Abstract: The present invention is directed towards a malleable sleeve used in conjunction with a multi-lumen catheter with an expandable device, such as a balloon, incorporated into its surface. The malleable sleeve allows the catheter to be pre-formed into a shape that corresponds with the shape of the nasal passageway. The present invention also covers endoscopic surgical methods utilizing the malleable sleeve.

Abstract: The improved balloon catheter includes a first tubular segment, which has multiple zones of differing malleability along its length. The catheter further includes a coaxially aligned hypotube formed of a malleable material, which is positioned within the lumen of the first tubular segment and extends from the distal end of the first tubular segment. In one embodiment the hypotube runs the length of the first tubular segment; while in another embodiment, the hypotube runs along only a portion of the length of the first tubular segment. A portion of the outer circumferential surface of the hypotube is permanently affixed and sealed to an inner circumferential surface of the first tubular segment in the vicinity of the distal end of the first tubular segment. The outer circumference of the distal end of the first tubular segment is gently tapered along its length so as to smoothly transition to the circumference of the hypotube.