Short wire cable catheter

A medical balloon catheter, comprising:

• an elongate non-interlaced swaged stainless steel multifilar tube, said tube comprising
• a proximal multifilar tube end,
• a distal multifilar tube end from which extends a connecting tube element having a smaller outer diameter than the distal multifilar tube end;
• an outer diameter of about 20-100 mil of the multifilar tube exclusive of the connecting tube element, and an inner diameter of about 20-80 mil, where the inner diameter is less than the outer diameter;
• a polymer barrier coating thermoformed around the multifilar tube and the connecting tube element, the polymer barrier comprising a polyether block amide material, and
• wherein a fluid-patent longitudinal multifilar tube lumen portion extends from the proximal multifilar tube end to a distal end of the connecting tube element;
• a dual-lumen polymer tube comprising
• a proximal polymer tube end configured to receive the connecting tube element and attached directly to a roughened surface adjacent the distal multifilar tube end,
• a distal polymer tube end,
• a first lumen configured as a fluid-patent polymer tube inflation lumen that extends distally from, and is in patent fluid communication with, the multifilar tube lumen, and
• a second lumen configured as a wire guide lumen extending parallel to the first lumen with a wire guide aperture immediately adjacent the proximal polymer tube end;
• an inflatable balloon directly attached to the distal polymer tube end such that a lumen of the balloon is in patent fluid communication with the first lumen;
• where the multifilar tube lumen and the first lumen together comprise a substantially patent path of fluid communication between the multifilar tube end and the balloon lumen;
• and
• where the second lumen forms a fluid-patent path of mechanical communication for a wire guide, which extends from a wire guide aperture near the proximal polymer tube end through the balloon lumen to a distal end of the balloon.

A method of making a catheter, the method comprising the steps of:

• providing an elongate non-interlaced swaged stainless steel multifilar tube, said tube comprising a longitudinal lumen disposed therethrough, a proximal multifilar tube end, and a distal multifilar tube end;
• swaging at least one of an outside-facing surface and an inside-facing surface of the tube;
• roughening an outside-facing surface of the distal multifilar tube end;
• assembling a polymer barrier coating to an outside-facing surface of the tube;
• attaching a proximal end of a polymer tube directly to the polymer barrier coating adjacent the distal multifilar tube end, where the polymer tube includes a first, fluid-patent, longitudinal lumen in attaching contact with the polymer barrier and a second longitudinal lumen configured for passage of a wire guide;
• and
• attaching an inflatable balloon to the polymer tube such that an inflation lumen of the balloon is in patent fluid communication with the first longitudinal lumen of the polymer tube and the second longitudinal lumen provides a patent path of mechanical communication through the balloon lumen to a distal end of the balloon.

A method of making a catheter, the method comprising the steps of:

• providing an alloy tube configured for use as a medical catheter, the alloy tube including a proximal alloy tube end, a distal alloy tube end, and an alloy tube lumen extending therebetween;
• providing a connecting tube element continuous with and extending distally beyond the distal alloy tube end;
• providing a heat-shrink coating over an external surface of the alloy tube and connecting tube element, wherein a portion the heat-shrink coating extends distally beyond the connecting tube element in tube-like fashion continuing the alloy tube lumen;
• providing a dual-lumen polymer shaft having a first lumen and a second lumen, where the second lumen is longer than the first lumen;
• expanding a proximal length of the first lumen from a first inner cross-sectional area to a second inner cross-sectional area that is greater than the first cross-sectional area and that is configured to receive the connecting tube element;
• inserting the connecting tube element into the expanded first lumen portion;
• and
• fusing the coated alloy tube to the dual-lumen polymer shaft.