One-Piece Molded Catheter and Method of Manufacture

Abstract

A one-piece catheter ( 30 ) and manufacturing method therefor are disclosed. The catheter ( 30 ) includes a catheter tube ( 33 ) and an adapter ( 31 ). The catheter catheter tube ( 33 ) includes a tip ( 331 ) at one end and an end portion ( 332 ) at another other end. The adapter ( 31 ) can be configured for receiving a septum ( 402 ). The adapter ( 31 ) includes a narrow opening. The end portion ( 332 ) of the catheter tube ( 33 ) is connected to the adapter ( 31 ) at the narrow opening for fluid communication between the catheter tube ( 33 ) and the adapter ( 31 ). The catheter tube ( 33 ) and adapter ( 31 ) are formed as a one-piece element that is preferably injection molded in a single-shot process. Additional elements, such as one or more retention tabs ( 313 ) for attaching to a base can be formed on the catheter ( 30 ). The one-piece catheter ( 30 ) can be made by a single-shot injection molding process. Additional structures, such as a base can be attached to the catheter ( 30 ) by a second-shot injection molding process.

1 . A method of making a catheter, comprising the steps of:
 heating a polymer to a desired temperature; and   injection molding the heated polymer to form a one-piece catheter comprising a catheter tube connected to an adapter with a retention tab for attaching to a base.   
     
     
         2 . The method as claimed in  claim 1 , wherein the injection molding is a one-shot process to form the catheter. 
     
     
         3 . The method as claimed in  claim 1 , further comprising the steps of:
 heating a second polymer to a desired temperature;   injection molding the second polymer to form the base fused to the retention tab of the catheter.   
     
     
         4 . The method as claimed in  claim 1 , wherein the first and second polymers are the same material. 
     
     
         5 . The method as claimed in  claim 1 , wherein the first and second polymers are different material.