Method of creating a tip on a catheter

A method of forming a tip on a catheter having an elongate shaft, the method comprising the steps of:

• providing an elongate shaft having a distal portion including a distal end, a proximal end, and a lumen extending between the distal end and the proximal end thereof;
• the elongate shaft further including a joining region having a proximal end, a distal end, and a joining surface extending therebetween;
• providing a first tubular member having a proximal end, a distal end, and a lumen extending therebetween;
• providing a second tubular member having a proximal end, a distal end, and a lumen extending therebetween;
• providing a third tubular member having a proximal end, a distal end, and a lumen extending therebetween;
• inserting a mandrel into the lumen of the elongate shaft so that a portion of the mandrel extends distally from the distal portion of the elongate shaft;
• inserting the distal end of the elongate shaft into the lumen of the first tubular member so that the first tubular member is disposed about the joining portion of the elongate shaft;
• inserting the mandrel into the lumen of the second tubular member and positioning the proximal end of the second tubular member adjacent to the distal end of the first tubular member and having the lumen of the second tubular member in axial alignment with the lumen of the elongate shaft;
• sliding the third tubular member over the first and second tubular members;
• heating the first tubular member, the second tubular member, the third tubular member, and the distal portion of the elongate shaft, wherein the first tubular member, the second tubular member, and the third tubular member are fused to form the catheter tip affixed to the distal portion of the elongate shaft;
• and
• removing the mandrel from the lumen of the elongate shaft.

A method of forming a tip on a catheter having a elongate shaft, the method comprising the steps of:

• providing a elongate shaft having a proximal portion, a distal portion, and a lumen extending longitudinally therethrough;
• positioning a first tubular member so that it is overlying the distal portion of the elongate shaft;
• positioning a second tubular member so that a proximal end of the second tubular member is proximate a distal end of the first tubular member and a lumen of the second tubular member is in axial alignment with the lumen of the elongate shaft;
• positioning a mandrel so that a portion of the mandrel is disposed inside a lumen of the second tubular member and a portion of the mandrel is disposed inside the lumen of the elongate shaft;
• positioning a third tubular member so that it overlays both the first tubular member and the second tubular member;
• surrounding the distal portion of the elongate shaft with a shrink tube member;
• applying heat to the shrink tube member, whereby the shrink tube member contracts;
• heating at least the distal portion of the elongate shaft, wherein the first tubular member, the second tubular member, and the third tubular member are fused to form the catheter tip affixed to the distal portion of the elongate shaft;
• removing the shrink tube member;
• and
• removing the mandrel from the lumen of the elongate shaft.