Catheter with embedded components and method of its manufacture
First Claim
1. A method of manufacturing a catheter, comprising:
- providing an outer shaft having a lumen therethrough and at least one catheter component disposed at least partially within the lumen;
after the step of providing an outer shaft having a lumen therethrough and at least one catheter component disposed at least partially within the lumen, placing an inner shaft within the lumen such that the at least one catheter component is located between an inner surface of the outer shaft and an outer surface of the inner shaft, thereby forming a catheter assembly having an outer surface; and
after the step of placing an inner shaft within the lumen such that the at least one catheter component is located between an inner surface of the outer shaft and an outer surface of the inner shaft, applying energy to the catheter assembly to melt at least the outer shaft, whereby the outer shaft bonds to the inner shaft to form a catheter shaft having the at least one catheter component substantially embedded therein.
1 Assignment
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Accused Products
Abstract
A method of manufacturing a catheter includes providing an outer shaft having a lumen therethrough and at least one catheter component disposed at least partially within the lumen, placing an inner shaft within the lumen such that the at least one catheter component is located between the shafts, thereby forming a catheter assembly having an outer surface, and applying energy to the catheter assembly to melt at least the outer shaft to bond the outer shaft to the inner shaft. A unitary catheter shaft having the at least one catheter component substantially embedded therein results. The durometer of the outer shaft may differ from the durometer of the inner shaft, such that the catheter shaft varies radially in durometer. The durometer of the catheter shaft may also vary longitudinally. A shaping wire may be provided to form the distal end of the catheter shaft into a desired shape.
26 Citations
23 Claims
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1. A method of manufacturing a catheter, comprising:
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providing an outer shaft having a lumen therethrough and at least one catheter component disposed at least partially within the lumen; after the step of providing an outer shaft having a lumen therethrough and at least one catheter component disposed at least partially within the lumen, placing an inner shaft within the lumen such that the at least one catheter component is located between an inner surface of the outer shaft and an outer surface of the inner shaft, thereby forming a catheter assembly having an outer surface; and after the step of placing an inner shaft within the lumen such that the at least one catheter component is located between an inner surface of the outer shaft and an outer surface of the inner shaft, applying energy to the catheter assembly to melt at least the outer shaft, whereby the outer shaft bonds to the inner shaft to form a catheter shaft having the at least one catheter component substantially embedded therein. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method of manufacturing a catheter, the method comprising:
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providing a outer shaft having a generally circular outer cross section, a central lumen, and at least one catheter component disposed at least partially within the central lumen; after the step of providing a outer shaft having a generally circular outer cross section, inserting an inner shaft within the central lumen such that the at least one catheter component is located between an outer surface of the inner shaft and an inner surface of the outer shaft, thereby forming a catheter assembly; and after the step of inserting an inner shaft within the central lumen such that the at least one catheter component is located between an outer surface of the inner shaft and an inner surface of the outer shaft, heating the outer surface of the catheter assembly to melt at least the outer shaft, whereby the outer shaft bonds to the inner shaft to form a catheter shaft having the at least one catheter component substantially embedded therein. - View Dependent Claims (20, 21, 22, 23)
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Specification