Method of making a catheter

Claim 2

The process of manufacturing a catheter which comprises: a. providing an elastomeric catheter shaft having a drainage lumen extending longitudinally thereof; b. inserting a guide in the drainage lumen of said shaft; c. inserting at least a portion of said shaft, including at least a portion of said guide in a mold; d. molding a hollow tip and simultaneously bonding said tip to the distal end of said shaft by introducing elastomeric material under pressure into said mold; and e. providing at least one drainage eye through said tip and communicating via the hollow tip with said drainage lumen.

Claim 3

The process of claim 1 wherein said at least one drainage eye is formed when said hollow tip is molded and simultaneously bonded to said shaft.

Claim 4

The process of claim 1 wherein said shaft and said tip are silicone rubber.

Claim 5

The process of claim 3 wherein said shaft is an extruded shaft.

Claim 6

The process of claim 1 further comprising removing the guide from the interior of the catheter by passing said guide through said at least one drainage eye.

Claim 7

The process of claim 1 wherein the pull strength between said tip and said shaft is at least about 5 pounds.

Claim 8

The process of claim 6 wherein the bond strength between said tip and shaft is at least about 150 lbs./in. 2 .

Claim 9

The process of claim 1 wherein said guide is inserted into the drainage lumen so that it extends distally in said mold at least substantially to the distal end of said shaft.

Claim 10

The process of manufacturing a catheter which comprises: a. providing an elastomeric catheter shaft having a drainage lumen extending longitudinally thereof and an inflation lumen extending longitudinally for at least a major portion thereof and communicating with the exterior of said shaft through an aperture adjacent the distal end of said shaft; b. inserting a guide in the drainage lumen of said shaft; c. inserting at least a portion of said shaft, including at least a portion of said guide in a mold; d. molding a hollow tip and simultaneously bonding said tip to the distal end of said shaft with said guide inserted therein by introducing elastomeric material under pressure into said mold; e. bonding one end of a balloon sleeve to the catheter shaft on the proximal side of said aperture and the other end of the balloon sleeve to the catheter on the distal side of said aperture; and f. providing at least one drainage eye through said tip and communicating via the hollow tip with said drainage lumen.

Claim 11

The process of manufacturing a catheter which comprises: a. providing an elastomeric catheter shaft having a drainage lumen extending longitudinally thereof and an inflation lumen extending longitudinally for at least a major portion thereof and communicating with the exterior of said shaft through an aperture adjacent the distal end of said shaft; b. inserting a guide in the drainage lumen of said shaft; c. inserting at least a portion of said shaft, including at least a portion of said guide in a mold; d. molding a hollow tip and simultaneously bonding said tip to the distal end of said shaft with said guide inserted therein by introducing elastomeric material under pressure into said mold; e. bonding one end of a balloon sleeve to the catheter shaft on the proximal side of said aperture and the other end of the balloon sleeve to the catheter on the distal side of said aperture; and f. providing at least one drainage eye through said tip and communicating via the hollow tip with said drainage lumen.

Claim 12

The process of claim 9 which further includes the step of providing a peripheral groove in the exterior of the shaft on the distal side of said aperture and bonding said balloon sleeve to said shaft within said groove.

Claim 13

The process of claim 9 further comprising removing the guide from the interior of the catheter by passing said guide through said at least one drainage eye.

Claim 14

The process of claim 9 wherein said at least one drainage eye is formed when said hollow tip is molded and simultaneously bonded to said shaft.

Claim 15

The process of claim 9 wherein said guide is inserted into the drainage lumen so that it extends distally in said mold at least substantially to the distal end of said shaft.

Claim 16

The process of claim 9 wherein said other end of the balloon sleeve is bonded to said tip.

Claim 17

The process of claim 14 which further includes the step of molding a peripheral groove into the exterior of said tip when said tip is molded and simultaneously bonded to said shaft.

Claim 18

The process of claim 9 wherein said shaft, said balloon sleeve and said tip are silicone rubber.

Claim 19

The process of claim 16 wherein said shaft is an extruded shaft.

Claim 20

The process of manufacturing a catheter which comprises: a. providing an elastomeric catheter shaft having a drainage lumen extending longitudinally thereof and an inflation lumen extending for at least a major portion thereof and communicating with the exterior of said shaft through an aperture adjacent the distal end of said shaft; b. inserting at least a portion of said shaft into a mold and inserting a mandrel into the drainage lumen of said shaft; c. molding a balloon sleeve and simultaneously bonding said balloon sleeve to said shaft adjacent the distal end thereof and on one side of said aperture by introducing elastomeric material under pressure to said mold; d. bonding a hollow tip to the distal end of said shaft; e. providing at least one drainage eye through said tip and communicating via the hollow tip with said drainage lumen; and f. bonding the exposed end of said balloon sleeve to said catheter on the other side of said aperture.

Claim 21

The process of manufacturing a catheter which comprises: a. providing an elastomeric catheter shaft having a drainage lumen extending longitudinally thereof and an inflation lumen extending for at least a major portion thereof and communicating with the exterior of said shaft through an aperture adjacent the distal end of said shaft; b. inserting at least a portion of said shaft into a mold and inserting a mandrel into the drainage lumen of said shaft; c. molding a balloon sleeve and simultaneously bonding said balloon sleeve to said shaft adjacent the distal end thereof and on one side of said aperture by introducing elastomeric material under pressure to said mold; d. bonding a hollow tip to the distal end of said shaft; e. providing at least one drainage eye through said tip and communicating via the hollow tip with said drainage lumen; and f. bonding the exposed end of said balloon sleeve to said catheter on the other side of said aperture.

Claim 22

The process of claim 18 wherein said shaft, said balloon sleeve and said tip are silicone rubber.