Method to adjust catheter body mechanical properties via selective cold crystallization in continuous processing

A method of manufacturing a length of catheter tubing, the method comprising:

• extruding a base layer;
• overlaying a braided layer on the base layer;
• overlaying a jacket sub-layer over the braided layer, wherein the jacket sub-layer is at least partially composed of a crystallizable material;
• overlaying an outer jacket on the jacket sub-layer;
• and
• heating at least a portion of at least one selected from the group consisting of the base layer, outer jacket layer, and jacket sub-layer to change a characteristic of the length of catheter tubing,
• wherein the crystallizable material is polyethylene terephthalate (PET) and heating at least a portion the jacket sub-layer to change a characteristic of the length of catheter tubing includes crystallizing at least a portion of the PET.

A method of manufacturing a length of catheter tubing, the method comprising:

• extruding a base layer and passing the base layer to a first reel;
• overlaying a braided layer on the base layer as the base layer passes from the first reel to a second reel, the braided layer and base layer together being a first intermediate product;
• overlaying a sub-jacket layer over the braided layer of the first intermediate product as the first intermediate product passes from the second reel to a third reel, the sub-jacket layer and the first intermediate product together being a second intermediate product;
• overlaying an outer jacket on the jacket sub-layer of the second intermediate product as the second intermediate product passes from the third reel to a fourth reel, the outer jacket and the second intermediate product together being a third intermediate product;
• and
• heating at least a portion the jacket sub-layer of the third intermediate product as the third intermediate product passes from the fourth reel to a fifth reel to change a characteristic of the length of catheter tubing,
• wherein heating at least a portion of the jacket sub-layer includes passing the third intermediate product through a heating element between the fourth reel and the fifth reel, and
• wherein heating at least a portion of the jacket sub-layer includes adjusting a speed at which the third intermediate product passes from the fourth reel to the fifth reel and adjusting a time at which the at least a portion of the jacket sub-layer is exposed to the heating element.

A method of manufacturing an elongate body of a medical device, the method comprising:

• extruding a base layer, the base layer including a main lumen land a plurality of minor lumens, each of the main lumen and the plurality of minor lumens being without a liner;
• overlaying a braided layer on the base layer;
• overlaying a sub-jacket layer over the braided layer, the jacket sub-layer being at least partially composed of a crystallizable material;
• overlaying an outer jacket on the jacket sub-layer, the outer jacket being at least partially composed of a material that resists crystallization;
• heating the jacket sub-layer to change a flexibility of at least a portion of the length of catheter tubing;
• and
• cutting the length of catheter tubing into a plurality of sub-lengths of catheter tubing.