Catheters with lubricious linings and methods for making and using them

Abstract

Apparatus and methods are provided for creating tubular devices, e.g., as components for catheters, sheaths, and or other devices sized for introduction into a patient. In one embodiment, a method is provided for making a tubular device using a sheet of material including a coated first surface. The sheet is rolled around a mandrel until longitudinal edges of the sheet are disposed near or adjacent one another, e.g., without attaching the longitudinal edges together. A tubular braid is positioned over the sheet-wrapped mandrel, one or more tubular segments are positioned over the tubular braid, and heat shrink tubing is positioned over the tubular segments. The resulting assembly is heated to cause the tubular segments to at least partially reflow and/or otherwise laminate the tubular segments to the tubular braid and sheet. The heat shrink tubing and mandrel are then removed to create the tubular device.

We claim: 
     
         1 . A tubular device, comprising a proximal end, a distal end sized for introduction into a body lumen, and a lumen extending between the proximal and distal ends, the tubular device comprising:
 an inner liner comprising longitudinal edges extending substantially axially between the proximal and distal ends and a coating on an inner surface thereof, the coating imparting one or more predetermined properties to a wall of the lumen, the longitudinal edges being disposed adjacent one another;   a braid surrounding at least a portion of the liner; and   an outer layer surrounding the braid and liner,   wherein the inner surface of the liner at least partially defines a lumen of the tubular device, and wherein material of the inner surface has a reduced bond angle selected to resist air bubbles sticking to the liner when the lumen is flushed.   
     
     
         2 . The tubular device of  claim 1 , wherein the liner comprises hydrophobic material, the tubular device further comprising a temporary coating on the inner surface to provide the reduced bond angle. 
     
     
         3 . The tubular device of  claim 2 , wherein the temporary coating comprises a water soluble material. 
     
     
         4 . The tubular device of  claim 2 , wherein the temporary coating comprises a biocompatible salt. 
     
     
         5 . The tubular device of  claim 2 , wherein the temporary coating comprises a surfactant. 
     
     
         6 . The tubular device of  claim 2 , wherein the liner comprises one of silicone, HDPE, or a fluoropolymer. 
     
     
         7 . The tubular device of  claim 1 , wherein the inner surface of the liner comprises a surface modification configured to provide the reduced bond angle. 
     
     
         8 . The tubular device of  claim 7 , wherein the surface modification comprises one of micro-abrasions, texturing, corona treatment, plasma treatment, and etching. 
     
     
         9 . The tubular device of  claim 1 , wherein the coating comprises at least one of a lubricious material and a hydrophilic material configured to provide the reduced bond angle. 
     
     
         10 . The tubular device of  claim 1 , wherein the material of the inner surface has a bond angle of less than ninety degrees (90°). 
     
     
         11 . A method for preparing a catheter, comprising:
 providing a catheter comprising a proximal end, a distal end, and a lumen extending between the proximal and distal ends defining an inner surface; and   applying a temporary coating to the inner surface, the coating providing a reduced bond angle selected to resist air bubbles sticking to the liner when the lumen is flushed.   
     
     
         12 . The method of  claim 11 , wherein the temporary coating comprises a water soluble material. 
     
     
         13 . The method of  claim 11 , wherein the temporary coating comprises a biocompatible salt. 
     
     
         14 . The method of  claim 11 , wherein the temporary coating comprises a surfactant. 
     
     
         15 . The method of  claim 11 , wherein the inner surface comprises one of silicone, HDPE, or a fluoropolymer. 
     
     
         16 . The method of  claim 11 , further comprising flushing the lumen to remove air within the lumen. 
     
     
         17 . The method of  claim 16 , wherein the coating is at partially rinsed from the lumen when the lumen is flushed. 
     
     
         18 . The method of  claim 16 , wherein the coating is at partially dissolved when the lumen is flushed. 
     
     
         19 . The method of  claim 11 , wherein the reduced bond angle is less than ninety degrees (90°).