Echogenic devices

Abstract: An echogenic medical devices adapted to be inserted into a patient, comprises an elongated member (123, 901, 1003) including a material (127, 1002) having an acoustic impedance different from that of the surrounding medium. For enhancing an image produced in response to a sonic beam produced from imaging equipment, the medium includes biological tissue or fluids surrounding the member when inserted into a passageway of the patient. The elongated member (901) also provides an interface (903) including the outside surface of the member and a plurality of partially spherical indentations (905). Alternatively, generally spherical particles (1002) are attached to the surface of the member (1003) for producing the image in response to the sonic beam. Materials such as stainless steel, plastic, and glass are utilized in the manufacture of the medical device. The device may also include an echogenic body member including a composite material echogenically imageable in the patient. The composite material includes a matrix material with discrete sound reflective particles made from a material different from the matrix material and embedded therein. Several sound reflective particles are disclosed, one type of particle being a glass microsphere about 5 microns in diameter. The matrix material (125) may be a plastic, and may be formed or extruded into devices such as catheters or other medical devices. The composite material may include different quantities of sound reflective particles by percent volume. Furthermore, a radiopaque material may be included in the composite material so the medical device is both ultrasonically imageable and radiographically imageable.

Description: This invention relates to echogenic medical devices to be positioned within a medium of a patient and with ultrasonic imaging equipment. Ultrasonic imaging in the medical field is widely used for a variety of applications. In addition to imaging physiological structures and tissue it is often desirable to produce an image of a medical device which has been inserted into a patient. Various approaches have been used to enhance ultrasonic imaging by modifying the reflective surface characteristics of these devices. U.S. Patent No. 4,401,124 and US-A-4 805 628, on which the first part of claim 1 is based, disclose systems for enhancing images of ultrasonic beams reflected from medical instruments. According to the present invention, there is provided a device as claimed in claim 1. The present invention is based upon the discovery that when discrete particulate type acoustic discontinuities which includes particles or indentations within the surface of the body of the device, or particles on the surface of the device, then the ultrasonic imaging of the device is significantly improved. The particles can be solid and have an acoustic impedance significantly different from that of the body of the device. The particulate type discontinuities can alternatively be shell-like in which case they can be filled with gas such as air. The particles or the particulate discontinuities which includes indentations, are either partially embedded in the surface of the body or formed entirely on the outer surface of the body say by adhesion. In the case of the particulate type discontinuities being shell-like and being partially embedded in the surface of the body, the outer parts of the shells may be removed to leave the discontinuities in the form of indentations in the outer surface of the body. These indentations produce a scattering component of the image in response to an input beam. The image is produced regardless of the angle of the incident beam. The above particles or indentations are formed or positioned in a random manner in or on the surface of the body, but it is to be understood that the indentations in the outer surface of the body, could be formed in an orderly manner if required without the use of shells, say by etching. The body of the device in most of the above inventive instances is regarded as being a composite body, and in many practical uses, the outer surface of the body forms an interface with the biological tissue of a patient. In all of the embodiments there are interfaces with regions of low to high impedance discontinuities and in some embodiments there are also regions of high to low impedance discontinuities. These interfaces extend in a multiplicity of directions due to the spherical nature of each interface. These have the effect of scattering the reflected ultrasonic waves in a multiplicity of directions and that enables the device surface to be observed from those directions, thus making observation uncritical, this being particularly advantageous when an article being observed in non-linear, or flexible. The difference in the acoustic impedances of the member material and surrounding medium enhances the intensity of the scattered component of the image. The particles or indentations are formed from a substance as a plurality of spherical shaped particles or indentations that each have a predetermined spherical surface for establishing the interface. This substance is attached to, partially embedded in, or formed as indentations in the outside surface of the member material. In one case, glass particles are attached to the outside surface of the member with an adhesive material. In another case, the particles are partially embedded in the outside surface of the member material. In still another illustrative embodiment, the contoured substance such as the glass particles are affixed to the outside surface of a stainless steel member using, for example, another material such as silver solder. In such instance, the substance has an acoustic impedance different from at least one of the impedances of the member material and surrounding tissue for enhancing the image produced in response to the sonic beam. The silver solder also presents another acoustic impedance to enhance an image. The greater the difference between the acoustic impedances of the member material and the biological tissue, the greater the enhancement of the image produced. In the embodiment which includes forming the interface by attaching a plurality of spherical particles to the surface of the elongated member, the particles have an acoustic impedance having at least the predetermined difference between at least one of the two impedances of the elongated member and biological tissue. A preferred diameter for the spherical indentations is in the range of between 1-50 microns. In a preferred embodiment, the composite material includes a formable matrix material with further discrete sound reflective particles made from a material different from and more sonically reflective than the matrix material and being embedded in the matrix material to enhance the echogenicity of the body member. The device can easily be made biologically inert and sterile for patient safety. The composite material of the embodiments still maintains the requisite flexibility for many medical applications, while providing echogenicity throughout the body of the device. In this way, the physician may observe a full image of the medical device in the patient. Furthermore, these advantages may be combined by including in the composite material a radiopaque material such as barium or tungsten to provide imaging with radiographic equipment. These advantages may be incorporated without a significant modification to the fabrication technique presently being used. The reflective particles, and optionally the radiopaque material, are mixed into the matrix material prior to forming the device by, for example, extrusion in the case of most catheters. Thus, no additional post extrusion fabrication steps are required to provide the desired echogenicity and a high level of quality control may be maintained. The echogenic body member is positioned in a sonic imaging beam; and an image is generated of the echogenic body member including the sound reflective particles from the sonic imaging beam. Fig.1 is a perspective view of a first embodiment of the present invention; Fig.2 is a cross-sectional view of a second embodiment not having particles according to the present invention; Fig.3 is a cross-sectional perspective view of a third embodiment of the present invention; Fig.4 is a cross-sectional perspective view of a fourth embodiment of the present invention; Fig.5 is a schematic diagram of a method of fabrication according to the present invention; Fig.6 illustrates one embodiment of the present invention inserted in a medical patient; Fig.7 is a cross-sectional perspective view of a fifth embodiment of the present invention; Fig.8 has been cancelled; Fig.9 is a partial cross-sectional view of another illustrative embodiment of the medical device of the present invention; Fig.10 is a partial view of still another illustrative embodiment of the medical device of the present invention; Fig.11 is a partial view of the distal end of yet another illustrative embodiment of the medical device of the present invention; Fig.12 is a partial view of a needle embodiment of the present invention; Fig.13 is a partial view of a catheter embodiment of the present invention; and Fig.14 is a partial view of a stent embodiment of the present invention. Referring to Fig.1, echogenic body member 123 is a part of an echogenic device which may be utilized in a large variety of medical devices. Member 123 is at least partially made up of a composite material which is echogenically imageable in the patient, such as by the use of ultrasonic imaging equipment. The composite material of the interface includes matrix material 125 with discrete sound reflective particles 127 partially embedded on the outer surface of the matrix material 125. The term "embedded in" is intended to include within its meaning "partially embedded on the surface", and "adhered to the surface". Preferably, matrix material 125 is a plastic, such as urethane, silicone, polyethylene, tetrafluorethylene. Preferably, matrix 125 is a formable, pliable material which may be molded and/or extruded to a variety of shapes, depending upon a specific application. Particles 127 are preferably made of a hard material, such as small glass particles, of spherical shape forming glass microspheres. Glass microspheres with an outer diameter of about 5 microns is one acceptable size. Other sized particles may be utilized as, for example, ranging between 1 and 50 microns and beyond. Furthermore, a spherical surface may be provided on the outside and/or the inside of particles 127, as for example a particle with a hollow spherical space therein. Particles 127 are made up of a different material than matrix 125. It is believed that the external and/or internal spherical shape provides for ultrasonic reflections at a variety of angles regardless of the direction from which the ultrasonic waves are emanating, and accordingly, are more likely to reflect at least a portion of the transmitted signal back to the ultrasonic receiver to generate an image. Since many of the matrix materials available are relatively ultrasonically transparent in a patient, ultrasonic reflective particles 127 provide adequate reflection. The use of a composite, rather than a solution, provides adequate size for acoustic reflection from the discrete particles embedded in the matrix. As indicated, a variety of materials may be utilized for the ultrasonic reflective particles, such as aluminum, hard plastic, sand, metal particles, and the like. Additionally, liquids, gases, gels, microen-capsulants, and/or coacervates suspended in the matrix may alternatively be used either alone or in combination, so long as they form a composite with ultrasonically reflective particles in the matrix. Of this variety, glass balls or microspheres have been found to be very well suited. Another application is to have the matrix 125 comprise solder used to fuse parts together. For example, the solder matrix with ultrasonically reflective particles associated with the outer surface thereof may be used to solder wires together in medical baskets (not shown) used to remove stones and other objects from medical patients. In addition to removal baskets, this technique may be used for other devices such as blood clot filters, guide wires and the like. Depicted in Fig.9 is a partial cross-sectional view of another illustrative embodiment of an echogenic medical device 901 that is insertable into a patient. Device 901 comprises an elongated tubular member 902 with a passageway 903, commonly known as a lumen, extending longitudinally therein. Member 902 is part of any well-known catheter, stent, needle, and the like for insertion into biological tissue or passageway of a patient. The elongated member has a characteristic or acoustic impedance, different from the characteristic or acoustic impedance of the surrounding medium. Approximate values of characteristic or acoustic impedances for a variety of materials, both non-biological and biological are disclosed in Table 1.4 of Wells, Physical Principles of Ultrasonic Diagnosis, Academic Press, London, New York, 1969, p.10, and in Table 3.1 of McDicken, Diagnostic Ultrasonics: Principle and Use of Instruments, John Wiley & Sons, New York, 1976, p.43. A mean characteristic impedance value for human tissue is indicated as 1.63 X 10 6 MKS rayl. Another table of characteristic impedances of various solids, liquids, and gasses are listed in Kinsler et al., Fundamentals of Acoustics, 2nd Edition, John Wiley & Sons, Inc., New York, 1962, pp.502-503. The difference between the characteristic impedance of the member material and the surrounding medium enhances the intensity of an image produced in response to an ultrasonic beam emitted from ultrasonic imaging equipment. The magnitude of the difference is proportional to the enhancement factor. A more detailed discussion is found in Chapter III of the McDicken reference. In one embodiment, elongated member 902 comprises a plastic material. From the Kinsler and Wells references, soft plastic such as polythene is listed as having a characteristic impedance of 1.84 X 10 6 MKS rayl. A hard plastic such as Lucite in bulk form is listed as having a characteristic impedance of 3.2 X 10 6 MKS rayl. When device 902 is inserted into the tissue or passageway of a patient, the difference in impedance between the tissue of the patient and the plastic material of the device is sufficient to enhance an image produced in response to an ultrasonic beam from imaging equipment. Medical device 901 also includes an interface including outside surface 904 having a shape responsive to a sonic beam for producing one component such as a reflective component of the sonic image. The outside surface of the elongated member also includes a plurality of spherical indentations 905 therein. These spherical indentations scatter the ultrasonic beam to produce another component of the image. A dimension of 2.5 microns is one acceptable size for the radius of spherical indentations 905. The radius of the indentations may range, for example, between 0.5 and 25 microns and beyond. This radial dimension is related to the wavelength of the incoming ultrasonic beam in a predetermined manner such that the radius is much less than the wavelength of the beam. For example, an ultrasonic beam emitted at 3.5 MHz has a wavelength of approximately 17,700 microns, whereas an ultrasonic beam emitted at 7.5 MHz has a wavelength of approximately 8,200 microns. Both of these frequencies are emitted from commercially available ultrasonic imaging equipment. The spherical indentations provide a curved surface from which the incident sonic beam may be scattered to produce the desired image regardless of the angle of incidence with respect to outer surface 904. The image produced by the interface including the outer surface and spherical indentations includes one or more components. When the dimensions of an object such as the spherical indentations are very much less than the wavelength of the sonic beam, Rayleigh scattering occurs. One known example of Rayleigh scattering is the interaction of ultrasound with blood cells. As discussed in Chapter III of the McDicken reference, the intensity of the scattered wave depends on the acoustic impedance change at the interface, the dimensions of the interface and the wavelength of the sonic beam. The amplitude of the scattered wave component is proportional to the square of the frequency of the sonic beam. Therefore, high frequency sonic beams are scattered the most strongly. For a reflection component to occur, dimensions of the reflecting surface must be greater than several wavelengths of the incident sonic beam. A refraction component is also produced when the incident beam propagates through the interface with a change in direction governed by well-known Snell's law. The needle 1201 of Fig.12 has spherical indentations 1202 in outer surface 1203 of tubular stainless steel cannula 1209. The indentations are grouped together in three millimeter bands 1204-1205 spaced approximately two millimeters apart about the distal end 1207 of the needle. The catheter 1301 of Fig.13 also has spherical indentations such as 1302 in outer surface 1303 of flexible plastic material cannula 1304. To ultrasonically image the catheter, three millimeter bands 1305-1309 of the indentations are grouped together and spaced approximately two millimeters apart about distal end 1310, an exploded view of band 1309 being shown. In the Fig.1 embodiment, the spherical surface of particles 127 comprise glass, which has a characteristic or acoustic impedance ranging from 12.0 to 12.9 X 10 6 MKS rayls as indicated by the Kinsler reference. The acoustic impedance difference between the plastic matrix material 125 and the glass particles 127 is much greater than that of the plastic and tissue, thereby enhancing the scattered component of the image produced by the spherical surfaces. The surrounding medium includes the matrix material. From another aspect, the matrix material is considered the member material having a first acoustic impedance, whereas the glass particles are considered a substance having a predetermined contour for establishing the interface. The particles can be included within the member material and, according to the invention, are either partially embedded in, or attached to or indented in, the surface of the elongated member of the device. In such case, the glass particles have a third acoustic impedance different from the acoustic impedance of the matrix material and surrounding biological tissue when inserted therein. In another embodiment of medical device 901, elongated tubular member 902 comprises a stainless steel material having an acoustic or characteristic impedance in the range of 39.0 to 51.5 X 10 6 MKS rayls. Again, the outer surface of the elongated member includes a plurality of spherical indentations 905. Since the acoustic impedance difference between the stainless steel material and the surrounding tissue is even greater than that of glass or plastic and tissue, the intensity of the scattered component of the image produced from the spherical indentations is further increased. The elongated member of device 901 has an acoustic impedance different from the biological tissue or medium in which the member is to be inserted. The interface is produced in one of several different manners. First, the elongated member may be extruded from one material and the spherical indentations formed or embossed in the material as the elongated member is being, for example, extruded. This would include the use of a well-known roller dye for selectively engaging the extruded material at designated positions. The dye would include spherical projections having the desired predetermined radius to form the indentations in the extruded material. Device 1001 (Fig. 10) comprising a plurality of spherical particles 1002 consisting of, for example, glass may be attached to elongated tubular member 1003 using, for example, a well-known adhesive 1004. Member 1003 comprises suitable plastics material. Alternatively, particles 1002 may be attached to a stainless steel tubular member 1003 by silver solder. The acoustic impedance of the particles and solder may enhance the image. In Fig.14, the stent 1401 has curled ends 1402 and 1403 for positioning the stent in a body passageway such as the ureter. The elongated plastic tubular member 1404 of the stent includes a plurality of ports 1405 for passing fluid therethrough . Similar to the configuration described with respect to Fig.10, several bands 1406 of glass particles 1407 are attached to surface 1408 of the tubular member using a well-known medical grade adhesive 1409. Alternatively, the glass particles are partially embedded in the surface of the matrix material that forms the plastic tubular member. The bands are approximately three millimeters in width and positioned approximately two millimeters apart at ends 1402 and 1403. The bands of glass particles may also be spaced along the entire length of the tubular member. The glass particles form an interface that is imageable with sonic imaging equipment. To provide a smooth outer surface for inserting the stent, a layer of plastic material 1410 coats the particles and surface 1408. Medical device 1101 (Fig.11) comprises an elongated member such as cylindrical rod or stylet wire 1102 that is inserted into a passageway or lumen of catheter 1005 for inserting and guiding the catheter into a passageway or blood vessel of a patient. The outside surface 1103 of the rod includes a plurality of spherical indentations 1104 for producing an image. Elongated member includes a material such as stainless steel with an acoustic impedance for enhancing any image produced by the spherical indentations in surface 1103. The elongated rod may be inserted into the lumen or passageway of a smooth outer surface catheter and inserted into a vessel of the patient and guided through the vessel with the assistance of the image produced by the indentations of the rod. The image produced by the indentations assists the physician in guiding the catheter and elongated rod through the passageway of the patient. This methodology includes directing a sonic beam toward the passageway of the patient with the device inserted therein and receiving an image from the indentations of the rod. Again, the material of the rod is selected to have an acoustic impedance different from that of the surrounding medium. It is envisioned that this surrounding medium may include body fluids from the patient or air which has an acoustic impedance of approximately 428 MKS rayls. Echogenic body member 223 (Fig. 2) forms a catheter with catheter wall 231 surrounding lumen 229. Lumen 229 has an inside diameter ID. In one embodiment, this internal diameter may be 0.1 cms (0.040 inches). The outside diameter OD of member 223 is 0.165 cms (0.065 inches). The outside diameter X of a typical microsphere is 5 µm. Reflective particles 227 can be totally embedded in matrix material 225, as well as being partially embedded on the outer surface of the catheter. Echogenic body member 323 (Fig. 3) is a two lumen catheter with lumens 329a and 329b being disposed in catheter wall 331. A multitude of ultrasonic reflective particles 327 can be totally embedded in matrix material 325, as well as being partially embedded in the outer surface of the catheter. Echogenic body member 423 (Fig. 4) is a triple lumen catheter having lumens 429a, 429b and 429c within catheter wall 431. Ultrasonic reflective particles 427 are shown in matrix 425. Catheter wall 731 (Fig. 7) supports echogenic body member 723. Member 723 is a composite as described above, with the matrix material being painted on adhesive with sound reflective particles ( 727 therein. Lumen 729 is in catheter wall 731. The ultrasonic reflective body is painted onto only a portion of the catheter as an annular stripe which is to be imaged. Typically, the composite material is made up of between about 5% and 30% of the sound reflective particles by volume. One embodiment comprises about 10% by volume of particles. Another has about 2 or 3% by volume particles. However, one percent or even a fraction of one percent, and up to 60% by volume of the ultrasonic reflective particles have been tested and determined to be acceptable for at least some applications. Nevertheless, as the percentage volume increases, the amount of matrix material cohesively bonding the particles together is reduced. Accordingly, there ultimately occur trade-offs in terms of flexibilty, durability and cohesiveness. Furthermore, even ranges of less than 5% volume of particles may be utilized in specific applications. Certain medical instruments such as an echogenic ruler may utilize the composite material of the present invention only in selected localized positions on the medical device. The matrix material may be a glue or other compound which can be painted or otherwise applied to localized regions on the device where only that region of the device needs to be imaged echogenically (see e.g. Fig.7). It is noteworthy that in at least certain applications, such as catheters, where the sound reflective particles comprise about 30% of the volume of the composite material, no significant loss in tensile strength was detected. Matrix material 525 (Fig.5) may comprise plastic pellets which may be mixed with sound reflective particles 527 in the mixing step 533. Mixing may occur by gravity feed of the parts to be mixed into a screw or worm-gear type mechanism well known in extruder machines such as are used for catheter manufacture. Optionally, but not necessarily, radiopaque material 528 may also be mixed with the matrix material and the sound reflective particles. The radiopaque material may be one of numerous radiopaque materials already known, as for example, barium, bismuth or tungsten. The radiopacifier may be finely ground powder mixed during the mixing step 533. Before, during or after the mixing step 533 the mixture may be heated in the heating step 535. The heating maintains the matrix material in a molten or liquid state allowing it to be formed to the desired shape. During the forming step 537, which is illustrated as an extruding step known in the catheter industry, the composite mixture is formed into an echogenic body member 523, including the sound reflective particles from 527 embedded in the matrix material. As illustrated, echogenic body 523 is a tubular catheter body having a longitudinal lumen as previously described. Other types of forming may be used, such as molding or other such shaping. Thereafter, the echogenic body member may be cut and/or shaped, as for example, cut into a specified length and/or cutting side drainage lumens, curling, tapering, or other such processes known in the plastics industry and in the catheter industry. Thereafter, the medical device is packaged during the packaging step 541, preferably hermedically sealed as is known to maintain the medical device in a surgically sterile condition. Finally, the medical device may be sterilized during the sterilizing step 543, using heat, chemicals or other known techniques. Fig.6 shows an echogenic medical device 221, such as a tubular catheter, inserted surgically into medical patient 645. Device 221 is sonically imaged using imaging device 647 with probe 651 to create image 649. This involves placing a device in the sonic imaging beam or field of the probe as illustrated and using ultrasonic imaging equipment, to produce image 649. and identifiable component of the image. Naturally occurring crystalline structures are also contemplated.

Claims: An echogenic medical device to be positioned within a medium of a patient and for use with ultrasonic equipment, said device comprising a body member (123) with image enhancing means (127) for improving the ultrasonic imaging of the device, the enhancing means comprising a plurality of discrete acoustic discontinuities (127) having a spherical surface to enhance the ultrasonic imaging of the device, CHARACTERISED IN THAT said enhancing means is associated with the outer surface (904) of the body member; said discontinuities being in the form of particles (1002) on the said surface or partially embedded therein; or indentations (905) in the outer surface, each particle or indentation having said spherical surface. A device according to claim 1, wherein the particles (127) have acoustic impedance(s) different from that of the body. A device according to claim 2, wherein the particles are hollow or are solid. A device according to claim 1. wherein the indentations have a surface of material different from that of the body. A device according to claim 1, 2, 3 or 4, wherein the said discontinuities are disposed in a random manner on the surface of the body. A device according to any one preceding claim, wherein the particulate discontinuities each have a dimension substantially less than the wavelength to be used in the ultrasonic equipment. A device according to claim 4. or any claim appendant thereto, wherein the body member has an acoustic impedance different from the said medium. A device according to any one preceding claim, wherein the characteristic impedance of the body has a difference from that of medium or biological tissue to achieve image enhancement, and wherein the characteristic impedance of the particles has at least said difference between the other characteristic impedances. the particles being more reflective than the material of the body member. A device according to any one preceding claim, wherein the discontinuities have diameter(s) in the range of 1 to 50 microns.

Inventors: BOSLEY RODNEY WAYNE, FOSTER THOMAS LEE, THOMSON PAUL GUY, BOSLEY, RODNEY WAYNE, FOSTER, THOMAS LEE, THOMSON, PAUL GUY
Applicants: VANCE PRODUCTS INC, VANCE PRODUCTS INCORPORATED
Application year: 1990
Main classification: A61B8
IPC codes: G01S7, A61B8, G01S15, A61L31, A61B19, A01K85, A61M25