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US20080119825A1 - Catheter and Process for Producing the Catheter - Google Patents

Catheter and Process for Producing the Catheter Download PDF

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Publication number
US20080119825A1
US20080119825A1 US11/795,601 US79560106A US2008119825A1 US 20080119825 A1 US20080119825 A1 US 20080119825A1 US 79560106 A US79560106 A US 79560106A US 2008119825 A1 US2008119825 A1 US 2008119825A1
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Prior art keywords
catheter
layer
ptfe
etfe
composition
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Abandoned
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US11/795,601
Inventor
Yukio Imai
Takashi Suzuki
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Terumo Corp
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Terumo Corp
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Assigned to TERUMO KABUSHIKI KAISHA reassignment TERUMO KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: IMAI, YUKIO, SUZUKI, TAKASHI
Publication of US20080119825A1 publication Critical patent/US20080119825A1/en
Abandoned legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M25/00—Catheters; Hollow probes
    • A61M25/0043—Catheters; Hollow probes characterised by structural features
    • A61M25/0045—Catheters; Hollow probes characterised by structural features multi-layered, e.g. coated
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L29/00—Materials for catheters, medical tubing, cannulae, or endoscopes or for coating catheters
    • A61L29/04—Macromolecular materials
    • A61L29/041—Macromolecular materials obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M25/00—Catheters; Hollow probes
    • A61M25/0009—Making of catheters or other medical or surgical tubes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M25/00—Catheters; Hollow probes
    • A61M25/0043—Catheters; Hollow probes characterised by structural features
    • A61M25/0045—Catheters; Hollow probes characterised by structural features multi-layered, e.g. coated
    • A61M2025/0046—Coatings for improving slidability
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M25/00—Catheters; Hollow probes
    • A61M25/0043—Catheters; Hollow probes characterised by structural features
    • A61M25/0045—Catheters; Hollow probes characterised by structural features multi-layered, e.g. coated
    • A61M2025/0046—Coatings for improving slidability
    • A61M2025/0047—Coatings for improving slidability the inner layer having a higher lubricity

Definitions

  • the present invention relates to a catheter for medical use to be used for diagnosis or therapy by being inserted into a blood vessel or other body lumen, and to a process for producing the catheter.
  • catheters have been being used in an increasing number of diagnostic and/or therapeutic methods for alleviating the physical and time-basis burdens on patients.
  • the catheter must meet the structural requirements for high operationality and safety when serving as a medical device and, simultaneously, the luminal internal surface of its tube (referred to also as “catheter body”) must exhibit lubricity.
  • the lubricity is necessary for externally injecting a liquid medicine or the like to a predetermined site in the patient's body through the lumen of the catheter body, for draining a body fluid in the living body or the like, or for passing other therapeutic device therethrough.
  • Patent Document 1 describes a catheter including a catheter body having an outer layer and an inner layer, the outer layer having a first region and a second region located on the proximal end side of the first region, wherein the first region is composed of a polyester elastomer, and the second region is composed of a polyurethane elastomer higher in hardness than the polyester elastomer constituting the first region.
  • This catheter is excellent in operationality such as pushability, torque transmitting property, following property, and anti-kinking property.
  • a material capable of reducing the friction of an internal surface of the inner layer for example, a fluorinated resin such as polytetrafluoroethylene (PTFE) is used as the material constituting the inner layer, so that the luminal internal surface of the catheter body has lubricity.
  • PTFE polytetrafluoroethylene
  • a fluorinated resin particularly, PTFE is thus used as the material constituting the luminal internal surface of the catheter body.
  • a catheter must be sterilized before used, since it is used for a living body, like other medical devices.
  • General sterilization methods include the methods in which a gas or water vapor is used. These methods, however, have problems as to the toxicity of the gas, the long treatment time required for sterilization, etc.
  • the sterilizing method using radioactive rays such as electron beams have come to be paid attention to. According to this method, toxicity is obviated and the treatment time required for sterilization is short.
  • PTFE is deteriorated when irradiated with ionizing radiations of not less than 1 kGy, and is extremely deteriorated in mechanical properties at an absorbed dose of around 25 kGy, which is a sterilizing dose generally used in the cases of sterilization with ⁇ -rays, electron beams and the like.
  • Patent Document 1 Japanese Patent Laid-open No. 2001-190681
  • a catheter including a catheter body composed of a composition containing ETFE (ethylene-tetrafluoroethylene copolymer) and PTFE (polytetrafluoroethylene) in a mass ratio of from 99:1 to 45:55.
  • ETFE ethylene-tetrafluoroethylene copolymer
  • PTFE polytetrafluoroethylene
  • a catheter including a catheter layer composed of a composition containing ETFE (ethylene-tetrafluoroethylene copolymer) and PTFE (polytetrafluoroethylene) in a mass ratio of from 99:1 to 45:55.
  • ETFE ethylene-tetrafluoroethylene copolymer
  • PTFE polytetrafluoroethylene
  • a catheter comprising an elongated tube, said elongated tube having a proximal end section and a distal end section defining a lumen and a wall, said wall having a tubular cross section substantially uniform in thickness between said distal end section and said proximal end section, and said wall being composed of a composition containing ETFE and PTFE in a mass ratio of from 99:1 to 45:55.
  • a process for producing a catheter including the steps of:
  • the luminal internal surface of the catheter according to the present invention has a lubrication characteristic substantially identical with that of PTFE. Therefore, the use of the catheter according to the present invention makes it possible to easily carry out injection externally a liquid medicine or the like to a predetermined site in a patient's body through the lumen of the catheter body, drainage of a body fluid or the like present in the living body, and passage of other therapeutic devices therethrough.
  • the luminal internal surface of the catheter according to the present invention is composed of a material having a resistance to radioactive rays not had by PTFE. Therefore, a sterilizing method using radioactive rays, which obviates toxicity and ensures that the treatment time required for sterilization is short, can be applied to the catheter according to the present invention.
  • FIG. 1 [ FIG. 1 ]
  • FIG. 1 illustrates an embodiment of overall configuration in the case where the catheter according to the present invention is applied to a blood vessel catheter.
  • FIG. 2 [ FIG. 2 ]
  • FIG. 2 is a diagram showing the relationship between PTFE blending proportion and tensile strengths before and after irradiation with electron beams.
  • FIG. 3 [ FIG. 3 ]
  • FIG. 3 is a diagram showing the relationship between PTFE blending proportion and the retention of tensile strength before and after irradiation with electron beams.
  • FIG. 4 is a schematic illustration of a measuring instrument for friction test of a material forming the catheter body pertaining to the present invention.
  • FIG. 1 is a plan view showing an example of overall configuration in the case where the catheter of the present invention is applied to a blood vessel catheter.
  • a tip section which is inserted in a lumen such as a blood vessel is shown in section.
  • the right side in FIG. 1 will be referred to as “the proximal end”, and the left side as “the distal end”.
  • the catheter 1 shown in FIG. 1 is composed of a catheter body 2 , a hub 4 mounted to the proximal end 21 of the catheter body 2 , and an anti-kinking protector 41 .
  • the catheter body 2 is formed with a lumen (i.e., inner cavity) 3 in the inside thereof ranging from the proximal end 21 to the distal end 22 .
  • a guide wire is inserted in the lumen 3 .
  • the lumen 3 can be used also as a passage for a liquid medicine or the like.
  • the hub 4 functions as an insertion port for inserting the guide wire into the lumen 3 , an injection port for injecting a liquid medicine or the like into the lumen 3 , and the like, and functions also as a grip section to be gripped at the time of operating the catheter 1 .
  • the overall length of the catheter body, the thickness of the tube wall and the like in the catheter according to the present invention are not particularly limited, and can be appropriately selected according to the purpose of use of the catheter.
  • the overall length of the catheter body (tube) is 800 to 1500 mm, and the thickness of the tube wall is 0.02 to 0.5 mm.
  • hub 4 As for the hub 4 , common hubs can be used.
  • the catheter body has a catheter layer composed of a composition containing ETFE and PTFE in a mass ratio of from 99:1 to 45:55 (the composition hereinafter referred to also as “the composition in the present invention”).
  • the ETFE used in the present invention is not particularly limited, and may be any of those conventionally used widely in the production of medical devices such as catheters.
  • the ETFE can be prepared by copolymerizing TFE (tetrafluoroethylene) with ethylene by a conventionally known method.
  • the TFE/ethylene polymer composition of the ETFE used in the present invention is not particularly limited.
  • the ETFE may contain a small amount of a third ingredient in such a range as not to spoil the characteristics aimed at in the invention in addition to TFE and ethylene in the composition.
  • the TFE/ethylene polymer composition is from about 50/50 to 60/40 mol %, and the ETFE is substantially an alternate copolymer.
  • the ETFE contains a third ingredient as follows. Namely, the ETFE generally widely utilized is a ternary copolymer containing the third ingredient. Furthermore, the ETFE has an MFR (melt flow rate: fluidity in a molten state) of 3 to 45 g/10 min, and a density of 1.70 to 1.75 g/cm 3 .
  • the ETFE thus generally utilized widely can be preferably used.
  • Examples of the third ingredient includes fluorinated ⁇ -monoolefin, fluorinated vinyl ether, hydrofluorocarbon fluorinated vinyl ether, hydrocarbon fluorinated vinyl ether monomer, and vinyl esters.
  • the PTFE used in the present invention is not particularly limited, and may be any of those conventionally used widely in the production of medical devices such as catheters.
  • the PTFE can be prepared by polymerizing the TFE (tetrafluoroethylene) monomer by a conventionally known method.
  • the PTFE has a melt viscosity of 5,000 to 100,000 poise, and a density of 2.13 to 2.22 g/cm 3 .
  • the forms of the ETFE and the PTFE used in the present invention are not particularly limited, but these materials are each preferably in a pellet form or a powdery form (a dry powder or a dispersion (a uniform dispersion of a fine powder in a solvent)). It is preferable that the ETFE and/or the PTFE is in a pellet form or a powdery form, since they can be easily mixed with each other.
  • the ETFE and/or the PTFE is in the form of a dispersion
  • a further homogeneous dispersed state of finer PTFE particles can be obtained, which is preferable from the viewpoint of the possibility that a catheter with a smaller tube wall thickness (1 to 40 ⁇ m) can be easily obtained.
  • Dry powdery ETFE and PTFE are commercially available as molding powders and fine powders, and these powders can be preferably used in the present invention.
  • a composition containing the ETFE and the PTFE in a mass ratio of from 99:1 to 45:55, preferably from 95:5 to 60:40, more preferably from 90:10 to 80:20 is applied as the material.
  • the relationship between the mixing ratio of the ETFE with the PTFE and the resistance to radioactive rays is considered to depend on which of the ETFE and the PTFE forms the sea phase in the sea-island structure upon mixing of the ETFE with the PTFE. Specifically, it is considered that the resistance to radioactive rays is exhibited with priority in the case where the ETFE having a resistance to radioactive rays has a greater volumetric ratio than the PTFE having a higher lubricity; it means that the ETFE forms the sea phase.
  • the luminal internal surface of the catheter body produced from the composition in the present invention containing the ETFE and the PTFE in the above-mentioned ratio exhibits a high resistance to radioactive rays without loosing the general lubricity characteristic.
  • the use of the catheter according to the present invention makes it possible to easily carry out external injection of a liquid medicine or the like to a predetermined site in a patient's body through the lumen of the catheter body, drainage of a humor or the like present in the living body, and passage of other medical devices therethrough.
  • a sterilizing method using radioactive rays which obviates toxicity and ensures that the treatment time required for sterilization is short can be applied to the catheter according to the present invention.
  • the radioactive rays herein includes ⁇ -rays, electron beams, X-rays and the like, and is not particularly limited, insofar as the rays can be used for sterilization of medical devices.
  • the irradiating temperature and the irradiation dose of the rays are not limited, and may be at the levels which are commonly applied in sterilization of medical devices.
  • the atmosphere for irradiation is room temperature (about 23° C.)
  • the irradiation dose is 1 to 100 kGy, preferably 15 to 60 kGy.
  • the mass ratio of the ETFE to the PTFE is within from 99:1 to 55:45, more preferably from 95:5 to 70:30 in the composition in the present invention such that the composition in the present invention has a fluidity optimal for injection molding and extrusion molding and is excellent in processibility.
  • composition in the present invention may contain other organic material(s), in addition to the ETFE and the PTFE.
  • organic material(s) examples include polystyrene, polyethylene, polyamide, polyimide, polysulfone, polyphenylene sulfide, polyvinyl chloride, polycarbonate, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-styrene copolymer, polyvinyl, silicone, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polyvinylidene fluoride, polyvinyl fluoride, and ethylene-chlorotrifluoroethylene copolymer.
  • composition in the present invention may contain the organic material(s) in a proportion of 0.1 to 10 mass % based on the total mass of the ETFE and the PTFE.
  • composition in the present invention may contain additives, in addition to the ETFE and the PTFE.
  • additives examples include pigments, dyes, X-rays contrast agent (barium sulfate, tungsten, bismuth oxide or the like), reinforcing agent (glass fiber, carbon fiber, talc, mica, clay mineral, potassium titanate fiber, or the like), filler (carbon black, silica, alumina, titanium oxide, metal powder, wood flour, rice hull, or the like), thermal stabilizer, oxidation/deterioration inhibitor, UV absorber, lubricant, mold release agent, crystalline nucleophile, plasticizer, flame retardant, antistatic agent, and foaming agent.
  • X-rays contrast agent barium sulfate, tungsten, bismuth oxide or the like
  • reinforcing agent glass fiber, carbon fiber, talc, mica, clay mineral, potassium titanate fiber, or the like
  • filler carbon black, silica, alumina, titanium oxide, metal powder, wood flour, rice hull, or the like
  • thermal stabilizer oxidation/deterioration inhibitor
  • composition in the present invention may contain the additive(s) in a proportion of 1 to 50 mass % based on the total mass of the ETFE and the PTFE.
  • the catheter layer of the catheter body of the catheter according to the present invention is produced from the above-mentioned composition in the present invention by a method which will be described later.
  • the catheter according to the present invention may have the catheter layer serving alone as the catheter body; however, it is preferable for the catheter to have a resin layer composed of a resin composition different from the composition in the present invention on the catheter layer. This ensures effectively that the rigidity of the catheter body is enhanced, and the pushability and torque transmitting performance of the catheter body are enhanced.
  • the catheter body in the present invention has such as the resin layer constituting an outer layer, it is effectively ensured that the reinforcement layer to be described later can be firmly fixed within the catheter body.
  • the resin composition constituting the resin layer is not particularly limited, but it is preferably a resin composition more flexible than the catheter layer (i.e., inner layer).
  • the resin composition include polyamide resin, polybutylene terephthalate, polyester elastomer, polyethylene terephthalate, and mixtures and copolymers thereof.
  • these resin compositions preferred are polyamide resin and polyester elastomer, in view of their excellent resistance to radioactive rays and little lowering in mechanical properties upon irradiation with radioactive rays.
  • polyamide resin examples include nylon 6, nylon 66, nylon 610, nylon 46, nylon 9, nylon 11, nylon 12, and nylon 12 elastomer.
  • nylon 12 and nylon 12 elastomer preferred are nylon 12 and nylon 12 elastomer, in view of their excellent flexibility and chemical resistance.
  • the thickness of the resin layer is not particularly limited. Usually, the thickness is preferably about 0.01 to 1.0 mm, more preferably about 0.03 to 0.1 mm.
  • the resin layer can be formed on the catheter layer in the present invention, by a method which will be described later.
  • a reinforcement layer between the catheter layer and the resin layer. This ensures effectively that the rigidity of the catheter body is further enhanced, and the pushability and torque transmitting performance of the catheter body are further enhanced.
  • the reinforcement layer is composed, for example, a spiral element.
  • the spiral element may be composed of at least one of a metallic member and a nonmetallic member.
  • Examples of the spiral element include those obtained by forming a metallic wire or plate member into a spiral shape, those obtained by forming a nonmetallic string or plate member into a spiral shape, and those obtained by forming a laminate of a metallic member and a nonmetallic member into a spiral shape.
  • Examples of the material constituting the metallic member include stainless steels, nickel-titanium alloys, platinum, iridium, and tungsten, which may be used either singly or in combination of two or more of them.
  • examples of the material constituting the nonmetallic member include carbon, polyamide, polyethylene terephthalate, and polybutylene terephthalate, which may be used either singly or in combination of two or more of them.
  • the pitch of winding of the spiral element is not particularly limited.
  • the pitch is preferably about 0 to 2 mm, more preferably about 0.02 to 0.5 mm.
  • an appropriate rigidity is imparted to the catheter body, and the pushability and torque transmitting performance of the catheter body are further enhanced.
  • the cross-sectional shape of the spiral element is not limited to circle, and may be a flat shape; namely, the spiral element may be ribbon-like (i.e., belt-like) in shape.
  • the diameter of the circle is preferably about 0.03 to 0.06 mm, more preferably about 0.04 to 0.05 mm.
  • the width of the ribbon-like shape is preferably about 0.1 to 1.0 mm, and the thickness is preferably about 0.04 to 0.05 mm.
  • the reinforcement layer is not particularly limited, insofar as it can impart an appropriate rigidity to the catheter body.
  • the reinforcement layer may be composed of the spiral element alone, a braided element alone, or a combination of a braided element and the spiral element (for example, one which is composed of a braided element on the proximal end side and of the spiral element on the tip side, one which is a laminate of a braided element and the spiral element, or the like).
  • the braided element may be composed of at least one of a metallic member and a nonmetallic member.
  • the braided element include those obtained by braiding metallic wires alone, those obtained by braiding nonmetallic strings alone, and those obtained by braiding a metallic wire with a nonmetallic string.
  • Examples of the material constituting the metallic wire include stainless steels and nickel-titanium alloys, or the like, which may be used either singly or in combination of two or more of them.
  • examples of the material constituting the nonmetallic string include carbon, polyamide, polyethylene terephthalate, and polybutylene terephthalate, which may be used either singly or in combination of two or more of them.
  • the reinforcement layer composed of such a spiral element or braided element provides a sufficient reinforcing effect even when comparatively small in thickness. Therefore, the catheter body having such a reinforcement layer is advantageous in adopting a smaller diameter.
  • the catheter layer is produced by using the composition containing the ETFE and the PTFE and, optionally, the organic material(s) and/or the additive(s).
  • the process for producing the catheter layer is not particularly limited; for example, the catheter layer is produced by the following process.
  • the mixture is fed into a melt extruder, and is stirred at a temperature of 230 to 280° C.
  • the stirred mixture is extruded by the extruder onto a mandrel to form a coating film, which is subjected to baking together with the mandrel in a furnace.
  • the baking temperature should be not lower than the melting point of ETFE, namely, not lower than 220° C.
  • the baking temperature is preferably not higher than 330° C., which is the melting point of PTFE, and is preferably not higher than 250° C.
  • a lumpy composition can be obtained by compressing the stirred composition, which is preferable since the supply of the composition into the extruder and the coating of the mandrel with the composition are stabilized.
  • a volatile oil kerosene or the like
  • the catheter layer produced by such a process as above can be used alone as the catheter body.
  • the above-mentioned metallic wire or nonmetallic string is wound therearound at the above-mentioned pitch at a time after the coating of the mandrel with the composition in the present invention by the above-mentioned process and before the baking in a furnace or at a time after the baking in the furnace and before the detaching of the coating film from the mandrel.
  • the winding is conducted before the baking
  • the baking is conducted after the winding.
  • the composition in the present invention is coated on the mandrel by the above-mentioned process, baked in a furnace, and the reinforcement layer is formed on it. Thereafter, a resin composition as a material for forming the resin layer is applied on the reinforcement layer by use of a melt extruder.
  • the baking may be conducted after the reinforcement layer is formed. In addition, the baking step may be omitted.
  • a hollow tube is preliminarily formed by extrusion molding using the resin composition prepared as the material for forming the resin layer. Then, the hollow tube is covered with on the thing which composed with the mandrel coated with the composition in the present invention by the above-mentioned process and the reinforcement layer formed on it. Then, a heat-shrinkable tube composed of a fluorinated resin (e.g., FEP) is fitted over the hollow tube, and the assembly is passed through a heat tunnel (about 340° C.) over a predetermined time (about 10 min), whereby the catheter layer formed of the composition in the present invention, the reinforcement layer, and the resin layer are adhered to each other. Thereafter, the heat-shrinkable tube is peeled off, and the mandrel is drawn out, whereby the catheter body in the present invention having the reinforcement layer and the resin layer can be produced.
  • a fluorinated resin e.g., FEP
  • a hub and an anti-kinking protector are attached by an ordinary method to the catheter body produced by the above-mentioned process, whereby the catheter according to the present invention can be configured. Further, the catheter is sealed with a packaging material having a barrier property with respect to bacteria, followed by radiation sterilization (preferably, electron-beam sterilization), to complete the production of the catheter according to the present invention.
  • the use of the catheter in the present invention is not particularly limited.
  • the catheter of the present invention can be applied to guiding catheters, angiographic catheters, various balloon catheters for PTCA, PTA, IABP, etc., ultrasonic catheters, atherectomy catheters, endoscopic catheters, indwelling catheters, medical solution injection catheters, and embolism catheters (micro catheters) introduced into an organ such as brain, liver, etc.
  • Catheter bodies corresponding to Examples of the present invention and Comparative Examples were produced by the method described below.
  • ETFE and PTFE powders were mixed for a sufficient time in each of the mass ratios given in Table 1 below, to obtain uniform mixtures. Thereafter, the mixed powders were supplied into a melt extruder so that the compositions in the present invention in a molten state are propared.
  • the melting temperature was 250° C.
  • a copper wire (circular in section with 0.65 mm diameter) as a mandrel was mounted into the melt extruder, and melt extrusion at a controlled extrusion rate was conducted, to form a 0.04 mm-thick coating of the composition on the mandrel.
  • the coated mandrel with the composition was fed continuously into a furnace (referred to a “continuous furnace”).
  • the temperature in the continuous furnace was controlled to 225° C.
  • the baking time in the continuous furnace was about five minutes.
  • the catheter bodies thus obtained had an overall length of about 1,000 mm, a tubular section, an inside diameter of 0.65 mm, and an outside diameter of 0.73 mm.
  • the specimens were held at room temperature (23 ⁇ 3° C., 50% RH) for four weeks, and then they were subjected to a tensile test (according to JIS K7113).
  • the tensile test speed was 100 mm/min, and the chuck-to-chuck distance was 50 mm.
  • the measurement results of tensile strength by the tensile test are shown in Table 1, and the measurement results of breaking elongation are given in Table 2. Incidentally, the results of measurement for specimens not irradiated with electron beams are also shown. Furthermore, the results given in Table 1 are shown also in FIGS. 2 and 3 .
  • ETFE is present in an amount of not less than 45 mass %
  • the ETFE forms the sea phase, whereby the deterioration of strength by irradiation with electron beams can be suppressed.
  • ETFE is present in an amount of about 45 to 60 mass %
  • the effect of the present invention may partly not be exhibited.
  • the ETFE is present in an amount of not less than 60 mass % (namely, where PTFE is present in an amount of less than 40 mass %), the effect on the whole is exhibited sufficiently.
  • the shaft strength of the distal section was also measured by a method similar to that for the tensile test.
  • the shaft strength of the distal section means the tensile strength of a flexible part in the range of about 100 mm from the distal end of the catheter.
  • each of the specimens was put in a warm air circulation type oven (product code: STAC P-500M, produced by Shimadzu Corporation) for 168 hours.
  • the temperature inside the oven was set to 60° C.
  • each of the specimens was cooled at room temperature (23 ⁇ 3° C., 50RH) for 24 hours, and then subjected to the same tensile test as above.
  • FIG. 4 shows a schematic illustration of the measurement.
  • Each of the catheter bodies having an overall length of about 1,000 mm produced by the above-mentioned process was pressed down in a diametral direction to form a rectangular parallelepiped piece of about 500 mm ⁇ 1.2 mm ⁇ 0.08 mm, which was used as a specimen 10 .
  • the specimen 10 is mounted on a smooth table 12 (made of SUS304) having a sufficiently large area and kept horizontal, a PTFE sheet 14 (30 ⁇ 30 mm, 0.5 mm thickness) is mounted on the specimen 10 , and a 200-g weight 16 is mounted on the PTFE sheet 14 .
  • the weight 16 is put on the PTFE sheet 14 without protruding from the area of the PTFE sheet 14 , and a contact area between the PTFE sheet 14 and the specimen 10 is about 36 mm 2 .
  • a contact area (i.e., sliding area) between the specimen 10 and the smooth table 12 is also about 36 mm 2 .
  • the coefficient of static friction was calculated from the tensile load immediately before the specimen 10 started moving.
  • the coefficient of dynamic friction was calculated from the tensile load measured as a fixed value after the specimen 10 started moving.
  • Each of the catheter bodies having an overall length of 1,000 mm produced by the above-mentioned process was fixed in a U shape.
  • the curved portion of the U shape had an overall length of 160 mm and a radius of curvature of 50 mm.
  • a diagnostic guide wire (commercial name: Radifocus Guidewire, produced by TERUMO CORPORATION) or a spring type guide wire (produced by ASAHI INTECC CO., LTD.) was inserted into the lumen of the catheter body from its one end.
  • the guide wire was fixed at its end part to a chuck of the same tensile testing machine as used above and reciprocatory slid. Accordingly, the internal surface sliding resistance was measured.

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Abstract

A catheter having a catheter layer composed of a composition containing ETFE and PTFE in a weight ratio of 99:1 to 45:55, wherein there is got a luminal internal surface consisting of a material that exhibits lubricity substantially identical with that of PTFE and has a resistance to radioactive rays not had by PTFE.

Description

    TECHNICAL FIELD
  • The present invention relates to a catheter for medical use to be used for diagnosis or therapy by being inserted into a blood vessel or other body lumen, and to a process for producing the catheter.
    • BACKGROUND ART
  • In recent years, catheters have been being used in an increasing number of diagnostic and/or therapeutic methods for alleviating the physical and time-basis burdens on patients. Generally, for insertion of a catheter into a living body-through a blood vessel, ureter, trachea, esophagus or the like and bringing the catheter accurately to a predetermined site in the living body without damaging the blood vessel wall, organs or the like, the catheter must meet the structural requirements for high operationality and safety when serving as a medical device and, simultaneously, the luminal internal surface of its tube (referred to also as “catheter body”) must exhibit lubricity.
  • The lubricity is necessary for externally injecting a liquid medicine or the like to a predetermined site in the patient's body through the lumen of the catheter body, for draining a body fluid in the living body or the like, or for passing other therapeutic device therethrough.
  • As a catheter which meets such structural requirements and further has lubricity at the luminal internal surface of a catheter body, for example Patent Document 1 describes a catheter including a catheter body having an outer layer and an inner layer, the outer layer having a first region and a second region located on the proximal end side of the first region, wherein the first region is composed of a polyester elastomer, and the second region is composed of a polyurethane elastomer higher in hardness than the polyester elastomer constituting the first region. This catheter is excellent in operationality such as pushability, torque transmitting property, following property, and anti-kinking property. Besides, in the catheter, a material capable of reducing the friction of an internal surface of the inner layer, for example, a fluorinated resin such as polytetrafluoroethylene (PTFE) is used as the material constituting the inner layer, so that the luminal internal surface of the catheter body has lubricity.
  • There are many examples in which a fluorinated resin, particularly, PTFE is thus used as the material constituting the luminal internal surface of the catheter body.
  • Meanwhile, a catheter must be sterilized before used, since it is used for a living body, like other medical devices. General sterilization methods include the methods in which a gas or water vapor is used. These methods, however, have problems as to the toxicity of the gas, the long treatment time required for sterilization, etc.
  • In view of these problems, the sterilizing method using radioactive rays such as electron beams have come to be paid attention to. According to this method, toxicity is obviated and the treatment time required for sterilization is short.
  • However, the sterilization method using radioactive rays cannot be applied to the above-mentioned catheters using PTFE.
  • This is because PTFE is deteriorated when irradiated with ionizing radiations of not less than 1 kGy, and is extremely deteriorated in mechanical properties at an absorbed dose of around 25 kGy, which is a sterilizing dose generally used in the cases of sterilization with γ-rays, electron beams and the like.
  • For example, when the radioactive-ray sterilization is applied to the catheter described in Patent Document 1 in which PTFE is used to form the inner layer, PTFE is conspicuously lowered in breaking elongation and, therefore, mere bending of the catheter body would result in exfoliation or cracking of the inner layer.
  • Patent Document 1: Japanese Patent Laid-open No. 2001-190681
    • DISCLOSURE OF INVENTION Problems to be Solved by the Invention
  • It is an object of the present invention to provide a catheter including a catheter layer having a luminal internal surface consisting of a material that has lubricity substantially identical with that of PTFE and has a resistance to radioactive rays not had by PTFE, and a process for producing the catheter.
    • Means for Solving the Problems
  • The above object is attained according to the present invention which resides in the following (1) to (12).
  • (1) A catheter including a catheter body composed of a composition containing ETFE (ethylene-tetrafluoroethylene copolymer) and PTFE (polytetrafluoroethylene) in a mass ratio of from 99:1 to 45:55.
  • (2) The catheter according to (1) above, wherein the mass ratio is from 95:5 to 60:40.
  • (3) The catheter according to (1) or (2) above, further including a resin layer composed of a resin composition different from the composition, on the catheter body.
  • (4) The catheter according to (3) above, further including a reinforcement layer between the catheter body and the resin layer.
  • (5) A catheter including a catheter layer composed of a composition containing ETFE (ethylene-tetrafluoroethylene copolymer) and PTFE (polytetrafluoroethylene) in a mass ratio of from 99:1 to 45:55.
  • (6) The catheter according to (5) above, wherein the mass ratio is from 95:5 to 60:40.
  • (7) The catheter according to (5) or (6) above, further including a resin layer composed of a resin composition different from the composition, on the catheter layer.
  • (8) The catheter according to (7) above, further including a reinforcement layer between the catheter layer and the resin layer.
  • (9) The catheter according to (4) or (8) above, wherein the reinforcement layer is composed of a metallic wire material.
  • (10) The catheter according to any of (1) to (9) above, wherein the catheter layer constitutes a luminal internal surface of the catheter.
  • (11) A catheter comprising an elongated tube, said elongated tube having a proximal end section and a distal end section defining a lumen and a wall, said wall having a tubular cross section substantially uniform in thickness between said distal end section and said proximal end section, and said wall being composed of a composition containing ETFE and PTFE in a mass ratio of from 99:1 to 45:55.
  • (12) A process for producing a catheter including the steps of:
  • mixing ETFE and PTFE in a mass ratio of from 99:1 to 45:55 and forming the mixture into a tubular body;
  • forming a reinforcement layer and a resin layer on the tubular body obtained and forming a catheter;
  • sealingly packaging the catheter; and
  • sterilizing the packaged catheter with radioactive rays.
    • EFFECTS OF THE INVENTION
  • The luminal internal surface of the catheter according to the present invention has a lubrication characteristic substantially identical with that of PTFE. Therefore, the use of the catheter according to the present invention makes it possible to easily carry out injection externally a liquid medicine or the like to a predetermined site in a patient's body through the lumen of the catheter body, drainage of a body fluid or the like present in the living body, and passage of other therapeutic devices therethrough. In addition, the luminal internal surface of the catheter according to the present invention is composed of a material having a resistance to radioactive rays not had by PTFE. Therefore, a sterilizing method using radioactive rays, which obviates toxicity and ensures that the treatment time required for sterilization is short, can be applied to the catheter according to the present invention.
    • BRIEF DESCRIPTION OF DRAWINGS
  • [FIG. 1]
  • FIG. 1 illustrates an embodiment of overall configuration in the case where the catheter according to the present invention is applied to a blood vessel catheter.
  • [FIG. 2]
  • FIG. 2 is a diagram showing the relationship between PTFE blending proportion and tensile strengths before and after irradiation with electron beams.
  • [FIG. 3]
  • FIG. 3 is a diagram showing the relationship between PTFE blending proportion and the retention of tensile strength before and after irradiation with electron beams.
  • [FIG. 4]
  • FIG. 4 is a schematic illustration of a measuring instrument for friction test of a material forming the catheter body pertaining to the present invention.
    •  BEST MODE FOR CARRYING OUT THE INVENTION
  • Now, the catheter according to the present invention will be described, based on preferred embodiments thereof shown in the accompanying drawings.
  • FIG. 1 is a plan view showing an example of overall configuration in the case where the catheter of the present invention is applied to a blood vessel catheter. A tip section which is inserted in a lumen such as a blood vessel is shown in section. Hereinafter, the right side in FIG. 1 will be referred to as “the proximal end”, and the left side as “the distal end”.
  • The catheter 1 shown in FIG. 1 is composed of a catheter body 2, a hub 4 mounted to the proximal end 21 of the catheter body 2, and an anti-kinking protector 41.
  • The catheter body 2 is formed with a lumen (i.e., inner cavity) 3 in the inside thereof ranging from the proximal end 21 to the distal end 22. At the time of inserting the catheter 1 into a blood vessel, a guide wire is inserted in the lumen 3. In addition, the lumen 3 can be used also as a passage for a liquid medicine or the like.
  • The hub 4 functions as an insertion port for inserting the guide wire into the lumen 3, an injection port for injecting a liquid medicine or the like into the lumen 3, and the like, and functions also as a grip section to be gripped at the time of operating the catheter 1.
  • The overall length of the catheter body, the thickness of the tube wall and the like in the catheter according to the present invention are not particularly limited, and can be appropriately selected according to the purpose of use of the catheter.
  • For example, in the case of the catheter 1 which is a preferable embodiment of the present invention shown in FIG. 1, the overall length of the catheter body (tube) is 800 to 1500 mm, and the thickness of the tube wall is 0.02 to 0.5 mm.
  • As for the hub 4, common hubs can be used.
  • In the above-mentioned catheter according to the present invention, the catheter body has a catheter layer composed of a composition containing ETFE and PTFE in a mass ratio of from 99:1 to 45:55 (the composition hereinafter referred to also as “the composition in the present invention”).
  • The ETFE used in the present invention is not particularly limited, and may be any of those conventionally used widely in the production of medical devices such as catheters. The ETFE can be prepared by copolymerizing TFE (tetrafluoroethylene) with ethylene by a conventionally known method.
  • The TFE/ethylene polymer composition of the ETFE used in the present invention is not particularly limited. In addition, the ETFE may contain a small amount of a third ingredient in such a range as not to spoil the characteristics aimed at in the invention in addition to TFE and ethylene in the composition.
  • In the ETFE generally widely utilized, the TFE/ethylene polymer composition is from about 50/50 to 60/40 mol %, and the ETFE is substantially an alternate copolymer. Besides, for solving the generation of stress cracking based on its crystallinity, the ETFE contains a third ingredient as follows. Namely, the ETFE generally widely utilized is a ternary copolymer containing the third ingredient. Furthermore, the ETFE has an MFR (melt flow rate: fluidity in a molten state) of 3 to 45 g/10 min, and a density of 1.70 to 1.75 g/cm3.
  • In the present invention, the ETFE thus generally utilized widely can be preferably used.
  • Examples of the third ingredient includes fluorinated α-monoolefin, fluorinated vinyl ether, hydrofluorocarbon fluorinated vinyl ether, hydrocarbon fluorinated vinyl ether monomer, and vinyl esters.
  • The PTFE used in the present invention is not particularly limited, and may be any of those conventionally used widely in the production of medical devices such as catheters. The PTFE can be prepared by polymerizing the TFE (tetrafluoroethylene) monomer by a conventionally known method.
  • The PTFE has a melt viscosity of 5,000 to 100,000 poise, and a density of 2.13 to 2.22 g/cm3.
  • The forms of the ETFE and the PTFE used in the present invention are not particularly limited, but these materials are each preferably in a pellet form or a powdery form (a dry powder or a dispersion (a uniform dispersion of a fine powder in a solvent)). It is preferable that the ETFE and/or the PTFE is in a pellet form or a powdery form, since they can be easily mixed with each other.
  • In addition, where the ETFE and/or the PTFE is in the form of a dispersion, a further homogeneous dispersed state of finer PTFE particles can be obtained, which is preferable from the viewpoint of the possibility that a catheter with a smaller tube wall thickness (1 to 40 μm) can be easily obtained. Dry powdery ETFE and PTFE are commercially available as molding powders and fine powders, and these powders can be preferably used in the present invention.
  • In the catheter layer of the catheter according to the present invention, a composition containing the ETFE and the PTFE in a mass ratio of from 99:1 to 45:55, preferably from 95:5 to 60:40, more preferably from 90:10 to 80:20 is applied as the material.
  • The relationship between the mixing ratio of the ETFE with the PTFE and the resistance to radioactive rays is considered to depend on which of the ETFE and the PTFE forms the sea phase in the sea-island structure upon mixing of the ETFE with the PTFE. Specifically, it is considered that the resistance to radioactive rays is exhibited with priority in the case where the ETFE having a resistance to radioactive rays has a greater volumetric ratio than the PTFE having a higher lubricity; it means that the ETFE forms the sea phase.
  • The luminal internal surface of the catheter body produced from the composition in the present invention containing the ETFE and the PTFE in the above-mentioned ratio exhibits a high resistance to radioactive rays without loosing the general lubricity characteristic.
  • Therefore, the use of the catheter according to the present invention makes it possible to easily carry out external injection of a liquid medicine or the like to a predetermined site in a patient's body through the lumen of the catheter body, drainage of a humor or the like present in the living body, and passage of other medical devices therethrough. In addition, a sterilizing method using radioactive rays which obviates toxicity and ensures that the treatment time required for sterilization is short can be applied to the catheter according to the present invention.
  • Incidentally, the radioactive rays herein includes γ-rays, electron beams, X-rays and the like, and is not particularly limited, insofar as the rays can be used for sterilization of medical devices.
  • The irradiating temperature and the irradiation dose of the rays are not limited, and may be at the levels which are commonly applied in sterilization of medical devices. For example, the atmosphere for irradiation is room temperature (about 23° C.), and the irradiation dose is 1 to 100 kGy, preferably 15 to 60 kGy.
  • In addition, the mass ratio of the ETFE to the PTFE is within from 99:1 to 55:45, more preferably from 95:5 to 70:30 in the composition in the present invention such that the composition in the present invention has a fluidity optimal for injection molding and extrusion molding and is excellent in processibility.
  • Besides, the composition in the present invention may contain other organic material(s), in addition to the ETFE and the PTFE.
  • Examples of the organic material(s) include polystyrene, polyethylene, polyamide, polyimide, polysulfone, polyphenylene sulfide, polyvinyl chloride, polycarbonate, acrylonitrile-styrene copolymer, acrylonitrile-butadiene-styrene copolymer, polyvinyl, silicone, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polyvinylidene fluoride, polyvinyl fluoride, and ethylene-chlorotrifluoroethylene copolymer.
  • The composition in the present invention may contain the organic material(s) in a proportion of 0.1 to 10 mass % based on the total mass of the ETFE and the PTFE.
  • Besides, the composition in the present invention may contain additives, in addition to the ETFE and the PTFE.
  • Examples of the additives include pigments, dyes, X-rays contrast agent (barium sulfate, tungsten, bismuth oxide or the like), reinforcing agent (glass fiber, carbon fiber, talc, mica, clay mineral, potassium titanate fiber, or the like), filler (carbon black, silica, alumina, titanium oxide, metal powder, wood flour, rice hull, or the like), thermal stabilizer, oxidation/deterioration inhibitor, UV absorber, lubricant, mold release agent, crystalline nucleophile, plasticizer, flame retardant, antistatic agent, and foaming agent.
  • The composition in the present invention may contain the additive(s) in a proportion of 1 to 50 mass % based on the total mass of the ETFE and the PTFE.
  • The catheter layer of the catheter body of the catheter according to the present invention is produced from the above-mentioned composition in the present invention by a method which will be described later.
  • The catheter according to the present invention may have the catheter layer serving alone as the catheter body; however, it is preferable for the catheter to have a resin layer composed of a resin composition different from the composition in the present invention on the catheter layer. This ensures effectively that the rigidity of the catheter body is enhanced, and the pushability and torque transmitting performance of the catheter body are enhanced.
  • In addition, when the catheter body in the present invention has such as the resin layer constituting an outer layer, it is effectively ensured that the reinforcement layer to be described later can be firmly fixed within the catheter body.
  • The resin composition constituting the resin layer is not particularly limited, but it is preferably a resin composition more flexible than the catheter layer (i.e., inner layer). Examples of the resin composition include polyamide resin, polybutylene terephthalate, polyester elastomer, polyethylene terephthalate, and mixtures and copolymers thereof. Among these resin compositions, preferred are polyamide resin and polyester elastomer, in view of their excellent resistance to radioactive rays and little lowering in mechanical properties upon irradiation with radioactive rays.
  • Examples of the polyamide resin include nylon 6, nylon 66, nylon 610, nylon 46, nylon 9, nylon 11, nylon 12, and nylon 12 elastomer. Among these polyamide resins, preferred are nylon 12 and nylon 12 elastomer, in view of their excellent flexibility and chemical resistance.
  • The thickness of the resin layer is not particularly limited. Usually, the thickness is preferably about 0.01 to 1.0 mm, more preferably about 0.03 to 0.1 mm.
  • The resin layer can be formed on the catheter layer in the present invention, by a method which will be described later.
  • Further, it is preferable to provide a reinforcement layer between the catheter layer and the resin layer. This ensures effectively that the rigidity of the catheter body is further enhanced, and the pushability and torque transmitting performance of the catheter body are further enhanced.
  • The reinforcement layer is composed, for example, a spiral element.
  • The spiral element may be composed of at least one of a metallic member and a nonmetallic member. Examples of the spiral element include those obtained by forming a metallic wire or plate member into a spiral shape, those obtained by forming a nonmetallic string or plate member into a spiral shape, and those obtained by forming a laminate of a metallic member and a nonmetallic member into a spiral shape.
  • Examples of the material constituting the metallic member include stainless steels, nickel-titanium alloys, platinum, iridium, and tungsten, which may be used either singly or in combination of two or more of them.
  • On the other hand, examples of the material constituting the nonmetallic member include carbon, polyamide, polyethylene terephthalate, and polybutylene terephthalate, which may be used either singly or in combination of two or more of them.
  • The pitch of winding of the spiral element is not particularly limited. For example, the pitch is preferably about 0 to 2 mm, more preferably about 0.02 to 0.5 mm. Where the pitch of winding of the spiral element is in such a range, an appropriate rigidity is imparted to the catheter body, and the pushability and torque transmitting performance of the catheter body are further enhanced.
  • In addition, the cross-sectional shape of the spiral element is not limited to circle, and may be a flat shape; namely, the spiral element may be ribbon-like (i.e., belt-like) in shape.
  • Where the cross-sectional shape of the spiral element is a circle, the diameter of the circle is preferably about 0.03 to 0.06 mm, more preferably about 0.04 to 0.05 mm.
  • Where the spiral element is ribbon-like in shape, the width of the ribbon-like shape is preferably about 0.1 to 1.0 mm, and the thickness is preferably about 0.04 to 0.05 mm.
  • Incidentally, the reinforcement layer is not particularly limited, insofar as it can impart an appropriate rigidity to the catheter body. For example, the reinforcement layer may be composed of the spiral element alone, a braided element alone, or a combination of a braided element and the spiral element (for example, one which is composed of a braided element on the proximal end side and of the spiral element on the tip side, one which is a laminate of a braided element and the spiral element, or the like).
  • Where a braided element is used, the braided element may be composed of at least one of a metallic member and a nonmetallic member. Examples of the braided element include those obtained by braiding metallic wires alone, those obtained by braiding nonmetallic strings alone, and those obtained by braiding a metallic wire with a nonmetallic string.
  • Examples of the material constituting the metallic wire include stainless steels and nickel-titanium alloys, or the like, which may be used either singly or in combination of two or more of them.
  • On the other hand, examples of the material constituting the nonmetallic string include carbon, polyamide, polyethylene terephthalate, and polybutylene terephthalate, which may be used either singly or in combination of two or more of them.
  • The reinforcement layer composed of such a spiral element or braided element provides a sufficient reinforcing effect even when comparatively small in thickness. Therefore, the catheter body having such a reinforcement layer is advantageous in adopting a smaller diameter.
  • In the present invention, the catheter layer is produced by using the composition containing the ETFE and the PTFE and, optionally, the organic material(s) and/or the additive(s).
  • The process for producing the catheter layer is not particularly limited; for example, the catheter layer is produced by the following process.
  • After the pellet form or powdery form ETFE and the powdery PTFE are mixed under stirring, the mixture is fed into a melt extruder, and is stirred at a temperature of 230 to 280° C. The stirred mixture is extruded by the extruder onto a mandrel to form a coating film, which is subjected to baking together with the mandrel in a furnace. The baking temperature should be not lower than the melting point of ETFE, namely, not lower than 220° C. In addition, the baking temperature is preferably not higher than 330° C., which is the melting point of PTFE, and is preferably not higher than 250° C.
  • Then, the mandrel is drawn out, whereby a round tubular molded article can be obtained as the catheter layer in the present invention.
  • Here, when a small amount of a volatile oil (kerosene or the like) is added at the time of mixing the ETFE and the PTFE under stirring, a lumpy composition can be obtained by compressing the stirred composition, which is preferable since the supply of the composition into the extruder and the coating of the mandrel with the composition are stabilized.
  • The catheter layer produced by such a process as above can be used alone as the catheter body. However, in the case where the reinforcement layer is further formed on the catheter layer, the above-mentioned metallic wire or nonmetallic string is wound therearound at the above-mentioned pitch at a time after the coating of the mandrel with the composition in the present invention by the above-mentioned process and before the baking in a furnace or at a time after the baking in the furnace and before the detaching of the coating film from the mandrel. In the case where the winding is conducted before the baking, the baking is conducted after the winding.
  • In the case where the resin layer is further formed on the catheter layer produced by the above process or on the reinforcement layer formed as above-mentioned, the composition in the present invention is coated on the mandrel by the above-mentioned process, baked in a furnace, and the reinforcement layer is formed on it. Thereafter, a resin composition as a material for forming the resin layer is applied on the reinforcement layer by use of a melt extruder. Incidentally, the baking may be conducted after the reinforcement layer is formed. In addition, the baking step may be omitted.
  • Alternatively, a hollow tube is preliminarily formed by extrusion molding using the resin composition prepared as the material for forming the resin layer. Then, the hollow tube is covered with on the thing which composed with the mandrel coated with the composition in the present invention by the above-mentioned process and the reinforcement layer formed on it. Then, a heat-shrinkable tube composed of a fluorinated resin (e.g., FEP) is fitted over the hollow tube, and the assembly is passed through a heat tunnel (about 340° C.) over a predetermined time (about 10 min), whereby the catheter layer formed of the composition in the present invention, the reinforcement layer, and the resin layer are adhered to each other. Thereafter, the heat-shrinkable tube is peeled off, and the mandrel is drawn out, whereby the catheter body in the present invention having the reinforcement layer and the resin layer can be produced.
  • A hub and an anti-kinking protector are attached by an ordinary method to the catheter body produced by the above-mentioned process, whereby the catheter according to the present invention can be configured. Further, the catheter is sealed with a packaging material having a barrier property with respect to bacteria, followed by radiation sterilization (preferably, electron-beam sterilization), to complete the production of the catheter according to the present invention.
  • By use of the producing process according to the present invention, it is possible to obtain a catheter composed of a material which has lubricity substantially identical with that of PTFE while having a resistance to radioactive rays not had by PTFE. Therefore, it is possible to produce a catheter having been subjected to a radiation sterilizing treatment which obviates toxicity and ensures that the treatment time required for sterilization is short.
  • In addition, the use of the catheter in the present invention is not particularly limited. For example, the catheter of the present invention can be applied to guiding catheters, angiographic catheters, various balloon catheters for PTCA, PTA, IABP, etc., ultrasonic catheters, atherectomy catheters, endoscopic catheters, indwelling catheters, medical solution injection catheters, and embolism catheters (micro catheters) introduced into an organ such as brain, liver, etc.
    • EXAMPLES
  • Now, specific examples of the present invention and the results of various tests will be described below.
  • <Production of Catheter Body>
  • Catheter bodies corresponding to Examples of the present invention and Comparative Examples were produced by the method described below.
  • First, ETFE and PTFE powders were mixed for a sufficient time in each of the mass ratios given in Table 1 below, to obtain uniform mixtures. Thereafter, the mixed powders were supplied into a melt extruder so that the compositions in the present invention in a molten state are propared. The melting temperature was 250° C.
  • A copper wire (circular in section with 0.65 mm diameter) as a mandrel was mounted into the melt extruder, and melt extrusion at a controlled extrusion rate was conducted, to form a 0.04 mm-thick coating of the composition on the mandrel.
  • The coated mandrel with the composition was fed continuously into a furnace (referred to a “continuous furnace”). The temperature in the continuous furnace was controlled to 225° C. The baking time in the continuous furnace was about five minutes.
  • Then, after cooling at room temperature, the mandrel was drawn out, to obtain a catheter body composed solely of a catheter layer in the present invention. The catheter bodies thus obtained had an overall length of about 1,000 mm, a tubular section, an inside diameter of 0.65 mm, and an outside diameter of 0.73 mm.
  • <Tensile Test>
  • From each of the catheter bodies having an overall length of about 1,000 mm produced by the above method, a specimen of about 80 mm in length was carved out, and was irradiated with electron beams by use of an electron beam irradiation system (Rhodotron T-300 model, produced by IBA located in Belgium) so that the absorbed dose would be 33 kGy.
  • Thereafter, the specimens were held at room temperature (23±3° C., 50% RH) for four weeks, and then they were subjected to a tensile test (according to JIS K7113). Here, the tensile test speed was 100 mm/min, and the chuck-to-chuck distance was 50 mm.
  • The measurement results of tensile strength by the tensile test are shown in Table 1, and the measurement results of breaking elongation are given in Table 2. Incidentally, the results of measurement for specimens not irradiated with electron beams are also shown. Furthermore, the results given in Table 1 are shown also in FIGS. 2 and 3.
  • TABLE 1
    Tensile strength Tensile strength (B) Retention ratio
    Composition (A) before after irradiation of tensile
    (mass %) irradiation with electron beams strength (B/A)
    ETFE PTFE (gf) (gf) (%)
    100 0 959 872 91
    90 10 557 521 94
    85 15 488 452 93
    80 20 358 341 95
    60 40 370 311 84
    50 50 420 195 47
    44 56 430 187 43
    40 60 480 161 34
    20 80 540 122 23
    0 100 634 104 16
  • TABLE 2
    Breaking elongation Breaking elongation Retention
    Composition (A) before (B) after irradiation ratio of
    (mass %) irradiation with electron beams toughness
    ETFE PTFE (%) (%) (B/A) (%)
    100 0 253 261 100
    90 10 439 435 99
    85 15 142 150 100
    80 20 58 56 97
    0 100 620 4 0.6
  • From FIGS. 2 and 3, it is seen that where the ratio of PTFE is not less than 40 mass %, a conspicuous difference in tensile strength is generated between the case of irradiation with electron beams and the case of not conducting the irradiation.
  • The reason is considered to be as follows. As has been above-mentioned, where ETFE is present in an amount of not less than 45 mass %, the ETFE forms the sea phase, whereby the deterioration of strength by irradiation with electron beams can be suppressed. Where ETFE is present in an amount of about 45 to 60 mass %, the effect of the present invention may partly not be exhibited. On the other hand, where the ETFE is present in an amount of not less than 60 mass % (namely, where PTFE is present in an amount of less than 40 mass %), the effect on the whole is exhibited sufficiently.
  • The shaft strength of the distal section was also measured by a method similar to that for the tensile test. The shaft strength of the distal section means the tensile strength of a flexible part in the range of about 100 mm from the distal end of the catheter.
  • Incidentally, as the catheter body, two compositions were respectively used, one corresponding to ETFE/PTFE=80/20, and the other corresponding to ETFE/PTFE=0/100. For each of these compositions, a specimen irradiated with electron beams and a non-irradiated specimen were subjected to the test, for comparison.
  • The results of the test are shown in Table 3.
  • TABLE 3
    Shaft strength Retention
    Composition of the ratio of
    (mass %) Irradiation with distal section strength
    ETFE PTFE electron beams (gf) (%)
    80 20 Non-irradiated 517 89.2
    Irradiated 461
    0 100 Non-irradiated 831 23.6
    Irradiated 196
  • The retention ratio of the shaft strength of the distal section (the ratio of the shaft strength of the electron beam-irradiated specimen to that of the non-irradiated specimen) in the case of ETFE/PTFE=80/20 was about 90%, which is apparently advantageous over the case of ETFE/PTFE=0/100.
  • <Accelerated Ageing Test>
  • In the same manner as in the above tensile test, an about 80 mm clipped specimen was got from the main body of the catheter which produced about 1,000 mm full length by the process mentioned above, and it was irradiated with electron beams by use of an electron beam irradiating system (Rhodotron T-300 model, produced by IBA located in Belgium) so that the absorbed dose would be 33 kGy.
  • Then, each of the specimens was put in a warm air circulation type oven (product code: STAC P-500M, produced by Shimadzu Corporation) for 168 hours. The temperature inside the oven was set to 60° C.
  • Thereafter, each of the specimens was cooled at room temperature (23±3° C., 50RH) for 24 hours, and then subjected to the same tensile test as above.
  • The results are shown in Table 4.
  • TABLE 4
    Tensile strength Breaking elongation
    Composition after irradiation after irradiation
    (mass %) with electron beams with electron beams
    ETFE PTFE (gf) (%)
    100 0 850.8 265
    90 10 515.5 408
    85 15 452.6 148
    80 20 321.6 46
  • <Lubricity Test>
  • The catheter bodies according to the present invention produced by the above process were subjected to measurement of frictional resistance (i.e., coefficient of static friction and coefficient of dynamic friction), by the following method. FIG. 4 shows a schematic illustration of the measurement.
  • Each of the catheter bodies having an overall length of about 1,000 mm produced by the above-mentioned process was pressed down in a diametral direction to form a rectangular parallelepiped piece of about 500 mm×1.2 mm×0.08 mm, which was used as a specimen 10.
  • The specimen 10 is mounted on a smooth table 12 (made of SUS304) having a sufficiently large area and kept horizontal, a PTFE sheet 14 (30×30 mm, 0.5 mm thickness) is mounted on the specimen 10, and a 200-g weight 16 is mounted on the PTFE sheet 14. Here, the weight 16 is put on the PTFE sheet 14 without protruding from the area of the PTFE sheet 14, and a contact area between the PTFE sheet 14 and the specimen 10 is about 36 mm2. In addition, a contact area (i.e., sliding area) between the specimen 10 and the smooth table 12 is also about 36 mm2.
  • Then, the specimen is pulled horizontally at a fixed rate of 100 mm/min by use of a testing machine (Autograph AG-IS, produced by Shimadzu Corporation) capable of measuring tensile load.
  • Here, the coefficient of static friction was calculated from the tensile load immediately before the specimen 10 started moving. Besides, the coefficient of dynamic friction was calculated from the tensile load measured as a fixed value after the specimen 10 started moving.
  • The results of the test are shown in Table 5.
  • TABLE 5
    Composition Coefficient of Coefficient of
    (mass %) static friction dynamic friction
    ETFE PTFE (F/W) (F/W)
    100 0 0.220 0.192
    90 10 0.257 0.235
    85 15 0.355 0.308
    80 20 0.435 0.380
    0 100 0.640 0.400
    F: Measured load,
    W: Press-down load
  • <Internal Surface Sliding Test>
  • Each of the catheter bodies having an overall length of 1,000 mm produced by the above-mentioned process was fixed in a U shape. Here, the curved portion of the U shape had an overall length of 160 mm and a radius of curvature of 50 mm.
  • A diagnostic guide wire (commercial name: Radifocus Guidewire, produced by TERUMO CORPORATION) or a spring type guide wire (produced by ASAHI INTECC CO., LTD.) was inserted into the lumen of the catheter body from its one end.
  • Then, the guide wire was fixed at its end part to a chuck of the same tensile testing machine as used above and reciprocatory slid. Accordingly, the internal surface sliding resistance was measured.
  • The results are shown in Table 6.
  • TABLE 6
    Internal surface
    Composition sliding resistance
    (mass %) Irradiation with (gf)
    ETFE PTFE electron beams vs. GW *1 vs. SW *2
    80 20 Non-irradiated 4.68 5.58
    Irradiated 4.80 5.38
    0 100 Non-irradiated 4.76 8.12
    Irradiated 5.00 12.50
    *1 Diagnostic guide wire
    *2 Spring type guide wire
  • It was found that the catheter body with ETFE/PTFE=80/20 according to the present invention has an internal surface sliding property of comparable to or better than that of a catheter body with ETFE/PTFE 0/100.

Claims (14)

1. A catheter comprising a catheter layer composed of a composition containing ETFE and PTFE in a mass ratio of from 99:1 to 45:55.
2. The catheter according to claim 1, wherein said mass ratio is from 95:5 to 60:40.
3. The catheter according to claim 1, further comprising a resin layer composed of a resin composition different from said composition, on said catheter layer.
4. The catheter according to claim 3, further comprising a reinforcement layer between said catheter layer and said resin layer.
5. The catheter according to claim 4, wherein said reinforcement layer is composed of a metallic wire material.
6. The catheter according to claim 1, wherein said catheter layer constitutes a luminal internal surface of said catheter.
7. A catheter comprising an elongated tube, said elongated tube having a proximal end section and a distal end section defining a lumen and a wall, said wall having a tubular cross section substantially uniform in thickness between said distal end section and said proximal end section, and said wall being composed of a composition containing ETFE and PTFE in a mass ratio of from 99:1 to 45:55.
8. A process for producing a catheter comprising the steps of:
mixing ETFE and PTFE in a mass ratio of from 99:1 to 45:55 and forming the mixture into a tubular body;
forming a reinforcement layer and a resin layer on said tubular body obtained and forming a catheter;
sealingly packaging said catheter; and
sterilizing said packaged catheter with radioactive rays.
9. The catheter according to claim 2, further comprising a resin layer composed of a resin composition different from said composition, on said catheter layer.
10. The catheter according to claim 9, wherein said catheter layer constitutes a luminal internal surface of said catheter.
11. The catheter according to claim 2, wherein said catheter layer constitutes a luminal internal surface of said catheter.
12. The catheter according to claim 3, wherein said catheter layer constitutes a luminal internal surface of said catheter.
13. The catheter according to claim 4, wherein said catheter layer constitutes a luminal internal surface of said catheter.
14. The catheter according to claim 5, wherein said catheter layer constitutes a luminal internal surface of said catheter.
US11/795,601 2005-01-21 2006-01-20 Catheter and Process for Producing the Catheter Abandoned US20080119825A1 (en)

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EP1839686A1 (en) 2007-10-03
JP5049596B2 (en) 2012-10-17
EP1839686A4 (en) 2009-04-15
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US20100251669A1 (en) 2010-10-07
JPWO2006077951A1 (en) 2008-06-19

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