Dual-lumen ultrasonic catheters, systems, and methods

A system configured for modifying intravascular lesions, comprising:

• a) a catheter assembly, including:
• a core wire;
• a dual-tube extrusion including a first tube with a first lumen and a second tube with a second lumen, wherein:
• the core wire is disposed within the first lumen, and
• the second lumen is configured to accommodate a guidewire;
• and
• a manifold disposed around at least a skived proximal-end portion of the dual-tube extrusion, wherein the skived proximal-end portion includes the second tube without the first tube;
• and
• b) an ultrasonic energy-producing mechanism, including:
• an ultrasound generator;
• and
• an ultrasound transducer, wherein a proximal end of the core wire is configured to vibrationally couple to the ultrasound transducer.

A method for manufacturing a catheter assembly configured for modifying intravascular lesions, comprising:

• extruding a dual-tube extrusion including a first tube with a first lumen and a second tube with a second lumen, wherein:
• the first lumen is configured for disposing a core wire therein, and
• the second lumen is configured to accommodate a guidewire;
• skiving off the first tube in a proximal-end portion of the dual-tube extrusion to provide a skived portion of the dual-tube extrusion including the second tube without the first tube;
• flaring the second tube in a distal-end portion of the dual-tube extrusion to provide a flared portion of the second tube;
• disposing at least the skived portion of the dual-tube extrusion in a manifold;
• and
• seating a lesion-modifying tip member in a distal end of the dual-tube extrusion.