Laser ablation process for removing a portion of dilation element from a balloon

1. A method of manufacturing a balloon catheter, comprising:

extruding a parison comprising a bead along an entire length of an outer surface of said parison, said bead comprising a head portion and a neck portion connecting said head region to said outer surface;

blow molding said parison to form an expanded balloon configuration comprising a working diameter region, a tapered region at each end of said working diameter region, and a neck region at each end of said tapered regions, said working diameter region being larger in diameter than said neck regions and said tapered regions providing transitions between said working diameter region and said neck regions; wherein said neck portion of said bead comprises a width less than a width of said head portion of said bead after blow molding;

mounting the blow molded balloon on a mandrel extending through an inner lumen of said neck regions;

positioning said mandrel and said blow molded balloon relative to a laser beam so that said laser beam is oriented 90° from said mandrel and is offset from said mandrel so that a width of said laser beam covers the entirety of said head portion and only part of said neck portion;

translating said laser beam and said mandrel relative to each other while said laser beam is activated, said laser beam thereby passing along each of said neck regions and ablating the entirety of said head portion and only part of said neck portion along said neck regions, a part of said neck portion remaining on said neck regions after ablating said bead;

removing said mandrel from said blow molded balloon after ablating said bead; and

inserting a catheter through said inner lumen of said neck regions and bonding said neck regions to said catheter.

2. The method according to claim 1 , further comprising rotating said laser beam and said mandrel relative to each other at the same time said laser beam and said mandrel are translated relative to each other, wherein more than one of said bead disposed around a circumference of said neck regions are partially ablated during each full rotation.

3. The method according to claim 1 , further comprising rotating said laser beam and said mandrel a full rotation relative to each other and translating said laser beam and said mandrel relative to each other a distance less than said width of said laser beam for said full rotation, wherein more than one of said bead disposed around a circumference of said neck regions are partially ablated during said full rotation.

4. The method according to claim 1 , further comprising translating said laser beam and said mandrel relative to each other, at the same time said offset between said laser beam and said mandrel is changed, said laser beam thereby passing along at least part of said tapered regions and ablating the entirety of said head portion and only part of said neck portion along said tapered regions, a part of said neck portion remaining on said tapered regions after ablating said bead.

5. The method according to claim 1 , further comprising disposing heat shrink tubing over said neck regions after said catheter is inserted through said inner lumen of said neck regions and heating said heat shrink tubing and said neck regions, said part of said neck portion remaining on said neck regions after ablating said beam thereby being substantially reformed into said neck regions.

6. The method according to claim 1 , wherein said parison is extruded from a nylon material.

7. The method according to claim 1 , wherein said width of said neck portion is about 0.010″ to about 0.020″ and said width of said head portion is about 0.015″ to about 0.030″.

8. The method according to claim 1 , wherein a height of said neck portion is about 0.010″ to about 0.025″ and a height of said head portion is about 0.010″ to about 0.020″.

9. The method according to claim 1 , wherein said width of said laser beam is about 0.020″ to about 0.045″.

10. The method according to claim 1 , wherein a wavelength of said laser beam is about 10 μm to about 12 μm.

11. The method according to claim 1 , wherein a focal length of said laser beam is about 3 mm to about 10 mm.

12. The method according to claim 1 , wherein a power of said laser beam is about 1 W to about 2 W.

13. The method according to claim 1 , wherein a rate of travel of said laser beam is about 0.1 mm/s to about 1 mm/s.

14. The method according to claim 1 , further comprising rotating said laser beam and said mandrel a full rotation relative to each other and translating said laser beam and said mandrel relative to each other a distance less than said width of said laser beam for said full rotation, wherein more than one of said bead disposed around a circumference of said neck regions are partially ablated during said full rotation, and disposing heat shrink tubing over said neck regions after said catheter is inserted through said inner lumen of said neck regions and heating said heat shrink tubing and said neck regions, said part of said neck portion remaining on said neck regions after ablating said beam thereby being substantially reformed into said neck regions.

15. The method according to claim 14 , further comprising translating said laser beam and said mandrel relative to each other, at the same time said offset between said laser beam and said mandrel is changed, said laser beam thereby passing along at least part of said tapered regions and ablating the entirety of said head portion and only part of said neck portion along said tapered regions, a part of said neck portion remaining on said tapered regions after ablating said bead.

16. The method according to claim 15 , wherein said parison is extruded from a nylon material, said width of said neck portion being about 0.010″ to about 0.020″, said width of said head portion being about 0.015″ to about 0.030″, a height of said neck portion being about 0.010″ to about 0.025″, a height of said head portion being about 0.010″ to about 0.020″, and said width of said laser beam being about 0.020″ to about 0.045″.

17. The method according to claim 16 , wherein a wavelength of said laser beam is about 10 μm to about 12 μm, a focal length of said laser beam is about 3 mm to about 10 mm, a power of said laser beam is about 1 W to about 2 W, and a rate of travel of said laser beam is about 0.1 mm/s to about 1 mm/s.

18. The method according to claim 1 , wherein said parison is extruded from a nylon material, said width of said neck portion being about 0.010″ to about 0.020″, said width of said head portion being about 0.015″ to about 0.030″, a height of said neck portion being about 0.010″ to about 0.025″, and a height of said head portion being about 0.010″ to about 0.020″.

19. The method according to claim 18 , wherein said width of said laser beam is about 0.020″ to about 0.045″, a wavelength of said laser beam is about 10 μm to about 12 μm, a focal length of said laser beam is about 3 mm to about 10 mm, and a power of said laser beam is about 1 W to about 2 W.

20. The method according to claim 19 , further comprising disposing heat shrink tubing over said neck regions after said catheter is inserted through said inner lumen of said neck regions and heating said heat shrink tubing and said neck regions, said part of said neck portion remaining on said neck regions after ablating said beam thereby being substantially reformed into said neck regions.