Catheters with intermediate layers and methods for making them

1. A method for constructing a tubular body sized for introduction into a body lumen comprising the steps of:

providing a strip of material comprising longitudinal edges extending between first and second ends;

positioning the strip around one or more underlying layers to form an intermediate layer having an interruption extending between the first and second ends;

after positioning the strip around the one or more underlying layers to form the intermediate layer, directing one or more outer layers around the strip and the one or more underlying layers to provide a sub-assembly; and

heating the sub-assembly to bond the one or more outer layers and underlying layers and the strip.

2. A method for constructing a tubular body sized for introduction into a body lumen, the tubular body comprising proximal and distal ends and a length between the proximal and distal ends, the method comprising:

providing a liner surrounding a mandrel along the length;

wrapping an intermediate layer around the liner and mandrel, the intermediate layer comprising an interruption extending along the length such that the intermediate layer is wrapped tightly around the liner to substantially eliminate a gap between the intermediate layer and the liner;

after wrapping the intermediate layer around the liner and mandrel, applying a reinforcing layer around the intermediate layer;

applying a continuous outer layer around the reinforcing layer to provide an assembly;

heating the assembly to bond the layers together; and

removing the mandrel, thereby providing an open central lumen along the length.

3. The method of claim 2 , wherein wrapping the intermediate layer comprises wrapping the intermediate layer around the liner such that longitudinal edges defining the interruption are positioned adjacent one another without overlapping one another.

4. The method of claim 3 , wherein the longitudinal edges reflow together to define a seam when the assembly is heated.

5. The method of claim 3 , wherein the longitudinal edges extend substantially axially along the length.

6. The method of claim 3 , wherein the longitudinal edges extend helically along the length.

7. The method of claim 2 , wherein the reinforcing layer comprises a braid or coil that is wrapped around the intermediate layer after wrapping the intermediate layer around the liner and mandrel.

8. The method of claim 7 , wherein heating the assembly comprises reflowing at least the intermediate layer and the outer layer, and wherein a position of elements of the braid or coil remain substantially constant during heating.

9. The method of claim 2 , wherein the liner comprises a fluoropolymer.

10. The method of claim 2 , wherein the liner is formed from polytetrafluoroethylene (PTFE) or fluorinated ethylene propylene (FEP).

11. The method of claim 2 , wherein the intermediate layer comprises a strip that is wound around the liner and mandrel.

12. The method of claim 11 , wherein the strip is formed by slitting a tubular layer of material.

13. The method of claim 2 , wherein the intermediate layer comprises inner and outer layers, the inner layer configured to adhere to the liner and the outer layer configured to adhere to the continuous outer layer.

14. The method of claim 2 , wherein the intermediate layer comprises inner and outer surfaces, the inner surface comprising a coating or adhesive configured to adhere to the liner and the outer surface comprising a coating or adhesive configured to adhere to the continuous outer layer.

15. The method of claim 2 , wherein the intermediate layer has a thickness that is thinner than a thickness of any of the other layers of the assembly.

16. The method of claim 4 , wherein the intermediate layer comprises a tacky thermoplastic.

17. The method of claim 2 , wherein the intermediate layer has a durometer that is lower than a durometer of any of the other layers of the assembly.

18. A method for constructing a tubular body sized for introduction into a body lumen, the tubular body comprising a length between proximal and distal ends thereof, the method comprising:

providing a liner surrounding a mandrel along the length, the liner comprising a fluoropolymer;

wrapping an intermediate layer around the liner and mandrel, the intermediate layer comprising a tacky thermoplastic material including an interruption defined by longitudinal edges extending along the length such that the intermediate layer is wrapped tightly around the liner to substantially eliminate a gap between the intermediate layer and the liner and the longitudinal edges are disposed adjacent one another;

after wrapping the intermediate layer around the liner and mandrel, applying a braid or coil around the intermediate layer to provide a reinforcing layer;

after applying a braid or coil around the intermediate layer, applying a continuous outer layer around the reinforcing layer to provide an assembly; and

heating the assembly to reflow at least the intermediate layer and the outer layer to bond the layers together and form a tubular body, and wherein a position of elements of the braid or coil remain substantially constant during reflow.

19. The method of claim 18 , wherein the longitudinal edges reflow together to define a seam when the assembly is heated.

20. The method of claim 19 , wherein the longitudinal edges extend helically or substantially axially along the length.

21. The method of claim 1 , wherein directing one or more outer layers around the strip and the one or more underlying layers to provide a sub-assembly comprises:

braiding or coiling a plurality of reinforcing elements around the strip and the one or more underlying layers; and

placing an uninterrupted tubular body around the reinforcing elements.