Catheter having an ultra soft tip and methods for making the same

1. A catheter comprising:

an elongate shaft including a reinforcement member having a proximal end and a distal end;

an outer layer having a proximal end and a distal end, at least a portion of the outer layer disposed about and permeating into a portion of the reinforcement member, the distal end of the outer layer terminating proximal of the distal end of the reinforcement member such that a distal segment of the reinforcement member is free of the outer layer;

a distal extension having a proximal end and a distal end, wherein a portion of the distal extension is disposed circumferentially about a portion of the reinforcement member and secured directly to the distal segment of the reinforcement member such that the distal extension permeates the distal segment of the reinforcement member, the proximal end of the distal extension disposed distal of the distal end of the outer layer; and

an inflatable member having a proximal waist section and a distal waist section, the distal waist section secured to the distal extension, wherein a portion of the distal waist section extends distal of the distal end of the distal extension;

wherein a material bonding strength between the inflatable member and the distal extension is greater than a material bonding strength between the inflatable member and the outer layer.

2. The catheter of claim 1 , wherein the proximal end of the distal extension is adjacent the distal end of the reinforcement member.

3. The catheter of claim 1 , wherein the portion of the distal waist section extending distal of the distal end of the distal extension forms a distal tip.

4. The catheter of claim 3 , wherein the distal tip is an ultra soft tip.

5. The catheter of claim 4 , wherein the ultra soft tip has a durometer hardness of between about 5 A to about 40 A.

6. The catheter of claim 1 , wherein the elongate shaft further comprises an inner layer, wherein at least a portion of the reinforcement member is disposed about the inner layer.

7. The catheter of claim 6 , wherein the inner layer has a proximal end and a distal end, the distal end of the inner layer disposed proximal of the distal end of the distal extension.

8. The catheter of claim 6 , wherein the inner layer includes a polytetrafluoroethylene (PTFE).

9. The catheter of claim 1 , wherein the outer layer includes a thermoplastic polyester elastomer.

10. The catheter of claim 1 , wherein the distal extension includes a low-density polyethylene (LDPE).

11. The catheter of claim 1 , wherein the inflatable member includes a thermoplastic rubber elastomer.

12. The catheter of claim 1 , wherein the reinforcement member is a braided member.

13. The catheter of claim 1 , wherein the reinforcement member is a slotted hypotube.

14. A catheter comprising:

a reinforcement member having a proximal end and a distal end; a first layer having a proximal end and a distal end, the first layer including a polymer that covers at least a portion of the reinforcement member and permeates at least a portion of the reinforcement member, the distal end of the first layer terminating proximal of the distal end of the reinforcement member;

a distal extension having a proximal end and a distal end, the proximal end of the distal extension secured to the reinforcement member distal of the distal end of the polymer layer, wherein a portion of the distal extension overlaps a portion of the reinforcement member, wherein the portion of the distal extension that overlaps a portion of the reinforcement member permeates the reinforcement member; and

an inflatable member having a proximal waist section and a distal waist section, the distal waist section secured to the distal extension, wherein a portion of the distal waist section extends distal of the distal end of the distal extension forming a distal tip;

wherein a material bonding strength between the inflatable member and the distal extension is greater than a material bonding strength between the inflatable member and the first layer.

15. The catheter of claim 14 , wherein the reinforcement member is a braided member.

16. The catheter of claim 14 , further comprising a second layer, wherein at least a portion of the reinforcement member is disposed about the second layer, and wherein the second layer has a proximal end and a distal end, the distal end of the second layer disposed proximal of the distal end of the distal extension.

17. The catheter of claim 14 , wherein the distal extension includes a low-density polyethylene (LDPE).

18. The catheter of claim 17 , wherein the inflatable member includes a thermoplastic rubber elastomer.