Rapid exchange catheters having a sealed guidewire lumen and methods of making the same

1. A rapid exchange catheter having a proximal end and a distal end, the catheter comprising:

an outer member having a proximal end and a distal end; and

an inner member having a proximal end and a distal end; wherein:

a guidewire port opens into the outer member and into the proximal end of the inner member at a location along the outer member distal of the proximal end of the outer member;

the inner member extends distally inside the outer member from the guidewire port beyond the distal end of the outer member;

the inner member is sized and adapted to receive a guidewire therethrough, the inner member having a first diameter along a majority of its length sufficient to allow fluid passage therethrough while the guidewire is disposed therethrough, wherein the inner member includes a first material; and

a seal is disposed within the inner member at a location spaced from the distal end of the inner member, wherein the seal is located nearer the proximal end of the inner member than the distal end of the inner member, wherein the seal includes the first material.

2. The rapid exchange catheter of claim 1 , wherein the inner member defines a first lumen and the outer member defines a second lumen, the second lumen including a portion disposed between the inner member and the outer member, wherein the inner member prevents fluid flow from the second lumen into the first lumen.

3. A rapid exchange catheter having a proximal end and a distal end, the catheter comprising:

an outer member having a proximal end and a distal end; and

an inner member having a proximal end and a distal end; wherein:

a guidewire port opens into the outer member and into the proximal end of the inner member at a location along the outer member distal of the proximal end of the outer member;

the inner member extends distally from the guidewire port past the distal end of the outer member;

the inner member is sized and adapted to receive a guidewire therethrough without allowing passage of a fluid therethrough while the guidewire is disposed therethrough, the inner member having a first diameter along a majority of its length sufficient to allow fluid passage therethrough while the guidewire is disposed therethrough; and

the inner member includes a tubular member having a necked portion spaced from the distal end of the inner member, wherein at least a portion of the necked portion is formed of the same material as the inner member.

4. The rapid exchange catheter of claim 3 , wherein the inner member includes a proximal tubular member and a bumper tip, the bumper tip and proximal tubular member joining at a butt-joint, and the necked portion is formed at the butt-joint using material from at least one of the bumper tip and the proximal tubular member.

5. The rapid exchange catheter of claim 4 , further comprising a balloon having a proximal balloon waist, a distal balloon waist, and a central balloon portion, wherein the distal balloon waist overlaps the butt joint between the bumper tip and the proximal tubular member.

6. The rapid exchange catheter of claim 3 , wherein the inner member includes a proximal tubular member and a bumper tip, the bumper tip forming a lap joint over the proximal tubular member, wherein the necked portion is formed at the distal end of the proximal tubular member beneath the bumper tip.

7. The rapid exchange catheter of claim 6 , further comprising a balloon having a proximal balloon waist, a distal balloon waist, and a central balloon portion, wherein the distal balloon waist and the bumper tip form a butt-joint over the proximal tubular member.

8. The rapid exchange catheter of claim 3 , further comprising a balloon having a proximal waist and a distal waist, the proximal waist being secured to the outer member and the distal waist being secured to the inner member;

wherein the outer member defines an inflation lumen and the inner member defines a guidewire lumen, the inflation lumen being in fluid communication with the interior of the balloon, the inflation lumen being fluidly isolated from the guidewire lumen by the inner member.

9. The rapid exchange catheter of claim 3 , wherein the inner member defines a first lumen and the outer member defines a second lumen, the second lumen including a portion disposed between the inner member and the outer member, wherein the inner member prevents fluid flow from the second lumen into the first lumen.

10. A method of using a rapid exchange catheter comprising:

providing a rapid exchange catheter having a proximal end, a distal end, a proximal section, a proximal guidewire port, and a distal section, the distal section defining a greater number of lumens than the proximal section, the distal section including a guidewire member having a proximal end opening into the guidewire port and a distal end extending to the distal end of the catheter, the guidewire member having a fluid stopping structure therein adapted to prevent fluid flow through the guidewire member when a guidewire is disposed through the fluid stopping structure, the fluid stopping structure being disposed nearer the proximal end of the guidewire member than the distal end of the guidewire member, and the fluid stopping structure being formed of the same material as the guidewire member;

inserting a proximal end of a guidewire to the distal end of the guidewire member;

manipulating the guidewire and/or rapid exchange catheter to cause relative movement between the two to advance the guidewire proximally through the guidewire member up to the fluid stopping structure; and

manipulating the guidewire and/or rapid exchange catheter to cause relative movement between the two to cause the guidewire to pass proximally of the fluid stopping structure.

11. The rapid exchange catheter of claim 3 , wherein the necked portion is located nearer the proximal end of the inner member than the distal end of the inner member.