Catheter assembly with tapered joints and method of manufacture

A method of forming a joint between tubular components comprising:

• providing a first tubular component and a second tubular component, the first tubular component having a first substantially cylindrical portion and a first tapered portion adjacent thereto, a first angle being formed between the first substantially cylindrical portion and the first tapered portion is about 1 degree to about 25 degrees, the second tubular component having a second substantially cylindrical portion and a second tapered portion adjacent thereto, a second angle being formed between the second cylindrical portion and the second tapered portion being substantially the same as the first angle;
• overlapping the first tapered portion about the second tapered portion thereby forming an interface therebetween;
• applying heat only to the first tapered portion and the second tapered portion such that a weld is formed along the interface.

A medical device assembly comprising:

• a first shaft, the first shaft comprising a substantially cylindrical portion and at least one tapered portion, the at least one tapered portion forming an angle with the cylindrical portion of about 1 degree to about 25 degrees;
• and
• a second shaft, the second shaft having a proximal end region and a distal end region, at least one of the proximal end region and distal end region sealingly engaged to the at least one tapered portion.