Echogenic devices, material and method

Abstract: Echogenic medical devices and methods of fabrication and of use are disclosed. The devices are adapted to be inserted into a patient. The device includes an elongated member (1502) including a material (1503) having an acoustic impedance different from that of the surrounding medium. The medium includes surrounding biological tissue or fluids surrounding the member (1502) when inserted into a passageway of the patient. The acoustic impedance of the elongated member (1502) is sufficiently different from the surrounding medium for enhancing an image produced in response to a sonic beam produced from imaging equipment. The elongated member (1502) also includes an interface layer (1506) of a high density metal (1510) of which the deposition on the base material (1503) of the member (1502) is ion beam assisted. The interface layer (1506) includes an outside surface (1507) having a plurality of particulate-type, discontinuous curved surfaces (1511,1708) of partially spherical indentations (1709) formed therein or spheres (1508) extending therefrom. The difference between the acoustic impedances of the interface layer (1506) and the surrounding medium along with the discontinuous surfaces (1511,1708) of the interface layer (1506) cooperate in response to a beam from sonic imaging equipment to significantly enhance the image of the medical device member.

Description: This invention relates generally to echogenic devices for sonic imaging, such as described In EP-A-0 386 936. U.S. Patent No. 4,401,124 (Guess et al.) discloses systems for enhancing images of ultrasonic beams reflected from medical instruments. Furthermore, medical devices exist in which radiopaque stripes or additives are utilized to make the medical device appear on an X-ray machine or other radiographic device. For example, U.S. Patent No. 365,750 to Sheridan et al. discloses an X-ray type catheter having an X-ray opaque pigment on the catheter tube. One disadvantage of some X-ray opaque medical devices is that there is a risk of the X-ray opaque material flaking or peeling off and remaining in the patient. Furthermore, with these X-ray opaque paints and with the outer surface treatment utilized in the ultrasonic imaging device, fabrication expenses are increased. According to the present invention, there is provided a device as defined in claim 1. In an illustrative embodiment of the device, the member Includes a base material such as a flexible polyurethane material with an interface layer deposited thereon for further enhancing the image produced in response to the sonic beam. The Interface layer comprises a material different from the base material and has an acoustic impedance different from the acoustic impedance of the medium. The acoustic Impedance of the deposited interface layer material is advantageously much higher than that of the base material or surrounding medium. As a result, the difference between the acoustic impedances of the interface layer and the medium is advantageously increased for further enhancing the image of the member. The interface layer is deposited on a particulate-type, discontinuous curved surface or contour with a dimension less than a wavelength of a sonic beam from the imaging equipment. The increased difference between these acoustic impedances and the curved surface or contour cooperate in response to a sonic beam from the imaging equipment to produce a significantly enhanced image of the member. The base material of the device includes a deposition surface. The member also includes a particulate in the deposition surface for forming the particulate-type discontinuous surface or contour in the deposition surface. The interface layer material is deposited over the at least partially spherical particles or indentations to advantageously further enhance the image of the device in response to a sonic beam from the imaging equipment. The deposition of the interface layer material on the deposition surface of the member base material is ion beam assisted. The invention includes forming an interface in the member for producing the image in response to the beam. The interface has a shape with a dimension less than a wavelength of the sonic beam. The particles have an acoustic impedance having at least said predetermined difference between at least one of the two impedances of the elongated member and biological tissue. A preferred diameter for the partially-spherical indentations is in the range of between 1 to 100 microns. The present invention may easily be made biological inert and sterile for patient safety. 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 composite material includes a formable matrix material with discrete sound reflective particles made from a material different than and more sonically reflective than a material material being embedded in the matrix material to enhance the echogenicity of the body member. Brief Description of the Drawings Fig. 1 is a partially sectioned view of a member of an embodiment of the present invention with a high density interface layer deposited thereon; FIG. 2 is an enlarged view of a section of the interface layer and the base material of the member of Fig. 1; FIG. 3 is a partially sectioned view of a member of an alternative embodiment of the present invention as depicted in Fig. 1 with at least partially spherical indentations formed in the surface thereof; and FIG. 4 is an enlarged view of a section of the interface layer and the base material of the member of Fig. 3. EP-A-0 386 936 describes how particles 1508 are made up of a different material than matrix 1503. It is believed that the spherical shape provides for sound reflections at a variety of angles regardless of the direction from which the ultrasonic sound waves are emanating from, and accordingly, are more likely to reflect at least a portion of the transmitted signal back to the ultrasonic receiver to generate an image. A full description of items 1501 to 1505, 1508, 1701 to 1703, 1706, 1709, are to be found in that document. The present invention, namely the application of interface layers 1506, or 1704 can be applied to all of the embodiments of that publication. Depicted in Fig. 1 is a partially sectioned view of flexible member 1501 of an embodiment echogenic medical device having a high density metal interface layer 1506 deposited thereon for significantly enhancing the image of the device when inserted into a medium such as tissue or a passageway of a patient. The member comprises an elongated tube 1502 having a base or matrix material 1503 preferably with some of the particulate 1504 completely embedded therein. The elongated tube has an outer deposition surface 1505 of which particulate 1508 are preferably partially embedded therein and at least partially or entirely extend therefrom. As a result, deposition surface 1505 forms a particulate type discontinuous curved surface with particulate 1508 forming discrete, particulate-type, discontinuous, acoustic discontinuities each having a curved surface. With the exception of the interface layer, the above arrangement is the same as, or similar to, the arrangements described in EP-A-0 386 936. The interface layer 1506 comprises at least one layer of at least one material, and preferably is a single layer of a single material such as a high density metal 1510, approximately 2x10 -7 to 3.2x10 -7 M (2,000 to 3,200 angstroms) in thickness, is deposited on deposition surface 1505 using ion beam assistance. The deposited interface layer conforms to deposition surface 1505 and has a similar outer, particulate-type, discontinuous curved surface 1507 as a result of particulate 1508 being partially embedded in or deposited on or associated with, the deposition surface of the base material. The particulate have a size or dimension such as a 50 micron diameter preferably in the range of 1 to 100 microns, which is less than the wavelength of the sonic beam from the sonic imaging equipment. The deposited interface layer has a thickness which is also much less than the said wavelength, covers surface particulate 1508 embedded in or partially embedded in deposition surface 1505 of the base material to form discrete, particulate-type, discontinuous, curved surfaces 1509 in the outer surface of the interface layer. The interface layer includes a high density metal material 1510 different from the flexible base material and has an acoustic impedance significantly different from the acoustic impedance of the medium of which the device is inserted therein. When the device is exposed to a sonic beam from the imaging equipment, the increased difference between the acoustic impedances of the interface layer material and the surrounding medium significantly enhances the image of the member in the medium. Base material 1503 of the elongated tube preferably comprises a commercially available, medical grade polyurethane, which is suitable for placement in the urinary system of a patient. As previously suggested, the medical device can take the form of a catheter or stent which is insertable into the urethra, bladder, ureter, or kidney of the patient. This polyurethane material is sufficiently flexible for atraumatic insertion through these portions of the urinary system, but is sufficiently pushable for placement. Alternatively, base material 1503 is a material selected from silicone, polyethylene, nylon, C-FLEX™, polytetrafluoroethylene, polyvinyl chloride, polypropylene, polyester, and other medical grade polymers. C-FLEX™ material is a styrene-ethylene-butylene-styrene block copolymer plasticized with various proportions of silicone and mineral oils and is commercially available from Concepts Polymer Technologies, Inc. of Clearwater, Florida. In addition to experiments performed with polyurethane, it was observed that the adherence of 2.8x10 -7 M (2800 angstrom) interface layer of titanium to the deposition surface of polyethylene and nylon was found not to be as good as that of the polyurethane. The acoustic impedance of these base materials are disclosed in the previously described references or are available from the manufacturers thereof. The acoustic impedance of these materials are sufficient to establish a difference between that of the surrounding medium to produce and enhance an image of the member in response to a beam from sonic imaging equipment. However, to further enhance the acoustic impedance difference particulate are mixed with the base material during the formation of the tube. Particulate 1504 and 1508 include a plurality of particles such as tungsten spheres having a diameter of approximately 50 microns. These 50 micron tungsten spheres are commercially available from the GTE Company of Towanda, Pennsylvania. The density of the tungsten spheres is approximately 19.3 grams per cubic centimeter. The volume of the tungsten spheres to that of the polyurethane material is approximately 30 percent. Alternatively, the particles comprise glass material spheres also having a diameter of approximately 50 microns. Experimentally, the glass spheres produced images in less dense tissue such as that of the uterus and bladder. The high density metal tungsten spheres produced better images in this less dense tissue and in higher density tissue such as the ureter and kidney. The glass beads did not produce the same quality images as that of the tungsten spheres in the higher density tissue. Depicted in Fig. 2 is an enlarged view of base material 1503 with particulate 1504 completely embedded therein and particulate 1508 partially embedded in or extending from deposition surface 1505. Surface particulate 1508 form discrete, particulate-type, discontinuous curved surfaces 1511 in deposition surface 1505. For nonflexible medical device applications, the base material comprises a rigid material such as stainless steel or other rigid metal or polymer materials. It is also contemplated that the spheres are attached to the base material as described with respect to Figs. 10 and 14 of EP 0 386 936 A1. Interface layer 1506 of high density metal material(s) 1510 is deposited on surface particulate 1508 and deposition surface 1505 of the base material. The deposition of high density material 1510 is ion beam assisted. Ion beam assisted deposition of the high density material(s) is commercially available from the Spire Corporation of Bedford, Massachusetts. The high density deposition material has a higher acoustic impedance than that of base material 1503 to further increase the acoustic impedance difference between that of the surrounding medium. The high density material is of higher density than the base material and preferably comprises titanium which is deposited as one or more layers having a thickness in a range of approximately (2,000 to 3,200 angstroms) 2x10 -7 to 3.2x10 -7 M. This ion beam assisted deposition of the high density material readily adheres to the deposition surface of the base material while maintaining the overall flexibility of the base material. This ion beam assisted deposition process is conducted in a vacuum chamber to bombard the deposition surface of the polyurethane base material with argon ions and to produce a smooth, nonporous polyurethane surface for vacuum deposition of the titanium thereon. Bombarding ions are selected as a function of the base material. Alternatively, the deposition material of the interface layer(s) includes a metal or metals selected from tungsten, platinum, silver, gold, palladium, barium and bismouth. Interface layer material 1510 deposited on surface particulate 1508 forms the discrete, particulate-type, dlscontinuous curved surfaces 1509. The interface layer is preferably extremely thin and permits the partially curved surface of the embedded particulate to be represented on the outer surface of the interface layer. These discontinuous curved surfaces in combination with the acoustic impedance difference established between the interface layer and the surrounding medium cooperate to significantly enhance the ultrasonic image of the medical device when inserted in the medium. Depicted in Fig. 3 is a partially sectioned view of member 1701 which is an alternative embodiment of member 1501 of Fig. 1. Member 1701 comprises an elongated tube 1702 having base material 1703 preferably as previously described. Member 1701 also includes an interface layer 1704 of high density material 1705, as also previously described, deposited on deposition surface 1706 of elongated tube 1702. The interface layer includes an outer surface 1707 of which discrete, particular-type, discontinuous curved surfaces 1708 are formed therein. Curved surfaces 1708 comprise a plurality of at least partially spherical indentations which conform to the at least partially spherical indentations 1709 formed in base material 1703. Indentations 1709 are formed in deposition surface 1706 of the base material in a uniform manner with a radius in the range from .5 to 50 microns. An enlarged view of indentations 1709 formed in deposition surface 1706 of the base material 1703 is depicted in Fig. 4. Interface layer 1704 of high density material 1705 is deposited on surface 1706 of the base material as previously described using ion beam assistance. Indentations 1709 are formed approximately 0.013 cms (.005") apart in the deposition surface of the base material in a uniform array as shown. The thickness of interface layer 1704 is also preferably in a range of approximately 2x10 -7 to 3.2x10 -7 metres (2,000 to 3,200 angstroms). Although the thickness of the interface layer is preferably in a range from 2x10 -7 to 3.2x10 -7 M (2,000 to 3,200 angstroms), the thickness may vary as a result of the base material and high density interface material selected. Although the interface layer has been described as preferably comprising one layer of deposited metal, two or more layers of similar or dissimilar materials or even mixtures are also contemplated for deposition. The embodiments described in Figs. 2, 3, 4, 7 and 8 of EP-A-0 386 936 set forth some of the members which may be embodied in the members or devices of the present invention. When the elongated tube 1502 or 1702 is formed in the manner described in Fig. 7 of the above mentioned publication, the interface layer 1506 or 1704 comprises a plurality of stripes superimposed on the particles or (indentations) 727. The foregoing embodiments are merely representative of the present invention. The proportions between matrix material and the sound reflective particles may be measured by their percentage volume of the composite material. Typically, the composite material made up of between about 5% and 30% of the sound reflective particles by volume. One preferred embodiment has the composite material made up of about 10% of the sound reflective particles by volume. Another embodiment has about two to three percent sound reflective particles by volume. However, one percent or even a fraction including zero (See Fig. 4) of one percent, and up to 60% by volume of the sound reflective particles have been tested and determined to be acceptable for at least some applications. Nevertheless, as the percentage volume of the sound reflective particles increase, the amount of matrix material cohesively bonding the particles together is reduced. Accordingly, there ultimately occur trade-offs in terms of flexibility, durability, and cohesiveness. Furthermore, even ranges of less than 5% volume of sound reflective 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. Such selected localization may include the use of only one, or only a few, sound reflective particles. The materix 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 of the publication). 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. Fig. 5 of the above publication and the related text discloses at least one method of fabricating the elongated tube 1502 or 1702. Fig. 6 of the above publication shows an echogenic medical device, such as a device according to the present invention, inserted surgically into a medical patient. As illustrated in Fig. 6, a tubular catheter is utilized, although other devices may be used. Although the particles have been described as being preferably generally spherical or partially spherical in shape, the shape may include any geometric shape having one or more flat or curved surfaces having a dimension for producing a scattered component of the image. Naturally occurring crystalline structures are also contemplated.

Claims: An echogenic medical device insertable into a biological tissue of a patient having a given acoustical impedance, and imageable with sonic imaging equipment, by means of a sonic beam of a predetermined wavelength, said device comprising an elongated member (1501) including a base material (1503) having an outer surface, for insertion into the patient: said elongated member comprising discrete spaced apart discontinuities with dimensions less than that of the predetermined wavelength, said discontinuities being associated with the outer surface (1505) of the said base material, said discontinuities each having a partially spherical surface and being in the form of particles (1508) on the said surface or partially embedded therein, or in the form of indentations (1709) in the outer surface, the elongated member having an outer surface formed by the partially spherical surfaces of said discontinuities and by the outer surface of the base material (1503) in between said discontinuities, characterised in that one or more layers (1506) of material or materials, different from the base material and having a thickness less than the radius of the spherical surface of said discontinuities is formed over the outer surface of the elongated member, such as to adhere to the outer surface of the base material (1503) in between said discontinuities and to the partially spherical surfaces of said discontinnities, with the outer surface of the layer or layers conforming to the shape of the particles or indentations, and in that the acoustic impedance of the layer or layers is higher than that of the elongated member and of the said patient tissue into which the device is intended to be inserted, whereby the layer or layers serve to enhance the ultrasonic image of the device. A device according to claim 1, wherein each particle or indentation has a spherical surface which further enhances the ultrasonic image. A device of claim 2, wherein said particles comprise a tungsten material or glass of a generally spherical shape. The device of claim 1, 2, or 3, wherein the layer or layers comprises metal selected from titanium, tungsten, barium, bismuth, platinum, silver, gold, and palladium. The device of any one preceeding claim, wherein said member comprises material selected from polyurethane, polyethylene, nylon, polytetrafluoroethylene, polyvinyl chloride, polypropylene, polyester, and silicone. The device of any one preceding claim, wherein each discontinuous surface includes a radius in a range of .5 to 25 microns. The device of claim 1, wherein the layer or layers is deposited on said outer surface of said member and is ion beam assisted, the layer having a thickness in a range of 2 x 10 -7 to 3.2x10 -7 metres. A device of any one preceding claim wherein the echogenic body member includes a solid matrix material and discrete sound reflective particles fixedly positioned throughout said matrix material, and ultrasonically different than tissue and more sonically reflective than said matrix material to enhance the echogenicity of said body member.

Inventors: BOSLEY RODNEY W JR, FOSTER THOMAS L, THOMSON PAUL G, BOSLEY, RODNEY W., JR., FOSTER, THOMAS L., THOMSON, PAUL G.
Applicants: VANCE PRODUCTS INC, VANCE PRODUCTS INCORPORATED
Application year: 1993
Main classification: A61B8
IPC codes: A61M25, A61B19, A61L31, A61B8, A61L29, G01N29, A01K85