MOLDED TIP WITH EXTENDED GUIDEWIRE LUMEN AND ASSOCIATED DEVICES, SYSTEMS, AND METHODS

1 . An intraluminal imaging device, comprising:

a flexible elongate member configured to be positioned within a body lumen of a patient, the flexible elongate member comprising a proximal portion and a distal portion;

an imaging assembly coupled to the distal portion of the flexible elongate member, the imaging assembly surrounding a lumen; and

a tip member coupled to the imaging assembly, the tip member comprising a molded body including a guiding portion and an extended portion,

wherein the guiding portion extends distally of the imaging assembly,

wherein the extended portion extends proximally of the guiding portion through the lumen within the imaging assembly, and

wherein the tip member comprises a guidewire lumen extending through the guiding portion and the extended portion.

2 . The intraluminal imaging device of claim 1 , further comprising:

an adhesive fillet positioned around an external surface of a proximal portion of the guiding portion, the adhesive fillet contacting a distal end of the imaging assembly such that the fillet seals a junction between the guiding portion of the tip member and the distal end of the imaging assembly.

3 . The intraluminal imaging device of claim 1 , wherein the imaging assembly comprises an intravascular ultrasound (IVUS) imaging assembly, the IVUS imaging assembly comprising a flexible substrate positioned around a support member.

4 . The intraluminal imaging device of claim 3 , wherein the imaging assembly comprises an extension tube attached to a proximal flange of the support member, and wherein a proximal end of the extended portion of the tip member is attached to the extension tube.

5 . The intraluminal imaging device of claim 4 , wherein the flexible substrate comprises an electrical interface disposed at a proximal end of the flexible substrate, the electrical interface secured to an outer surface of the extension tube.

6 . The intraluminal imaging device of claim 3 , wherein the tip member comprises an intermediate connection portion between the guiding portion and the extended portion, the intermediate connection portion comprising a recess extending distally into the guiding portion, wherein a distal flange of the support member is received within the recess.

7 . The intraluminal imaging device of claim 1 , wherein the flexible elongate member comprises a guidewire exit port, and wherein the extended portion extends proximally within the flexible elongate member to the guidewire exit port, such that the guidewire lumen extends from the guidewire exit port to a distal end of the tip member.

8 . The intraluminal imaging device of claim 1 , wherein the flexible elongate member comprises a proximal inner member and a proximal outer member, and wherein a proximal end of the extended portion of the tip member is coupled to a distal end of the proximal inner member.

9 . The intraluminal imaging device of claim 1 , wherein the extended portion comprises a radial projection at a proximal end of the extended portion of the tip member, the radial projection configured to engage a proximal surface of the imaging assembly to mechanically secure the tip member to the imaging assembly.

10 . The intraluminal imaging device of claim 1 , wherein the guiding portion of the tip member comprises a tapered tubular shape comprising a first outer diameter at a proximal end of the guiding portion and a second outer diameter at a distal end of the guiding portion, and wherein the extended portion comprises a non-tapered shape comprising a third outer diameter, wherein the first outer diameter is larger than the second outer diameter and the third outer diameter.

11 . A method for manufacturing an intraluminal imaging device, comprising:

providing a tip member comprising a molded body including a guiding portion, an extended portion extending proximally of the guiding portion, and an intermediate connection portion disposed at a junction of the guiding portion and the extended portion;

positioning the extended portion within a lumen of an imaging assembly;

applying adhesive on or near the intermediate connection portion; and

moving the tip member proximally such that the intermediate connection portion abuts a distal end of the imaging assembly, and such that a proximal end of the extended portion extends to a proximal portion of the imaging assembly.

12 . The method of claim 11 , wherein applying the adhesive comprises forming an adhesive fillet on an exterior surface of the intermediate connection portion such that the fillet provides a seal between the guiding portion of the tip member and the imaging assembly.

13 . The method of claim 11 , wherein the intermediate connection portion of the tip member comprises a recess extending distally into the guiding portion, and wherein moving the tip member proximally comprises inserting a distal flange of the imaging assembly into the recess.

14 . The method of claim 11 , wherein moving the tip member proximally comprises positioning a proximal end of the extended portion adjacent a proximal flange of the imaging assembly.

15 . The method of claim 14 , further comprising at least one of thermally or adhesively bonding an extension around the proximal flange of the imaging assembly and the proximal end of the extended portion.

16 . The method of claim 11 , further comprising coupling a distal end of a flexible elongate member to the imaging assembly, wherein moving the tip member proximally comprises positioning a proximal end of the extended portion at a guidewire exit port of the flexible elongate member.