Patent ID: 7060218

Claim:
A method of forming a catheter inflatable member, comprising (a) providing an adjustable length mold assembly, comprising a first mold piece having a first internal chamber defined at least in part by a first internal molding surface which is configured to form a first exterior surface of a first section of a catheter inflatable member formed in the mold and which has an internal shoulder section, and a second mold piece, at least in part slidably disposed within at least a portion of said first mold piece, having a second internal chamber defined at least in part by a second internal molding surface configured to form a second exterior surface of a second section of the catheter inflatable member formed in the mold, the second mold piece having an end with a radial dimension configured to abut the internal shoulder of the first mold piece so that the second mold piece end is effective as a stop, and an internal third mold piece at least in part slidably disposed within at least a portion of the first mold piece and having a third internal chamber defined at least in part by a third internal molding surface configured to form a third exterior surface of a third section of the catheter inflatable member formed in the mold, the internal third mold piece having an end configured to be slidable within the first mold piece to place the third mold piece in a plurality of longitudinal positions therein, and placing the second mold piece end against the internal shoulder of the first mold piece, and adjusting the longitudinal distance between the end of the second mold piece and the end of the third mold piece by sliding the third mold piece within the first mold piece; (b) placing a parison within the variable-length chamber defined by the internal molding surfaces of the mold pieces, (c) heating the parison to a temperature effective to soften the parison, and (d) raising the internal pressure of the parison effective to expand at least a portion of the parison so that at least a portion of the parison contacts the first, second and third internal molding surfaces of the mold, thereby forming the catheter inflatable member; and (e) separating the first and second mold pieces to access the inflatable member within the first and third internal chambers, and removing the inflatable member from the mold.