Catheter having a soft distal tip

Abstract

The present invention relates to a catheter having a soft distal tip that can be manufactured at lower cost than catheters in the prior art. In one embodiment, the catheter is produced by coupling a soft sleeve to the distal end of a catheter tube. The sleeve may affixed to the catheter tube under temperature and pressure conditions that cause the proximal end of the sleeve to taper against the outer surface of the catheter tube, avoiding or minimizing discontinuities in the insertion profile of the catheter, and that also cause the inner wall of the sleeve to taper against the distal end of the catheter tube, avoiding or minimizing discontinuities in the lumen of the catheter.

1 . A method of manufacturing a catheter having a soft distal tip, the method comprising:
 providing a catheter tube having a proximal end, a distal end, and a catheter lumen therebetween, the catheter lumen being defined by a catheter lateral wall; and   disposing a sleeve over the distal end of the catheter tube and extending the sleeve beyond the distal end of the catheter tube, the sleeve having a proximal end, a distal end, and a sleeve lumen therebetween, the sleeve lumen being defined by a sleeve lateral wall,   wherein the sleeve is softer than the catheter tube,   wherein a portion of the sleeve is affixed on the distal end of the catheter tube, and   wherein the sleeve lateral wall is free of recesses prior to overlaying the distal end of the catheter tube.   
     
     
         2 . The method of  claim 1 , further comprising,
 disposing an inflatable balloon over a portion of the catheter tube, the balloon comprising a balloon body, a proximal neck, and a distal neck, and   coupling an inflation tube to the catheter tube,   wherein the proximal neck couples the balloon body to the inflation tube, and   wherein the distal neck couples the balloon body to the catheter tube.   
     
     
         3 . The method of  claim 2 , wherein the proximal end of the sleeve abuts the distal neck. 
     
     
         4 . The method of  claim 2 , wherein the sleeve overlays the distal neck. 
     
     
         5 . The method of  claim 4 , wherein the sleeve completely overlays the distal neck. 
     
     
         6 . (canceled) 
     
     
         7 . The method of  claim 2 , wherein the distal neck overlays the sleeve and extends beyond the distal end of the sleeve. 
     
     
         8 . The method of  claim 2 , wherein the distal neck overlays the proximal end of the sleeve, and wherein the distal end of the sleeve extends beyond the distal neck. 
     
     
         9 . The method of  claim 2 , wherein the proximal end of the sleeve is longitudinally spaced from the distal neck. 
     
     
         10 - 13 . (canceled) 
     
     
         14 . A method of manufacturing a catheter having a soft distal tip, the method comprising:
 providing a catheter tube having a proximal end, a distal end, and a catheter lumen therebetween, the catheter lumen being defined by a catheter lateral wall; and   disposing a sleeve in the catheter lumen and extending the sleeve beyond the distal end of the catheter tube, the sleeve having a proximal end, a distal end, and a sleeve lumen therebetween, the sleeve lumen being defined by a sleeve lateral wall,   wherein the sleeve is softer than the catheter tube,   wherein a portion of the sleeve is affixed in the catheter lumen to the catheter lateral wall at the distal end of the catheter tube, and   wherein the sleeve lateral wall is free of recesses prior to affixing to the catheter lateral wall.   
     
     
         15 . The method of  claim 14 , further comprising,
 disposing an inflatable balloon that comprises a balloon body, a proximal neck, and a distal necks, and   coupling an inflation tube to the catheter tube,   wherein the proximal neck couples the balloon body to the inflation tube, and   wherein the distal neck couples the balloon body to the catheter tube.   
     
     
         16 . The method of  claim 15 , wherein the distal end of the sleeve is substantially laterally aligned with a distal end of the distal neck. 
     
     
         17 . The method of  claim 15 , wherein the distal end of the sleeve is longitudinally offset from a distal end of the distal neck. 
     
     
         18 - 20 . (canceled) 
     
     
         21 . A catheter comprising: a catheter tube having a proximal end, a distal end, and a catheter lumen therebetween, the catheter lumen being defined by a catheter lateral wall; and
 a sleeve disposed over the distal end of the catheter tube and extending beyond the distal end of the catheter tube, the sleeve having a proximal end, a distal end, and a sleeve lumen therebetween, the sleeve lumen being defined by a sleeve lateral wall,   wherein the sleeve is softer than the catheter tube,   wherein a portion of the sleeve is affixed on the distal end of the catheter tube, and   wherein the sleeve lateral wall is free of recesses prior to overlaying the distal end of the catheter tube.   
     
     
         22 . The catheter of  claim 1 , further comprising,
 an inflatable balloon disposed over a portion of the catheter tube, the balloon comprising a balloon body, a proximal neck, and a distal neck, and   an inflation tube coupled to the catheter tube,   wherein the proximal neck couples the balloon body to the inflation tube, and   wherein the distal neck couples the balloon body to the catheter tube.   
     
     
         23 . The catheter of  claim 22 , wherein the proximal end of the sleeve abuts the distal neck. 
     
     
         24 . The catheter of  claim 22 , wherein the sleeve overlays the distal neck. 
     
     
         25 . The catheter of  claim 24 , wherein the sleeve completely overlays the distal neck. 
     
     
         26 . (canceled) 
     
     
         27 . The catheter of  claim 22 , wherein the distal neck overlays the sleeve and extends beyond the distal end of the sleeve. 
     
     
         28 . The catheter of  claim 22 , wherein the distal neck overlays the proximal end of the sleeve, and wherein the distal end of the sleeve extends beyond the distal neck. 
     
     
         29 . The catheter of  claim 22 , wherein the proximal end of the sleeve is longitudinally spaced from the distal neck. 
     
     
         30 - 40 . (canceled)