended to be limited to the particular forms disclosed. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the claims. For example, while the devices shown in the figures are woven from multiple wires, in other embodiments, the present methods may be applied to devices woven or otherwise formed from only one wire (e.g., a nickel titanium wire). In addition, although stents are shown in the drawings, other devices suitable for placement within the anatomy, such as filters and occluders, may have their free wire ends attached according to the method of the present invention.

The claims are not to be read as including means-plus-function limitations or step-plus-function limitations unless in a particular claim such limitations are expressly set forth using the phrases "means for" or "step for," respectively.

Claims (91)

1. A method, comprising the steps of:

securing a coupling structure to a first strand end portion of a device shaped for insertion into an anatomical structure; and

securing the coupling structure to the second strand end portion of the device;

wherein the first strand end portion and the second strand end portion are substantially aligned, the coupling structure is not a strand of the device, and the device comprises one or more strands comprising nickel and titanium.

2. The method of claim 1, wherein the device is a braided, self-expanding stent.

3. The method of claim 1, where the coupling structure has a passageway that exists prior to securing the coupling structure to the first strand end portion and the second strand end portion.

4. The method of claim 1, wherein the device is a woven, self-expanding stent comprising two or more device ends, wherein each device end is defined by a wire curved turnaround portion, and wherein the wire curved turnaround portions of all of the device ends have substantially similar shapes.

5. The method of claim 1, where the coupling structure is secured to the first strand end portion by a weld that forms a first weld region, where the coupling structure is secured to the second strand end portion by a weld that forms a second weld region, and where the first and second weld regions are not directly connected to each other by another weld region.

6. The method of claim 5, wherein the coupling structure is a piece of material separate from the first strand end portion and the second strand end portion, and prior to the securing step, the method further comprises the steps of:

bringing the linker structure into direct contact with the first wire end; and

such that the coupling structure is in direct contact with the second wire end.

7. The method of claim 1, wherein the device comprises a plurality of half-wires, and each half-wire is secured to only one other wire.

8. The method of claim 1, where the coupling structure is positioned below a strand of the device that intersects the coupling structure.

9. The method of claim 1, wherein the device includes a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end by at least one strand intersection point along a line substantially parallel to the longitudinal axis.

10. The method of claim 1, wherein the device includes a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end along a line substantially parallel to the longitudinal axis by at least one device opening defined by at least three strand intersections.

11. The method of claim 1, where the coupling structure is secured to the first strand end portion by laser welding.

12. The method of claim 11, where the coupling structure is secured to the second strand end portion by laser welding.

13. The method of claim 12, where the laser welding securing the coupling structure to the first and second strand end portions is a semi-automated weld.

14. The method of claim 1, wherein the method further comprises the steps of:

securing a second coupling structure to a third strand end portion of the device; and

securing the second coupling structure to the fourth strand end portion of the device.

15. The method of claim 1, wherein the method further comprises the steps of:

one coupling structure is secured to each of the other five pairs of strand end portions of the device.

16. The method according to claim 15, wherein the joint construction is aligned in an axial direction.

17. The method of claim 15, where two or more of the joint structures are offset relative to each other around the circumference of the device.

18. The method of claim 1, wherein the method further comprises the steps of: laser welding a coupling structure to each of the other five wire end pairs of the device, wherein each coupling structure comprises nickel and titanium and each wire end portion comprises nickel and titanium.

19. The method of claim 18, wherein one of the other five pairs of wire end portions comprises wire end portions of two different wires of the device.

20. The method of claim 18, wherein one of the other five pairs of wire end portions comprises a wire end portion of the same wire of the device.

21. The method according to claim 18, wherein the joint construction is aligned in an axial direction.

22. The method of claim 18, where two or more of the coupling structures are offset relative to each other around the periphery of the device.

23. The method of claim 1, wherein the device comprises four different wires, each of the four different wires comprising nickel and titanium.

25. The method of claim 1, wherein the device comprises five different wires, each of the five different wires comprising nickel and titanium.

26. The method of claim 1, wherein the device comprises six different wires, each of the six different wires comprising nickel and titanium.

27. A method, comprising the steps of:

welding a coupling structure to a first strand end portion of a device shaped for insertion into an anatomical structure; and

welding the coupling structure to a second strand end portion of the device;

wherein the coupling structure is not a strand of the device, and the device includes one or more strands comprising nickel and titanium.

28. The method of claim 27, wherein the first wire end portion is substantially aligned with the second wire end portion.

29. The method of claim 27, wherein the device is a braided, self-expanding stent.

30. The method of claim 27, where the coupling structure has a passageway that exists prior to welding the coupling structure to the first strand end portion and the second strand end portion.

31. The method of claim 27, wherein the device is a woven, self-expanding stent comprising two or more device ends, wherein each device end is defined by a wire curved turnaround portion, and wherein the wire curved turnaround portions of all of the device ends have substantially similar shapes.

32. The method of claim 27, where a first welded region is formed by welding the coupling structure to the first strand end portion, a second welded region is formed by welding the coupling structure to the second strand end portion, and the first and second welded regions are not directly connected to each other by another welded region.

33. The method of claim 32, wherein the coupling structure is a separate piece of material from the first strand end portion and the second strand end portion, and prior to the welding step, the method further comprises the steps of:

bringing the linker structure into direct contact with the first wire end; and

such that the coupling structure is in direct contact with the second wire end.

34. The method of claim 27, wherein the device comprises a plurality of half-wires, and no half-wire is welded to more than one other half-wire.

35. The method of claim 27, where the coupling structure is positioned below the strand of the device that intersects the coupling structure.

36. The method of claim 27, wherein the device includes a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end by at least one strand intersection point along a line substantially parallel to the longitudinal axis.

37. The method of claim 27, wherein the device includes a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end along a line substantially parallel to the longitudinal axis by at least one device opening defined by at least three strand intersections.

38. The method of claim 27, where the coupling structure is welded to the first strand end portion by laser welding.

39. The method of claim 38, where the coupling structure is welded to the second strand end portion by laser welding.

40. The method of claim 39, where the laser welding of the coupling structure to the first and second strand ends is a semi-automated weld.

41. The method of claim 27, wherein the method further comprises the steps of:

welding a second coupling structure to a third strand end portion of the device; and

welding the second coupling structure to a fourth strand end portion of the device.

42. The method of claim 27, wherein the method further comprises the steps of:

one coupling structure is welded to each of the other five wire end pairs of the device.

43. The method according to claim 42, wherein the joint construction is aligned in an axial direction.

44. The method of claim 42, where two or more of the coupling structures are offset relative to each other around the circumference of the device.

45. The method of claim 27, wherein the method further comprises the steps of: laser welding a coupling structure to each of the other five wire end pairs of the device, wherein each coupling structure comprises nickel and titanium and each wire end portion comprises nickel and titanium.

46. The method of claim 45, wherein one of the other five pairs of wire end portions comprises wire end portions of two different wires of the device.

47. The method of claim 45, wherein one of the other five pairs of wire end portions comprises a wire end portion of the same wire of the device.

48. The method according to claim 45, wherein the joint construction is aligned in an axial direction.

49. The method of claim 45, where two or more of the coupling structures are offset relative to each other around the circumference of the device.

50. The method of claim 27, wherein the device comprises four different wires, each of the four different wires comprising nickel and titanium.

51. The method of claim 27, wherein the device comprises five different wires, each of the five different wires comprising nickel and titanium.

52. The method of claim 27, wherein the device comprises six different wires, each of the six different wires comprising nickel and titanium.

53. A device having one or more wires and shaped for insertion into an anatomical structure, the device comprising:

a coupling structure secured to two different strand end portions that are substantially aligned with each other;

wherein the two different strand end portions comprise nickel and titanium, and the coupling structure is not a strand of the device.

54. The device of claim 53, wherein the device is shaped as a braided, self-expanding stent.

55. The device of claim 53, where the coupling structure has a channel within which the two different strand end portions are positioned.

56. The device of claim 53, wherein the device is shaped as a woven, self-expanding stent comprising two or more device ends, wherein each device end is defined by a wire curved turnaround portion, and wherein the wire curved turnaround portions of all of the device ends have substantially similar shapes.

57. The apparatus recited in claim 53, where the coupling structure is secured to the first strand end portion by a weld that forms a first weld region, where the coupling structure is secured to the second strand end portion by a weld that forms a second weld region, and where the first and second weld regions are not directly connected to each other by another weld region.

58. The device of claim 53, wherein the device comprises a plurality of half-wires, and each half-wire is secured to only one other wire.

59. The device of claim 53, where the coupling structure is positioned below a strand of the device that intersects the coupling structure.

60. The device of claim 53, wherein the device includes a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end by at least one strand intersection point along a line substantially parallel to the longitudinal axis.

61. The device of claim 53, wherein the device includes a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end along a line substantially parallel to the longitudinal axis by at least one device opening defined by at least three strand intersections.

62. The apparatus of claim 53, where the coupling structure is laser welded to the first strand end portion.

63. The device of claim 62, where the coupling structure is laser welded to the second strand end portion.

64. The apparatus of claim 53, wherein the apparatus further comprises:

a second coupling structure secured to the other strand end portions.

65. The apparatus of claim 53, wherein the apparatus further comprises:

a coupling structure secured to each of the other five pairs of strand end portions.

66. The device according to claim 65, wherein the joint construction is arranged in a row in the axial direction.

67. The device of claim 65, where two or more of the coupling structures are offset relative to each other around the periphery of the device.

68. The apparatus of claim 32, wherein the apparatus further comprises:

a coupling structure laser welded to each of the other five wire pair ends of the device, wherein each coupling structure comprises nickel and titanium, and each wire end comprises nickel and titanium.

69. The device of claim 68, wherein one of the other five pairs of wire ends comprises wire ends of two different wires of the device.

70. The device of claim 68, wherein one of the other five pairs of wire ends comprises a wire end of the same wire of the device.

71. The device according to claim 68, wherein the joint construction is arranged in a row in the axial direction.

72. The device of claim 68, where two or more of the coupling structures are offset relative to each other around the periphery of the device.

73. A device having one or more wires and shaped for insertion into an anatomical structure, the device comprising:

a coupling structure welded to two different strand end portions;

wherein the two different strand end portions comprise nickel and titanium, and the coupling structure is not a strand of the device.

74. The device of claim 73, wherein the device is shaped as a braided, self-expanding stent.

75. The device of claim 73, where the coupling structure has a channel within which the two different strand end portions are positioned.

76. The device of claim 73, wherein the device is shaped as a woven, self-expanding stent comprising two or more device ends, wherein each device end is defined by a wire curved turnaround portion, and wherein the wire curved turnaround portions of all of the device ends have substantially similar shapes.

77. The apparatus recited in claim 73, wherein the apparatus includes a first weld region formed by a weld securing the first wire end to the joint structure and a second weld region formed by a weld securing the second wire end to the joint structure, and the first and second weld regions are not directly connected to each other by another weld region.

78. The device of claim 73, wherein the device comprises a plurality of half-wires, and each half-wire is secured to only one other wire.

79. The device of claim 73, where the coupling structure is positioned below a strand of the device that intersects the coupling structure.

80. The device of claim 73, wherein the device comprises a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end by at least one strand intersection point along a line substantially parallel to the longitudinal axis.

81. The device of claim 73, wherein the device comprises a longitudinal axis and at least two device ends, the coupling structure being closer to one of the device ends than to any other device end, and the coupling structure being spaced apart from the closest device end along a line substantially parallel to the longitudinal axis by at least one device opening defined by at least three strand intersections.

82. The device of claim 73, where the coupling structure is laser welded to the first strand end portion.

83. The device of claim 82, where the coupling structure is laser welded to the second strand end portion.

84. The apparatus of claim 73, further comprising:

a second coupling structure that is welded to the other pair of strand end portions.

85. The apparatus of claim 73, further comprising:

a coupling structure welded to each of the other five pairs of wire ends.

86. The device according to claim 85, wherein the joint structures are arranged in a row in the axial direction.

87. The device of claim 85, where two or more of the coupling structures are offset relative to each other around the periphery of the device.

88. The apparatus of claim 32, wherein the apparatus further comprises:

a coupling structure laser welded to each of the other five wire pair ends of the device, wherein each coupling structure comprises nickel and titanium, and each wire end comprises nickel and titanium.

89. The device of claim 88, wherein one of the other five pairs of wire ends comprises wire ends of two different wires of the device.

90. The device of claim 88, wherein one of the other five pairs of wire ends comprises a wire end of the same wire of the device.

91. The device according to claim 88, wherein the joint structures are arranged in a row in the axial direction.

92. The device of claim 88, where two or more of the coupling structures are offset relative to each other around the circumference of the device.