Strip lined catheters and methods for constructing and processing strip lined catheters

1. A method for making a tubular component of a catheter sized for introduction into a patient's body using a strip of thermoplastic polymer material including a length, a width, and a first surface comprising a surface modification, comprising:

directing the strip adjacent an elongate mandrel such that the length of the strip extends along the mandrel and the first surface is disposed towards the mandrel;

rolling the strip at least partially around the mandrel such that the first surface is disposed inwardly towards the mandrel; and

wrapping a plurality of strip-constrainment members around the rolled strip,

wherein the directing, rolling, and wrapping steps are substantially continuous to create one or more strip-mandrel-constrainment member subassemblies,

wherein side edges of the strip remain unattached to one another when the strip is rolled around the mandrel and the strip-constrainment members are wrapped around the rolled strip.

2. The method of claim 1 , further comprising collecting the one or more strip-mandrel-constrainment member subassemblies helically on a take-up reel.

3. The method of claim 1 , further comprising:

periodically separating the rolled strip and mandrel wrapped by the constrainment members into multiple strip-mandrel-constrainment member subassemblies; and

collecting the multiple strip-mandrel-constrainment subassemblies in a collection area.

4. The method of claim 1 , further comprising encasing the one or more strip-mandrel-constrainment member subassemblies in a jacket.

5. The method of claim 4 , wherein the one or more strip-mandrel-constrainment member subassemblies are encased in a jacket by extruding jacket material around the one or more strip-mandrel-constrainment member subassemblies.

6. The method of claim 4 , wherein encasing the one or more strip-mandrel-constrainment member subassemblies in a jacket comprises:

separating the rolled strip and mandrel wrapped by the constrainment members into multiple strip-mandrel-constrainment member subassemblies; and

encasing each strip-mandrel-constrainment member subassembly in an individual jacket.

7. The method of claim 6 , wherein each strip-mandrel-constrainment member subassembly is encased in an individual jacket by:

inserting a tubular member around the strip-mandrel-constrainment member subassembly; and

heating at least one of the tubular member and the strip-mandrel-constrainment member subassembly to soften, partially melt, or flow the strip and bond the tubular member around the strip-mandrel-constrainment member subassembly.

8. The method of claim 1 , wherein the strip of material is directed from a reel into a guide to place the strip adjacent to the mandrel, and wherein the guide rolls the strip at least partially around the mandrel.

9. The method of claim 1 , further comprising:

separating the one or more strip-mandrel-constrainment member subassemblies into multiple tubular bodies;

directing a plurality of the tubular bodies into a guide;

directing another strip of material into the guide to roll the strip at least partially around the plurality of tubular bodies; and

wrapping one or more strip-constrainment members around the rolled strip and plurality of tubular bodies to create one or more multiple lumen tubular bodies.

10. The method of claim 1 , wherein the surface modification comprises a coating on the first surface.

11. The method of claim 1 , wherein side edges of the strip substantially abut one another when the strip is rolled around the mandrel.

12. The method of claim 1 , wherein side edges of the strip are spaced apart from one another when the strip is rolled around the mandrel.

13. The method of claim 1 , wherein side edges of the strip overlap one another when the strip is rolled around the mandrel.

14. The method of claim 1 , wherein the plurality of strip-constrainment members comprise a plurality of filaments, and wherein wrapping a plurality of strip-constrainment members comprises substantially continuously braiding the plurality of filaments around the rolled strip.

15. The method of claim 1 , wherein the plurality of strip-constrainment members comprise a plurality of filaments, and wherein wrapping a plurality of strip-constrainment members comprises substantially continuously braiding individual filaments around the rolled strip.

16. A method for making a catheter body sized for introduction into a patient's body, comprising:

directing a strip of thermoplastic material substantially continuously from a reel to a guide to place the strip adjacent an elongate mandrel such that a length of the strip extends axially along the mandrel and a coating on a first surface of the strip is oriented towards the mandrel;

substantially continuously rolling the strip at least partially around the mandrel such that the coating is disposed radially inwardly towards the mandrel; and

substantially continuously wrapping one or more strip-constrainment members around the rolled strip to create one or more strip-mandrel-constrainment member subassemblies; and

encasing the one or more strip-mandrel-constrainment member subassemblies in a jacket to create one or more tubular bodies,

wherein side edges of the strip remain unattached to one another when the strip is rolled around the mandrel and the strip-constrainment members are wrapped around the rolled strip.

17. The method of claim 16 , further comprising collecting the one or more strip-mandrel-constrainment member subassemblies helically on a take-up reel.

18. The method of claim 16 , further comprising:

periodically separating the rolled strip and mandrel wrapped by the constrainment members to create multiple strip-mandrel-constrainment member subassemblies; and

collecting the multiple strip-mandrel-constrainment subassemblies in a collection area.

19. The method of claim 16 , wherein the one or more strip-mandrel-constrainment member subassemblies are encased in a jacket by extruding jacket material around the one or more strip-mandrel-constrainment member subassemblies.

20. The method of claim 16 , wherein the strip comprises a first strip, the method further comprising:

directing a second strip of material substantially continuously from a reel to the guide to place the second strip adjacent the mandrel such that a length of the second strip extends axially along the mandrel and a coating on a first surface of the second strip is disposed inwardly towards the mandrel; and

substantially continuously rolling the second strip at least partially around the mandrel before wrapping the one or more strip-constrainment members around the rolled second strip.

21. The method of claim 16 , wherein the strip comprises a polymer material and wherein the coating comprises a lubricious coating.

22. A method for making a tubular component of a catheter sized for introduction into a patient's body, comprising:

directing a strip of thermoplastic material and an elongate mandrel substantially simultaneously into a guide to align a length of the strip along a length of the mandrel and to roll the strip at least partially around the mandrel such that a first surface of the strip is disposed inwardly towards the mandrel; and

wrapping one or more strip-constrainment members helically around the rolled strip as the rolled strip exits the guide to create a strip-mandrel-constrainment member subassembly,

wherein side edges of the strip remain unattached to one another when the strip is rolled around the mandrel and the strip-constrainment members are wrapped around the rolled strip.

23. The method of claim 22 , further comprising encasing the strip-mandrel-constrainment member subassembly in a tubular jacket.

24. The method of claim 22 , wherein the first surface comprises a surface modification.

25. The method of claim 24 , wherein the surface modification comprises a lubricious coating.

26. A method for making a tubular component of a catheter sized for introduction into a patient's body using a strip of thermoplastic polymer material including a length, a width, and a first surface comprising a surface modification, comprising:

directing the strip adjacent an elongate mandrel such that the length of the strip extends along the mandrel and the first surface is disposed towards the mandrel;

rolling the strip at least partially around the mandrel such that the first surface is disposed inwardly towards the mandrel; and

wrapping one or more strip-constrainment members around the rolled strip, wherein the directing, rolling, and wrapping steps are substantially continuous to create one or more strip-mandrel-constrainment member subassemblies, and

wherein the thermoplastic comprises at least one of polyether block amide, urethane, and nylon.

27. A method for making a tubular component of a catheter sized for introduction into a patient's body, comprising:

directing a strip of thermoplastic material and an elongate mandrel substantially simultaneously into a guide to align a length of the strip along a length of the mandrel and to roll the strip at least partially around the mandrel such that a first surface of the strip is disposed inwardly towards the mandrel; and

wrapping one or more strip-constrainment members helically around the rolled strip as the rolled strip exits the guide to create a strip-mandrel-constrainment member subassembly,

wherein side edges of the strip remain unattached to one another when the strip is rolled around the mandrel and the strip-constrainment members are wrapped around the rolled strip, and

wherein the strip is formed from one of polyether block amide, urethane, and nylon.