Variable diameter woven medical tube textiles and method of making same

1. A textile greige comprising:

a plurality of the woven medical tube textiles in a series that share a set of warp yarns and a first weft yarn;

a diameter control weave of a second weft yarn with segments of at least a portion of the warp yarns that are outside of the woven medical tube textiles such that the diameter control weave is not part of, and is separable from, the plurality of woven medical tube textiles.

2. The textile greige of claim 1 wherein the first weft yarn is a monofilament; and

each of the warp yarns is a monofilament.

3. The textile greige of claim 1 wherein each of the medical tube textiles has at least one uniform diameter segment contiguous with at least one tapered diameter segment.

4. The textile greige of claim 1 wherein the diameter control weave is contiguous with the medical tube textiles.

5. The textile greige of claim 1 wherein each of the medical tube textiles includes a large diameter segment and a small diameter segment; and

less than all of warp yarns are included in the small diameter segment.

6. The textile greige of claim 1 wherein the woven medical tube textiles and the diameter control weave have independent weave patterns.

7. The textile greige of claim 1 wherein the plurality of medical tube textiles are segments of a continuous weave along the warp yarns; and

the diameter control weave includes a plurality of discontinuous woven areas connected by unwoven segments of the second weft yarn.

8. The textile greige of claim 1 wherein each of the medical tube textiles includes a first small diameter segment, a first tapered diameter segment, a large diameter segment, a second tapered diameter segment and a second small diameter segment.

9. The textile greige of claim 8 wherein each of the first weft yarn and the warp yarns is a monofilament.

10. The textile greige of claim 9 wherein each of the medical tube textiles is shaped to match an inflated medical balloon.

11. The textile greige of claim 10 wherein a wall of each of the medical tube textiles has a plain weave pattern.

12. A method of making a medical tube textile comprising the steps of:

weaving a first weft yarn with a set of warp yarns into a medical tube textile having a plurality of different diameters along a length;

controlling the different diameters with a diameter control weave by weaving a second weft yarn with segments of at least a portion of the warp yarns that are outside of the medical tube textile such that the diameter control weave is not part of, and is separable from, the plurality of woven medical tube textiles.

13. The method of claim 12 wherein the step of weaving the first weft yarn includes weaving a plurality of the medical tube textiles in a series using the set of warp yarns into a textile greige.

14. The method of claim 13 wherein the second weft yarn is woven with less than all the warp yarns.

15. The method of claim 13 wherein the textile greige includes the plurality of medical tube textiles as segments of a continuous weave along the warp yarns; and

the diameter control weave includes a plurality of discontinuous woven areas connected by unwoven segments of the second weft yarn.

16. The method of claim 12 wherein the step of weaving the first weft yarn is performed to yield a plain weave pattern in a wall of the medical tube textile.

17. The method of claim 12 wherein the medical tube textile and the diameter control weave have independent weave patterns.

18. The method of claim 12 wherein the first weft yarn is oriented perpendicular to the warp yarns in the medical tube textile.

19. The method of claim 12 wherein the medical tube textile includes a large diameter segment and a small diameter segment; and

less than all of the warp yarns are included in the small diameter segment.

20. The method of claim 12 including cutting the diameter control weave from the medical tube textile.