# US 7,407,498 B2 · Construction of medical components using gas assisted microcellular foaming > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,407,498 B2 - Document ID: US7407498B2 - Status: Granted - Kind: B2 - Application number: 10/653,123 - Filed: 2003-09-02 - Published: 2005-03-03 - Granted: 2008-08-05 - Earliest claimed: 2003-09-02 - Assignees: Boston Scientific Scimed, Inc. - Inventors: Greg Olson - Web page: https://patentgrep.com/patent/US7407498B2 ## CPC - B29C 44/12: Incorporating or moulding on preformed parts, e.g. inserts or reinforcements - A61M 25/0009: {Making of catheters or other medical or surgical tubes} - Y10T 428/249978: Voids specified as micro - Y10T 428/249981: Plural void-containing components - Y10T 428/249986: Void-containing component contains also a solid fiber or solid particle - Y10T 428/24999: Inorganic - Y10T 428/249991: Synthetic resin or natural rubbers - Y10T 428/249992: Linear or thermoplastic - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A61M: DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY (introducing media into or onto the bodies of animals A61D7/00; means for inserting tampons A61F13/26; devices for administering food or medicines orally A61J; containers for collecting, storing or administering blood or medical fluids A61J1/05); DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY (surgery A61B; chemical aspects of surgical articles A61L); DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR {(Electrotherapy, e.g. producing anaesthesia by the use of alternating or intermittent currents A61N1/36021)} - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of forming a medical device or components thereof, including the steps of providing a first component of said medical device which is formed a first material and providing a second polymeric material into a mold cavity to overmold a second component of the medical device over the first component, and wherein the second polymeric material is further injected with a blowing agent to form a foam, and to components and to the medical devices made therefrom. ## Claims ### Claim 1 A catheter comprising a catheter shaft assembly having a proximal end and a distal end, a manifold connected to said catheter shaft assembly at said proximal end, and a tip connected to said catheter shaft assembly at said distal end, said manifold formed from a first polymer composition in microcellular foam form. ### Claim 2 (depends on 1) The catheter of claim 1 wherein said polymeric composition comprises at least one member selected from the group consisting of polyolefins, polyamides, polycarbonates, polyurethanes, polyesters, polyphenylene sulfides, polyphenylene oxides, polyethers, polyirnides, styrenic polymers, silicones, copolymers thereof and mixtures thereof. ### Claim 3 (depends on 1) The catheter of claim 1 wherein said microcellular foam composition comprises a nucleating agent in an amount of about 2.5 to about 7 percent by weight of the polymer material. ### Claim 4 (depends on 1) The catheter of claim 1 wherein said catheter shaft assembly comprises at least one shaft having a proximal end and a distal end, said manifold connected to said proximal end of said at least one shaft of said catheter shaft assembly, said shaft is polymeric or metallic. ### Claim 5 (depends on 1) The catheter assembly of claim 1 wherein said microcellular foam is an essentially closed cell microcellular foam. ### Claim 6 (depends on 1) The catheter of claim 1 wherein said first polymer composition comprises a nucleating agent in an amount of about 1 to about 10 percent by weight of the polymer composition. ### Claim 7 (depends on 1) The catheter of claim 1 wherein said tip is formed from a second polymer composition, said second polymer composition is the same as or different than said first polymer composition, and said second polymer composition is in microcellular foam form. ### Claim 8 (depends on 1) The catheter of claim 1 wherein said manifold further comprising a strain relief, said strain relief formed from a third microcellular foam polymer composition which is the same as or different than said first microcellular foam polymer composition. ### Claim 9 (depends on 1) The catheter of claim 1 wherein said manifold further comprises a gripping structure, said gripping structure formed from a fourth polymer composition which is the same as or different than said first polymer composition, said fourth polymer composition is in a microcellular foam form. ### Claim 10 A catheter comprising a catheter shaft assembly having a proximal end and a distal end, said catheter shaft assembly comprising at least one catheter shaft, a manifold connected to said catheter shaft assembly at said proximal end, and a tip connected to said catheter shaft assembly at said distal end, said manifold formed from a first polymer composition, said shaft formed from a second polymer composition which is different than said first polymer composition, and said tip formed from a third polymer composition which is different than said first polymer composition and different than said second polymer composition, and at least one of said first polymer composition or said third polymer composition are in microcellular foam form.