IP Library › Granted Patent US 12,642,939
Granted Patent B2
US 12,642,939 · App. 17/969,626 · Granted Jun 2, 2026

Catheter tip structure and method of manufacture

Inventors: Juan Sepulveda (Centerville, UT); Glade H. Howell (Draper, UT)
Assignee: Bard Access Systems, Inc.
A61M25/0068A61M25/0009A61M25/001A61M25/003A61M25/0043B29C33/485A61M2025/0018A61M25/0026A61M2025/0031
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Quick Facts
Patent No.
US 12,642,939
App. No.
17/969,626
Filed
Oct 19, 2022
Granted
Jun 2, 2026
Kind
B2
Art Unit
1742
USPC
264/209.1
Abstract

The distal tip structure of a rapidly insertable central catheter (RICC) can be required to perform different functions from that of the remaining, multi-luminal section, of the RICC catheter. As such, the catheter body can be formed of a first material and the distal tip structure can be formed of a second material. Forming the RICC requires joining these two materials while maintaining a smooth abluminal surface. A bifurcated plug including a second material can be placed within a first lumen or second lumen of the catheter body. A mandrel can be placed within a third lumen. The assembly can then be placed within a die to plastically deform the bifurcated plug into a distal tip structure. Advantageously, only a single structure is required to plug the lumen and form the distal tip structure, reducing complexity and associated costs.

Claims (19)

1 . A method of forming a catheter, comprising:

extruding a multi-luminal section of a catheter body formed of a first material and having a first catheter lumen, a second catheter lumen, and a third catheter lumen; and

forming a distal tip structure coupled to the multi-luminal section of the catheter body, comprising:

placing a proximal end of a mandrel within a distal end of the third catheter lumen;

placing a portion of the mandrel, a distal end of the multi-luminal section of the catheter body, and a pellet of a second material, different from the first material, within a die; and

deforming the pellet around the mandrel to form the distal tip structure of the catheter, thereby occluding the first catheter lumen and the second catheter lumen at the distal end of the catheter body and extending the third catheter lumen from the distal end of the catheter body through the distal tip structure of the catheter.

2 . The method according to claim 1 , wherein the first material is more compliant, or of a softer durometer, relative to the second material.

3 . The method according to claim 1 , wherein the distal tip structure of the catheter includes a dilator section, an access section, or both.

4 . The method according to claim 1 , wherein deforming the pellet around the mandrel to form the distal tip structure of the catheter further includes applying one or more of pressure, thermal energy, radio frequency energy, or ultrasonic energy to plastically deform the pellet into the distal tip structure of the catheter.

5 . The method according to claim 1 , wherein placing the proximal end of the mandrel within the third catheter lumen of the multi-luminal section of the catheter body and deforming the pellet around the mandrel defines the third catheter lumen within the distal tip structure when forming the distal tip structure of the catheter.

6 . A method of forming a distal tip structure for a catheter, comprising:

forming from a first material a catheter body including a multi-luminal section defining a first lumen and a second lumen;

placing a proximal end of a mandrel within a distal end of the first lumen;

placing a portion of the mandrel, a distal end of the multi-luminal section of the catheter body, and a pellet of a second material, different from the first material, within a die; and

plastically deforming the pellet around the portion of the mandrel to form the distal tip structure of the catheter coupled to the distal end of the multi-luminal section of the catheter body, thereby occluding the second lumen at the distal end of the catheter body and extending the first lumen from the distal end of the catheter body through the distal tip structure of the catheter.

7 . The method according to claim 6 , wherein the first material is relatively more compliant, elastically deformable, or of a softer durometer relative to the second material.

8 . The method according to claim 6 , wherein the distal tip structure of the catheter includes a dilator section and a portion of an access section.

9 . The method according to claim 6 , wherein the distal tip structure of the catheter includes a dilator section having a recess configured to receive a proximal portion of an access section therein.

10 . The method according to claim 9 , further including coupling the proximal portion of the access section with the recess of the dilator section using adhesive, bonding, or welding.

Continuity (2)
Provisional Application 63270496 · Oct 21, 2021
Related Publication 20230126869A1 · Apr 27, 2023
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