BILUMEN CATHETER COMPRISING A POLAROGRAPHIC SENSOR AND METHOD OF MANUFACTURING IT

Abstract: In a bilumen catheter (101), one lumen (202) carries an electrical conductor (204) terminating as a cathode of an elec­ trochemical gas sensor. Potting material (206) such as epoxy seals off both lumens(201,202), encloses and holds the end of the conductor (204), and exposes a tip (207) thereof of pre­ determined cross-section, which defines the cathode elec­ trode. The tip (207) is dip-coated to form a selectively perme­ able membrane (208), and an opening (205) is provided into the second lumen (201) for withdrawal of samples of blood or the like.

Description: Monopolar Bilumen Electrochemical Sensor Catheter Field of the Invention This invention relates to electrochemical sensors for blood gases, and particularly to combination sensors, such as for neonatal applications, whereby blood samples may be withdrawn through the gas sensing -catheter. Background of the Invention and Prior-Art In U.S#PN. 3,912,614 to Spracklen-et al, issued October 14, 1975 and entitled "Sensor", there is disclosed a monopolar catheter type electrochemical sensor, to be used in conjunction with an external, such as transcutaneous, anode electrode for in vivo sensing of blood gas concentration. In accordance with the sensors set forth in that #atent, an elongated conductor terminates in a tip defining tie electrode, a noble metal of predetermined area, enclosed in an epoxy resin but for the active surface. The assembly is encapsulated in a selectively permeable membrane which allows selected fluid constituents to migrate through the membrane for electrochemical reaction at the electrode. Electrodes in accordance with the foregoing Spracklen et al patent are primarily intended for insertion, in catheter fashion, into a vein or an artery, or into cellular tissue. The external electrode is affixed to the body, and the potential difference between the respective electrodes is monitored, thereby yielding representation of concentration of the material (e.g. oxygen concentration in blood) to which the membrane is selectively permeable. Monopolar polarographic sensors of the type set forth in the aforementioned Spracklen et al patent are advantageously applied to the monitoring of blood gas conditions in neonates. Especially in the case- of premature babies for whom continuous and intensive care is required, it is important periodically to monitor many blood parameters simultaneously, and continuously to monitor a few specific parameters, such as oxygen partial pressure. One conventional procedure entails periodic umbilical insertion of a sampling catheter, whereby blood samples may be withdrawn and analyzed, followed by umbilical invention of blood gas sensor catheters such as those shown in the Spracklen et al patent. it is an object of-the present invention to provide an improved polarographic sensor, which is suitable for neonatal applications (or other similar epplications calling for periodic fluid sample withdrawals) without the need for intermittent withdrawals and insertions of various types of catheter. Prior art approaches to such dual function catheters include those in which a tubular catheter is extruded with an electrode wire/conductor embedded in the catheter walls. Such designs, however, involve manufacturing difficulty, and ultimate uncertainty as to the isolation of the entire electrode/conductor from the fluid withdrawal channel. Summary of the Present Invention The present invention involves a catheter type polarographic electrode assembly wherein an elongated flexible member, adapted for insertion into a patient, carrjies-two distinct longitudinal channels, or lumens, therein. One channel carries an electrical conductor, and the other is open for blood withdrawal or for drug or nutrient infusion. The assembly terminates in the actual polarographic sensor, wherein an epoxy resin seals the end of both lumens, holds the electrode wire, and exposes a predetermined cross-section thereof. The tip is coated with a membrane such as poly hydroxyethylmethacrylate, and the free lumen is opened to the exterior for purposes of fluid exchange. Description of the Drawings Fig. 1 shows a catheter apparatus embodying the principles of the present invention; Fig. 2 shows a cross-section of a relevant portion of the embodiment of Fig. 1, illustrating a preferred construction of a bilumen catheter employing the principles of the present invention; Fig. 3 shows an alternative embodiment of the principles of the present invention. Best Mode for Carrying Out the Invention Referring first to Figs. 1 and 2, there is shown- a-preferred embodiment of the principles of the present invention. ¯S bilumen catheter 101 has two separate lumens therein which separate at a junction block 102 into separate conduits 103 and 104. The former conduit 103 is coupled at junction block 102 with a first, open lumen 201 of the catheter 101, and thereby is useful for withdrawal or sampling of fluids from the tip of catheter 101. The conduit 103 terminates in a suitable connector 104 and port 105, for coupling with infusion/withdrawal apparatus, many types of which are readily available and well-known in the art. Conduit 104 is coupled via junction block 102 to a second lumen 202 of the catheter 101, which carries an electrical conductor 204 from a polarographic sensor 207-208 located at the tip of catheter 101. The conduit 104 includes an electrical insulator block 106 and terminates in a suitable electrical connector 107, whereby the polarographic sensing aspects may be coupled to external signal processing and/or metering equipment, which is Åalso suitably coupled. The signal processing aspects are also connected to a datum electrode (not# shown). As is known in the art, this datum (anode) electrode is preferably transcutaneously carried by the patient, Alternatively, as is also known in the art, suitable in vivo or subcutaneous datum electrical connections may be established with the patient. In practice, the catheter 101 is inserted into the patient (e.g. umbilically into a neonate, or intravascularly into a suitable limb of the patient) utilizing apparatus. and techniques known in the art (e.g. refer to U.-S.P.N. 3,913,614 to Spracklen et al, or to numerous sources of cannula design and use techniques}. The principles of the present invention are clearly manifest from consideration of-fig. 2, which sets forth a cross -sectional view of the tip of the catheter 101 of Fig. #l. In Fig. 2, the catheter 101 defines therein two distinct channels or lumens 201. and 202, the former lumen 201 being opened to form an intravascular port 203 which Communicates sw a catheter 101 to the infusion and sampling port 104 and 105 via junction block .102. The second lumen 202 carries an electrical conductor 204 through the catheter 101 to the insulator 106 and connector 107, and thence to external signal processing-and metering apparatus (not shown). In the embodiment of Fig. 2, the conductor 204 extends outwardly beyond the-extremity 205 of bilumen catheter 101, and is held there t-an inert potting means such as epoxy 206. Pursuant -to the embodiment of Fig - 2, the epoxy 206 extends into both lumens 20Land 202 of catheter 101, sealing-both whereby conductor 204 is held rigidly and permanently in place, as shown, and whereby intravascular port 203 opens the infusion/sampling lumen 2Ol to the ambient surroundings of the catheter tip. In accordance with the principles set forth in U.S.P.N. 3,912,614 to Spracklen et al, a monopolar sensor is formed. by covering the tip 207 of conductor 204 (which has a carefully controlled predetermined cross-section) with a selectively permeable membrane 208. Hence, in accordance with the teachings of the Spracklen et al patent, a gas in solution in the blood, such as oxygen, migrates through membrane 208, and sets up the now well-known polarographic electrochemical reaction in conjunction with the remote datum electrode. In a preferred mode of constructing the catheter electrode configuration of Fig. 2, the bilumen catheter body 101 is provided and formed as shown, with its central divider portion 209 being recessed backwardly from the extreme terminus 205 to accommodate bending of wire 204 and positioning of the tip 207 generally in the central extreme of the catheter. The conductor 204 is threaded through the lumen 202 and shaped as shown, and the epoxy compound 206 is provided to fill the ends of lumens 201 and 202, and-when set, to hold conductor 204 in place as shown. In a preferred construction, the conductor 204 is composed of a noble metal, e.g. silver, which is provided with a coating of varnish insulation at least in the end portion shown in Fig. 2, thereby promoting adhesion of the silver wire 204 with the epoxy resin 206. The active portion, tip 207 of conductor 204, is substantially free of varnish or epoxy coatings, providing full and even contact between the conductor tip 207 and the membrane 208. Once the epoxy has set, the intravasculÅar port 203 is provided by cutting the side of catheter 101 into lumen 201. A preferred location for the port 203# is substantially at the point of blockage of lumen 201 by the epoxy resin 206, as shown, thereby providing a smooth and relatively laminar flow capability for fluids being infused into the patient via lumen 201, or being withdrawn from the patient through that lumen. The membrane 208 is preferably composed of polyhydroxyethylmethacrylate, which preferably is formed by multiple dip coatings. In particular, it has been found that several (e.g. four) successive coatings of polyhydroxethylmethacrylate, flow capability for fluids being infused into the patient via lumen 201, or being withdrawn from the patient through that lumen. The membrane 208 is preferably composed of polyhydroxyethyl- methacrylate, which preferably is formed by multiple dip coatings. In particular, it has been found that several -(e.g. four) successive coatings of polyhydroxyethylmeth acrylate,#with each coating being allowed to dry before application of the next, eliminates formation of air bubbles in the membrane which would lead to sensor malfunctioning, yet provides membranes of the type and thickness useful, as is known in the art, for polarographic applications. Tn a preferred embodiment, the conductor tip diameter 207 of the silver conductor 204 is .004 inches, resulting in a current output from the sensor of about 6 x 10 9amperes at a blood oxygen partial# pressure of.150 millimeters of mercury. At such sensitivities, current output is relatively easy to measure by known means, while at the same time the consumption of oxygen my the sensor is so small that the sensor output is nearly Independent of flow velocity of blood past the catheter tip. It will be noted that the configuration of Fig. 2 locates the cathode of the sensor at the front tip of the -catheter, and thus in a region of relatively high blood velocity. Such would not necessarily be the case if the cathode were located at the side of the catheter tip, where blood may be virtually stagnant. The dip coating technique for formation of the membrane 208 enables the membrane to be coated onto the- catheter tip from solution and fall under gravity to form a smooth featureless membrane surface. This configuration contributes to biocompatibility and deposition free operation of the sensor. Intimate contact between the membrane and cathode is also thereby obtained, insuring that the relative move ment between these components is not possible, thereby substantially eliminating hydrostatic pressure sensitivity. In a preferred embodiment, the bilumen catheter material LOI is polyvinyl chloride. In a useful application of the embodiment of Figs. i and 2, the catheter is suitably placed in-the patient, and a blood sample is withdrawn via port 203, lumen 2Q1, and withdrawal port 104 and 105. A "one-shot" static measurement/ analysis is made with respect to a large variety of blood parameters and blood gases in solution, including P02. In conjunction with these readings, the--current output from sensor 207-208, via conductor 204#andrconnector 107, is monitored and the sensor system is calibrated. Thereupon, continuous or periodic p02 measurements may be taken via the sensor 207-208. At any time, nutrient -or medicinal materials may be infused into the patient, via lumen 201 and port 203, and any other appropriate blood parameters may be evaluated periodically by sample withdrawal through lumen 201, without the need to displace the catheter 101 or to interrupt P02 monitoring at the sensor 207-208. An alternative embodiment is set forth in Fig 3. Essentially, the Fig. 3 embodiment functions similarly to that of Fig. 2, except that the withdrawal port is located at the tip of the catheter (i.e. transversely to the axis of the withdrawal lumen 301). In Fig. 3, the catheter 101 defines lumens 301 and 302, the former being opened at its tip extremity, and the latter carrying a noble metal conductor 304. The noble metal conductor is potted into place by an appropriately set epoxy resin 306, and membrane 308 coats the active tip 307 of the conductor 304. It is understood that the above sets forth suggested and preferred embodiments of the present invention, buç that numerous alternative embodiments will occur to those of ordinary skill in the art without departure from the spirit or scope of the principles of the present invention,

Claims: What is claimed is: 1. A catheter type polarographic electrode assembly comprising: a) an elongated flexible member adapted for insertion of one end into a patient, said member defining at least two distinct, longitudinal channels therein and an opening at said one end for communication of one of said channels with ambient patient body fluids, b) at least one electrical conductor located in the other of said channels, said conductor terminating with a predetermined cross-section at said one 'wend of said member; c) potting means fór sealably-closing at least said other channel, said potting means-enclosing said conductor while exposing said predetermined cross-section; and d) selectively permeable membrane means overlaying at least said exposed predetermined cross-section 2. An assembly as described in claim l wherein said opening is located substantially at the terminus of said one channel at said one end of said member, transversely to the axis of said one channel at said terminus. 3. An assembly as described in claim 1 wherein said opening penetrates a side wall of said member in the region of said one end of said member. 4. An assembly as described in claim 3 wherein said potting means further sealably closes said other channel, insulating said membrane means and said conductor from said opening and said one channel. 5. An assembly as described in claim 1, further including means for withdrawal of samples of said ambient patient body fluid via said opening and said one channel. 6. An assembly as described in claim 5 wherein said other channel-carries only a single conductor, said assembly further including a datum electrode. coupled transcutaneously to the patient 7. An assembly as described in claim 1 wherein said predetermined cross-section is maintained by said potting means substantially at the tip of said one end of said member, transversely to the axis of said other channel. 8.- An assembly as described in claim 1 wherein said membrane means covers said one end, overlapping a portion of the outer walls of said member at said one end 9. An assembly as described in claim l wherein said connec-tion is varnish insulated in the area thereof to be enclosed by said potting means. 10. A method of making an in vivo polarographic sensor comprising the steps of: a) providing a flexible bilumen catheter means; b) providing a silver cathode wire in a first lumen - of said catheter means, said wire terminating at one extremity in a portion being varnish insulated, and an uninsulated cross-section of predetermined area; c) sealably closing both of said lumens at said one extremity with an inert material, with said wire cross-section being exposed; d) dip coating said extremity with a selectively permeable membrane, said membrane covering the outside walls of said catheter at said extremity, covering said material, and covering said exposed cross-section of catheter win; and e) opening the second of said lumens to the outside of said catheter. 11. A method as described in claim 10 wherein said dip coating step comprises application of four successive cup and dry cycles employing polyhydroxyethylmethacrylate. 12. A method as described in claim 10 wherein said closing step includes application of epoxy resin as said material

Inventors: PARKER, DAWOOD
Applicants: MCNEILAB, INC.
Application year: 1980
Main classification: A61B5
IPC codes: A61B5, G01N27