Balloon catheter for stent delivery having microchannels and method

Claim 1

A balloon catheter stent deployment system, comprising: a balloon catheter with an elongated flexible shaft having proximal and distal ends, a hub affixed to the shaft proximal end and having an inflation port, and an inflatable balloon affixed to the shaft near the shaft distal end; the shaft defining an inflation lumen providing fluid communication of an inflation fluid between the hub inflation port and the balloon, such that the balloon is adapted for selective inflation from a deflated state to an inflated state, as well as later deflation; the balloon being formed of a substantially inelastic material; the balloon having a cylindrical working portion with an inflated cross-sectional area located between a pair of conical portions and a pair of leg portions when the balloon is in the inflated state; the balloon being initially in the deflated state having multiple longitudinal pleats; an expandable tubular mesh stent defining a tubular wall thickness, mounted around the balloon and being crimped in an initial state to an initial outer diameter defined by an outer surface of the stent; the stent having substantially no tendency to self-expand absent an expansive force caused by inflating the balloon; wherein the balloon in its deflated state defines a first and second pillow located immediately proximal and distal of the stent; each balloon pillow in an initial deflated state having an initial outer diameter equal to at least the initial outer diameter of the stent, thereby tending to frictionally retain the stent in an initial longitudinal position while the catheter system is advanced or withdrawn along a vascular path; such that the balloon defines an indented bed shape for the stent in the deflated state; and a plurality of small channels defined by folds at the outer ends of the balloon pleats in the initial deflated state; the channels extending generally in a longitudinal direction and facilitating fluid communication from a portion of the balloon interior within the proximal balloon pillow to a portion of the balloon interior within the distal balloon pillow, such that the balloon tends to inflate at its proximal and distal ends in a substantially simultaneous manner; wherein inner and outer portions of the balloon adjacent to each fold define a gap, the gap being between the fold and adjacent inner and outer portions of the balloon that are in contact with each other in at least one location, so as to clearly define the channels; wherein the balloon is adapted to inflate and expand the stent to a deployed larger diameter, whereby the balloon forms said cylindrical working portion at above a preselected transition pressure, such that the cylindrical working portion and the portions defining the balloon pillows in the deflated state have substantially the same diameter in the inflated state; thereby causing said indented bed shape to substantially disappear.