Catheter sleeve assembly and one step injection molding process for making the same

A method for injection molding a sleeve for a catheter introducer, the method comprising:

• providing a mold with a cavity dimensioned to produce a sleeve for a catheter introducer, the cavity having a sleeve annulus, the sleeve annulus having a first semi-tubular portion and a second semi-tubular portion;
• providing a core pin and positioning the core pin within the cavity such that it is supported at both ends in a substantially untensioned manner;
• pressing a first flow of molten plastic into the first semi-tubular portion such that the first flow is substantially evenly distributed about a circumference of the first semi-tubular portion during motion of the first flow through the first semi-tubular portion;
• and
• pressing a second flow of molten plastic into the second semi-tubular portion such that the second flow is substantially evenly distributed about a circumference of the second semi-tubular portion during motion of the second flow through the second semi-tubular portion.

A method for forming a sleeve for a catheter introducer, the method comprising:

• providing a mold comprising a cavity dimensioned to produce a sleeve for a catheter introducer, the cavity containing a sleeve annulus, the mold further comprising a first ridge oriented along a length of the sleeve annulus and disposed to protrude into the sleeve annulus, and a second ridge oriented along a length of the sleeve annulus and disposed to protrude into the sleeve annulus opposite the first ridge;
• providing a core pin and positioning the core pin within the cavity such that it is supported at both ends in a substantially untensioned manner:
• injecting molten plastic into the sleeve annulus;
• and
• permitting the molten plastic to cool into a sleeve with a first thinned region formed by the first ridge and a second thinned region formed by the second ridge.

A method for forming a sleeve for a catheter introducer, the method comprising:

• providing a mold having a cavity dimensioned to produce a sleeve for a catheter introducer, the cavity comprising a sleeve annulus;
• providing a core pin to be positioned in the cavity, wherein the core pin is supported at both ends in a substantially untensioned manner;
• injecting molten plastic into the sleeve annulus such that the plastic has a longitudinal molecular alignment along a length of the sleeve annulus and a circumferential molecular alignment perpendicular to the length of the sleeve annulus, wherein the longitudinal molecular alignment is comparatively greater than the circumferential molecular alignment;
• and
• wherein injection of the molten plastic results in the creation of a first failure zone in the molten plastic, the first failure zone extending substantially along the length of the sleeve, and a second failure zone in the molten plastic, the second failure zone extending substantially along the length of the sleeve opposite the first failure zone.

A method for forming a sleeve assembly for a catheter introducer, the method comprising:

• providing a mold comprising a floating plate having a core pin extending therefrom and a cavity plate shaped to cooperate with the floating plate to form a cavity;
• mating the floating plate and the cavity plate such that the core pin extends into the cavity, wherein the core pin is supported at both ends in a substantially untensioned manner, wherein the cavity is sealed in a plastic-tight fashion;
• injecting molten plastic into the cavity;
• solidifying the molten plastic to form a sleeve assembly;
• and
• at least partially withdrawing the core pin through the floating plate while the floating plate and the cavity plate are mated to remove the core pin from the sleeve assembly.

A method for forming a tip for a sleeve of a catheter introducer, the method comprising:

• providing a mold having a cavity, the cavity having a sleeve portion with a substantially annular shape, the sleeve portion having a tip portion with a tapered outside diameter;
• positioning a core pin within the cavity to form a sleeve annulus between the sleeve portion and the pin, the core pin being supported at both ends in a substantially untensioned manner;
• and
• injecting molten plastic into the cavity such that the molten plastic travels through the sleeve annulus and into the tip portion, wherein, the molten plastic is substantially evenly distributed about a circumference of the sleeve annulus when the molten plastic enters the tip portion.