CN101711137B - 具有可生物降解层的支架 - Google Patents

具有可生物降解层的支架 Download PDF

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CN101711137B
CN101711137B CN200880007308.1A CN200880007308A CN101711137B CN 101711137 B CN101711137 B CN 101711137B CN 200880007308 A CN200880007308 A CN 200880007308A CN 101711137 B CN101711137 B CN 101711137B
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rapamycin
medicament
supercritical fluid
ethyl
support frame
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CN101711137A (zh
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J·B·麦克莱恩
D·泰勒
R·拉比纳
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Mixin Medical Technology (Suzhou) Co.,Ltd.
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MiCell Technologies Inc
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/08—Materials for coatings
    • A61L31/10—Macromolecular materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/82—Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L31/148—Materials at least partially resorbable by the body
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/82—Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure
    • A61F2/90—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure
    • A61F2/91—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure characterised by a net-like or mesh-like structure made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2210/00—Particular material properties of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
    • A61F2210/0004—Particular material properties of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof bioabsorbable
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2210/00—Particular material properties of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
    • A61F2210/0076—Particular material properties of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof multilayered, e.g. laminated structures

Abstract

制备层压冠状动脉支架的方法，包括：提供支架框架；和在所述支架框架上沉积多个层以形成所述层压冠状动脉支架；其中所述层中的至少一层包含可生物吸收聚合物。

Description

具有可生物降解层的支架
交叉引用
本申请要求2007年1月8日提交的美国临时申请No.60/884,005和2007年4月17日提交的美国临时申请No.60/912,408的权益，这些申请全文经此引用并入本文。
发明背景
本发明涉及形成支架的方法，包括将可生物吸收的聚合物和药剂或生物制剂以粉末形式沉积到基底上。
希望获得在规定时段后在脉管中留下尽可能少的物理、化学和治疗遗迹的药物洗脱支架。该时段基于在通过PCI/支架术打开阻塞后该脉管的有效愈合(目前主流临床医师认为是6-18个月)。
为了(a)放置的灵活性，(b)进入小脉管，(c)最少干扰管壁和血液，也希望获得具有极小横截面厚度的药物洗脱支架。
发明概述
在一个实施方案中，本发明提供了制备层压冠状动脉支架(coronary stent)的方法，包括：a.提供支架框架；b.在所述支架框架上沉积多个层以形成所述层压冠状动脉支架；其中所述层中的至少一层包含可生物吸收聚合物。该支架框架优选可生物吸收。在一个实施方案中，该支架框架由包含镁的可吸收材料制成。
一个实施方案提供了选自PGA聚(乙交酯)、LPLA聚(1-丙交酯)、DLPLA聚(dl-丙交酯)、PCL聚(e-己内酯)PDO、聚(二氧戊环)PGA-TMC、85/15DLPLG p(dl-丙交酯-共-乙交酯)、75/25DLPL、65/35DLPLG、50/50DLPLG、TMC聚(碳酸三甲酯)、p(CPP:SA)聚(1，3-双-对-(羧基苯氧基)丙烷-共-癸二酸)的可生物吸收聚合物。
在一个实施方案中，该一种或多种活性剂包含大环内酯免疫抑制(limus)药。优选地，该大环内酯免疫抑制药包含下列的一种或多种：雷帕霉素(rapamycin)、40-O-(2-羟乙基)雷帕霉素(依维莫司)、40-O-苄基-雷帕霉素、40-O-(4′-羟甲基)苄基-雷帕霉素、40-O-[4′-(1，2-二羟乙基)]苄基-雷帕霉素、40-O-烯丙基-雷帕霉素、40-O-[3′-(2，2-二甲基-1，3-二氧戊环-4(S)-基)-丙-2′-烯-1′-基]-雷帕霉素、(2′：E，4′S)-40-O-(4′，5′-二羟基戊-2′-烯-1′-基)-雷帕霉素、40-O-(2-羟基)乙氧基羰基甲基-雷帕霉素、40-O-(3-羟基)丙基-雷帕霉素、4O-O-(6-羟基)己基-雷帕霉素、40-O-[2-(2-羟基)乙氧基]乙基-雷帕霉素、4O-O-[(3S)-2，2-二甲基二氧戊环-3-基]甲基-雷帕霉素、40-O-[(2S)-2，3-二羟基丙-1-基]-雷帕霉素、4O-O-(2-乙酰氧基)乙基-雷帕霉素、4O-O-(2-烟酰氧基)乙基-雷帕霉素、4O-O-[2-(N-吗啉代)乙酰氧基]乙基-雷帕霉素、4O-O-(2-N-咪唑基乙酰氧基)乙基-雷帕霉素、40-O-[2-(N-甲基-N′-哌嗪基)乙酰氧基]乙基-雷帕霉素、39-O-去甲基-39，40-O，O-亚乙基-雷帕霉素、(26R)-26-二氢-40-O-(2-羟基)乙基-雷帕霉素、28-O-甲基-雷帕霉素、4O-O-(2-氨乙基)-雷帕霉素、4O-O-(2-乙酰氨基乙基)-雷帕霉素、4O-O-(2-烟酰氨基乙基)-雷帕霉素、4O-O-(2-(N-甲基-咪唑-2′-基乙氧甲酰氨基)乙基)-雷帕霉素、4O-O-(2-乙氧基羰基氨乙基)-雷帕霉素、40-O-(2-甲苯基磺酰氨基乙基)-雷帕霉素、40-O-[2-(4′，5′-二乙氧甲酰(Dicarboethoxy)-1′，2′，3′-三唑-1’-基)-乙基]-雷帕霉素、42-Epi-(四唑基)雷帕霉素(他克莫司)和42-[3-羟基-2-(羟甲基)-2-甲基丙酸酯]雷帕霉素(西罗莫司脂化物(temsirolimus))。
在一个实施方案中，在所述支架框架上沉积多个层以形成所述层压冠状动脉支架包括通过RESS法在所述框架上沉积聚合物颗粒。
在再一实施方案中，本发明提供了层压冠状动脉支架，其包含：a.支架框架；b.沉积在所述支架框架上以形成所述层压冠状动脉支架的多个层；其中所述层中的至少一层包含可生物吸收聚合物。
另一实施方案提供了制备层压冠状动脉支架的方法，包括：a.提供支架框架；b.在所述支架框架上沉积多个层以形成所述层压冠状动脉支架；其中所述层中的至少一层包含可生物吸收聚合物；至少一种治疗所需形态的药剂和/或至少一种活性生物制剂；其中在所述支架框架上沉积所述多层中的各层包括下列步骤：i.形成包含至少一种超临界流体溶剂和一种或多种药剂和/或至少一种活性生物制剂的超临界或近超临界流体溶液，在足以形成所述一种或多种药剂和/或至少一种活性生物制剂的固体颗粒的条件下经由第一孔排出所述超临界或近超临界流体溶液，ii.形成包含至少一种超临界流体溶剂和至少一种聚合物的超临界或近超临界流体溶液，并在足以形成该聚合物的固体颗粒的条件下经由所述第一孔或经由第二孔排出所述超临界或近超临界流体溶液；iii.使该聚合物和药剂和/或活性生物制剂颗粒沉积到所述框架上，其中维持框架与该聚合物和药剂和/或活性生物制剂颗粒之间的电势，由此形成所述层；和iv.在基本不改变所述药剂的形态和/或所述生物制剂的活性的条件下烧结所述层。优选地，该框架带静电。在一个实施方案中，框架可生物降解。
再一实施方案提供了制备冠状动脉支架的方法，包括a.形成包含可生物吸收聚合物的片材；b.在所述片材中刻出所述冠状动脉支架的图案；和c.卷绕所述片材以形成所述冠状动脉支架。在一个实施方案中，所述片材的形成包括沉积多个层以形成所述片材，且所述冠状动脉支架是层压冠状动脉支架。
引用
本说明书中提到的所有公开和专利申请经此引用并入本文，就好像各公开或专利申请逐一独立地被指明经此引用并入本文。
附图简述
图1-10显示了本发明的各种实施方案。
发明详述
在附图1-10中提供本发明的所选实施方案的图解。
下面更详细解释本发明。本描述不是本发明的所有不同实施方式或可添加到本发明中的所有要素的详细目录。例如，参照一个实施方案阐述的要素可并入其它实施方案中，且参照一具体实施方案阐述的要素可从该实施方案中删除。此外，对本文提出的各种实施方案的许多变动和增加是本领域技术人员依据本公开显而易见的，它们不背离本发明。因此，下列说明书旨在阐述本发明的一些具体实施方案而非穷尽地规定其所有排列、组合和变动。
申请人明确指出，本文列举的所有美国专利参考文献均全文经此引用并入本文。
在一个实施方案中，本发明提供了自底向上地构造支架的方法。使用支架模型(stent-form)(或框架)作模板，在其上覆盖一种或多种可生物吸收聚合物+一种或多种药物的层压结构，形成最终支架。如果采用可吸收的支架模型，该最终支架可以是完全可生物吸收的。在不可吸收支架模型(例如不锈钢)的情况下，所有聚合物和药物应被吸收/洗脱，仅留下极薄的金属支架模型嵌在管壁中。
在一个实施方案中，该支架模型可以是要制造的支架的精确结构复制品。在此实施方案中，该支架模型具有与最终支架大致相同的纵向和径向尺寸。该支架模型具有1/2-1/100细的线/支柱。
该层压结构在主要基于聚合物的、可生物吸收的球囊扩张支架中提供显著改进的机械性质。由支架模型上的连续涂层产生的层压结构提供具有比传统金属支架更细的支柱并优于已知可生物吸收的聚合支架的机械有效支架(例如，置入后的周向强度(hoop strength)＞300毫米Hg腔内压力)。
在制造可生物吸收的支架时，本方法在该支架模型上施加若干层(2-100层)可生物吸收的一种或多种聚合物(涂布-烧结-涂布-烧结，重复)。这在该支架模型上产生层压聚合物结构，由此将支柱构造至目标使用尺寸(其可以小于、等于或大于具有类似支柱设计的金属支架-取决于该支架的所需机械性质)。单种或多种药物可包含在一个、一些或所有这些层中。或者，该药物可基本位于聚合物层之间。
设计一种或多种药物的这种精心考虑的位置以提供特定的、受时间控制的洗脱模式，并且能够连续洗脱多种药物。
该实施方案的要素包括：
A.支架模型：●经由支架制造法(例如管坯的激光切割、平版转印到片料上，等)直接制造支架模型。本发明的支架模型是传统支架的1/2-1/100细(这导致其本身难以在无聚合物层压材料的增加强度和物理性质的情况下使用)。●通过蚀刻现有的永久金属支架(不锈钢、钴-铬、镍钛合金、铂合金、金、银等)以在原始支架的模板中制造线框，由此制造支架模型。由可生物吸收的导电材料制造支架模型以用作随后施加的一种或多种可生物降解聚合物+一种或多种药物的模板(例如如J IntervCardiol.2004年12月17日(6)：391-5中所述的导电聚合材料或镁)。
B.在支架模型上形成一种或多种可生物吸收聚合物+一种或多种药物基质的方式，形成最终器件●如Micell法(e-RESS、e-DPC、压缩气体烧结)中那样用药物和聚合物喷涂支架模型。●进行多个连续的涂布-烧结步骤，其中可以在各步骤中沉积不同材料，由此制造构成最终支架的具有一种或多种药物、一种或多种聚合物或药物+聚合物的多个薄层的层压结构。●在支架内(腔内)表面上包含掩模的情况下，进行一种或多种聚合物+一种或多种药物层压材料的沉积。这种掩模可以简单到是穿过支架模型内径插入的非导电心轴。这种掩蔽可以在添加任何层之前进行，或有意地在围绕整个支架模型连续沉积几个层后插入。
在另一实施方案中，本发明提供了在聚合材料片材(例如平片)中刻出支架图案的方法。在一个实施方案中，该聚合片材是可生物吸收聚合物+一种或多种药物制剂。此外，该片材可以含有由一种或多种可生物吸收聚合物制成的多层(2-100层)层压结构。该片材可不含、含有一种或多种药物。在将支架图案刻入聚合物片材中后，将该片材卷绕成用于支架的指定直径。将该卷绕支架焊接成圆筒形。
该层压结构在主要基于聚合物的、可生物吸收的球囊扩张支架中提供显著改进的机械性质。由支架模型上的连续涂层产生的层压结构提供具有比传统金属支架更细的支柱并确实优于已知可生物吸收的聚合支架的机械有效支架(例如，置入后的周向强度＞300毫米Hg腔内压力)。
设计一种或多种药物的这种精心考虑的位置以提供特定的、受时间控制的洗脱模式，并且能够连续洗脱多种药物。
聚合物层压材料：该聚合片材材料理想地由可生物吸收聚合物构成。该聚合片材材料理想地为层压结构。在该层压材料中，我们预计通过交叠“硬”-“软”可生物吸收聚合物来获得理想性质。本发明的第一材料方面是聚合物膜的制造和独特性质。
形成聚合物片材：
·成膜法(旋涂、溶剂浇注、挤出、吹塑)
·eRESS、eDPC和烧结的Micell′s压缩气体法：通过相继涂布片材基底，可以通过连续的涂布-烧结-涂布-烧结-涂布-烧结步骤形成聚合物片材。
药物夹杂：该药物可配制在该聚合物片材内的三个位置之一中。
在材料表面上(腔内或腔外)。要指出，可以在该支架制造过程中的任何步骤(成片、雕刻、卷绕、焊接、最后)施加这种表面药物处理。
在构成该层压材料的聚合物膜之一内。
在构成该层压材料的两个聚合物膜之间。
支架构造的雕刻：雕刻方法包括，但不限于：用压机、辊、刀具、射流或激光物理切割，和/或通过湿化学和干等离子体方式蚀刻。另一雕刻方法可以是在聚合物片材暴露在压缩流体环境中(例如类似于Micell′s烧结法)的同时物理雕刻该支架构造。这种暴露可以“软化”该聚合物片材，从而有助于雕刻。
所有形式的现有聚合物片材形成技术都适用；包括辅以润滑剂、脱模剂等的必要性。
将经雕刻片材卷绕和焊接成最终支架：该方法中的最终步骤是将该经雕刻片材卷绕成圆筒，并将该几何构造焊接就位。卷绕是围绕一定尺寸的心轴(可辅以温度或暴露在压缩流体中)的直接加工。可经由传统方法，如溶剂、温度(本体加热、激光等)等进行焊接。优选经由基于压缩流体的烧结进行焊接法。
本发明提供了与传统可生物吸收的支架相比改进的机械性质。本发明提供了具有显著提高的强度、可形变性、周向应力(扩张前和扩张后)和其它机械性质的层压可生物吸收聚合物支架。层压结构固有地在DES应用所必须的形变过程(压接到球囊上，扩张到患病脉管中)中更强韧和更有效。此外，本发明提供了基于支架的层压构造在置入的支架中获得更高周向强度的能力。例如，本发明能够形成具有不同机械性质的不同可生物吸收聚合物(例如PLA、PGA及其共聚物)的层压材料：硬-软-硬-软-硬-软型层压结构。
硬-软结构的一种属性是提供对支架扩张所需的压力的独特和新颖的控制。通过设计软层压层以充当相邻层之间的“滑动层”或“润滑材料”，可以“定量输入(dialed in)”扩张所需的应力(对于完全扩张，为3-30大气压)。
本发明的另一优点是制造具有全新的药物洗脱模式的支架。经由在该层压结构的各层中具有不同材料的能力和在这些层中独立地控制一种或多种药物位置的能力，该方法能够获得可以以非常特定的洗脱模式、程控的连续和/或并行洗脱模式释放药物的可生物吸收支架。此外，本发明能够在不影响第二药物(或相同药物的不同剂量)的洗脱的情况下实现一种药物的受控洗脱。
包含支架模型或框架的实施方案提供了用X射线照相术监测置入支架的能力。在另一实施方案中，可以掩蔽该支架的内径(例如用非导电心轴)。这种掩蔽防止在支架内径(腔外(abluminal))表面上添加层。所得构造可合意地提供药物朝器壁(支架腔内表面)(在此需要抗再狭窄的治疗作用)的优先洗脱，且在腔外表面上不提供相同的一种或多种抗增殖药物，在该腔外表面上，它们可能阻碍愈合，这又被怀疑是现有DES的后期安全问题的原因。
本发明提供了许多优点。本发明有利地能够使用综合基于压缩流体技术的成层法；静电捕获和烧结法的平台。该平台产生具有提高的治疗和机械性质的药物洗脱支架。本发明特别有利之处在于，其使用最优化的层压聚合物技术。特别地，本发明能够形成特定药物平台的分立层。
喷涂支架的传统方法要求在进行喷涂之前将药物和聚合物溶解在溶剂或互溶剂中。本文提供的平台在可以同时或交替进行的分立步骤中在支架框架上涂布药物和聚合物。这能够使活性剂(例如药物)分散在聚合物基质内，由此在含或不含中间聚合物层的情况下在单一医疗器件上在单一活性剂上安置多于一种药物。例如，本平台提供了双药物洗脱支架。
本发明提供的一些优点包括使用压缩流体(例如超临界流体，例如基于E-RESS的方法)；无溶剂沉积方法；允许在较低温度下加工以保持活性剂和聚合物基质的品质的平台；掺入两种、三种或更多种药物，同时使药物洗脱支架的制造和/或储存过程中由各种药物和/或其赋形剂之间的直接相互作用引起的有害作用最小化；干沉积；各层在支架框架上的提高的粘附和机械性质；精确沉积和迅速分批加工；和形成复杂结构的能力。
在一个实施方案中，本发明提供了多药物递送平台，其产生包括抗再狭窄药(例如limus或泰素(taxol))和抗血栓药(例如肝素或其类似物)以及充分表征的可生物吸收聚合物的强韧、有弹性和挠性的药物洗脱支架。本文中提供的该药物洗脱支架部分地通过减少或完全消除致血栓聚合物和减少或完全消除可能抑制愈合的残留药物来使血栓形成的可能性最小化。
该平台为例如早期治疗(再狭窄)和晚期治疗(血栓形成)提供多药物疗法的最佳递送。
该平台也提供了能够在无涂层受损危险的情况下穿过曲折损伤的粘附涂层。
本平台的另一优点是能够提供高度合意的洗脱模式(例如图1-10中所示的模式)。
本发明的优点包括能够减少或完全消除可能致血栓的聚合物以及可能抑制长期愈合的药物。本发明还提供具有最佳强度和弹性的有利支架且涂层又能到达复杂损伤并减轻或完全消除脱层(delamination)。可生物吸收聚合物的层压层能够实现一种或多种药物的受控洗脱。
本文提供的平台减轻或完全消除与传统药物洗脱支架相关联的缺点。例如，本文提供的平台能够更好地调节活性剂洗脱期和聚合物基质再吸附所必须的时期，由此使血栓形成和与不良受控的药物释放相关联的其它有害作用最小化。
本平台的其它优点显示在图1-10中。
定义
在本说明书中所用的下列词语和短语通常旨在具有下述含义，除非另行指明它们的应用背景。
本文所用的“基底”是指合意地在其上沉积包含聚合物和药剂或生物制剂的涂层的任何表面，其中涂布过程基本不改变药剂的形态或生物制剂的活性。生物医学植入物对本发明而言特别有意义；但是，本发明不限于这类基底。本领域技术人员会认识到可获益于本文所述的涂布方法的其它基底，如药片芯，作为化验装置的一部分，或作为诊断试剂盒(例如试验片)中的部件。
本文所用的“生物医学植入物”是指用于插入人体或动物对象体内的任何植入物，包括但不限于，支架(例如血管支架)、电极、导管、引线、可植入起搏器、复律器或去纤颤器外壳、接头、螺杆、杆、眼科植入物、股骨钉、骨板、移植物、吻合器、血管周围包裹物、缝线、钉(staples)、脑积水用的分流器、透析移植物、结肠瘘袋连接装置、耳部引流管(ear drainage tubes)、起搏器引线和可植入复律器和去纤颤器、椎盘、骨钉、缝合锚形体(suture anchors)、止血屏障(barriers)、夹钳、螺杆、板、夹子、血管植入物、组织粘合剂和密封剂、组织支架、各种类型的敷料(例如伤口敷料)、骨替代品、腔内器件、血管支撑体等。
该植入物可以由任何合适的材料形成，包括但不限于，有机聚合物(包括稳定或惰性聚合物和可生物降解聚合物)、金属、无机材料如硅，及其复合材料，包括具有一种材料的芯和不同材料的一个或多个涂层的分层结构。由导电材料制成的基底有利于静电捕获。但是，本发明考虑与具有低电导率的基底或非导电基底一起使用静电捕获。为了提高使用非导电基底时的静电捕获，在基底附近保持强电场的同时加工该基底。
可施加或插入本发明的生物医学植入物的对象包括人类对象(包括男性和女性对象以及婴儿、少年、青年、成年人和老年人对象)以及用于兽医用途的动物对象(包括但不限于，狗、猫、马、猴子等)。
在一个优选实施方案中，如授予Palmaz Shaz的美国专利No.4,733,665中所述，该生物医学植入物是可扩张的腔内血管移植物或支架(例如，包含丝网管)，其可以在血管内用与支架相连的血管成形术球囊扩张以扩大和张开血管内腔。
本文所用的“药剂”是指能用作活性剂以预防或治疗疾病(是指哺乳动物中的任何疾病治疗，包括预防该疾病，即，使疾病的临床症状不发生；抑制该疾病，即阻止临床症状的发展；和/或缓解该疾病，即，使临床症状消退)的任何药物或药用化合物。本发明的药剂还可以包含两种或更多种药物或药用化合物。药剂包括但不限于抗再狭窄药、抗糖尿病药、镇痛药、抗炎药、抗风湿药、抗低血压药、抗高血压药、精神药物、镇静剂、止吐剂、肌肉松弛药、糖皮质激素类、治疗溃疡性结肠炎或克罗恩氏病的药物、抗过敏药、抗生素、抗癫病药、抗凝血剂、杀真菌药、镇咳药、动脉硬化药物、利尿剂、蛋白质、肽、酶、酶抑制剂、痛风药、激素类及其抑制剂、强心苷、免疫治疗剂和细胞因子、软泻剂、降脂剂、偏头痛药、矿物产品、耳科药物、抗帕金森病药、甲状腺治疗剂、解痉药、血小板聚集抑制剂、维生素、细胞抑制药和病毒转移抑制药、植物性药物、化疗剂和氨基酸类。合适的活性成分的实例是阿卡波糖、抗原、β-受体阻滞剂、非甾族抗炎药(NSAID)、强心苷、乙酰水杨酸、阻止病毒生长的药物(virustatics)、阿克拉霉素、阿昔洛韦、顺铂、放线菌素、α-和β-拟交感神经药(sympatomimetics)(dmeprazole、别嘌呤醇、前列地尔、前列腺素、金刚胺、氨溴索、氨氯地平、甲氨蝶呤、S-氨基水杨酸、阿密曲替林、阿莫西林、阿那曲唑、氨酰心安、咪唑硫嘌呤、巴柳氮、倍氯米松、倍他司汀、苯扎贝特、比卡鲁胺、安定和安定衍生物、布地缩松、丁苯羟酸、丁丙诺啡、美沙酮、钙盐、钾盐、镁盐、坎地沙坦、卡马西平、卡托普利、头孢菌素类、西替利嗪、鹅脱氧胆酸、熊去氧胆酸、茶碱及茶碱衍生物、胰蛋白酶、西米替汀、克拉霉素、克拉维酸、氯林肯霉素、氯苯胺丁醇、可乐定、复方新诺明、可待因、咖啡因、维生素D及维生素D衍生物、考来烯胺、色甘酸、香豆素及香豆素衍生物、半胱氨酸、阿糖胞苷、环磷酰胺、环孢霉素、环丙孕酮、cytabarine、达哌唑、去氧孕烯、地索奈德、双肼苯哒嗪、地尔硫卓、麦角生物碱类、乘晕宁、二甲基亚砜、二甲硅油(dimeticone)、哌双咪酮及哌双咪酮衍生物、多巴胺、多沙唑嗪、阿霉素、多西拉敏、达哌唑、苯二氮卓、双氯芬酸、糖苷抗生素、脱甲丙咪嗪、益康唑、ACE抑制剂、依拉普利、麻黄碱、肾上腺素、依伯汀及依伯汀衍生物、吗啡喃、钙拮抗药、伊立替康、莫达非尼、奥利司他、肽抗生素、苯妥英、利鲁唑、利塞膦酸盐、西地那非、托吡酯、大环内酯抗生素、雌激素及雌激素衍生物、孕激素及孕激素衍生物、睾酮及睾酮衍生物、雄激素及雄激素衍生物、乙柳酰胺、依托芬那酯、依托贝特、非诺贝特、乙羟茶碱、依托泊甙、泛昔洛韦、法莫替丁、非洛地平、非诺贝特、芬太尼、芬替康唑、促旋酶抑制剂、氟康唑、氟达拉滨、氟桂利嗪、氟脲嘧啶、氟西汀、氟比洛芬、布洛芬、氟他胺、氟伐他汀、促卵泡素、福莫特罗、fosfomicin、速尿、梭链孢酸、戈洛帕米、更昔洛韦、吉非罗齐、庆大霉素、银杏、圣·约翰草、格列本脲、作为口服降糖药物的脲衍生物、胰高血糖素、葡糖胺及葡糖胺衍生物、谷胱甘肽、甘油及甘油衍生物、下丘脑激素、戈舍瑞林、促旋酶抑制剂、胍乙啶、卤泛群、氟哌啶醇、肝素及肝素衍生物、透明质酸、肼苯哒嗪、双氢氯噻嗪及双氢氯噻嗪衍生物、水杨酸盐、羟嗪、黄胆素、异环磷酰胺、丙咪嗪、吲哚美辛、吲哚拉明、胰岛素、干扰素类、碘及碘衍生物、异康唑、异丙肾上腺素、葡糖醇及葡糖醇衍生物、伊曲康唑、酮康唑、酮洛芬、酮替芬、拉西地平、兰索拉唑、左旋多巴、左美沙酮、甲状腺激素类、硫辛酸及硫辛酸衍生物、赖诺普利、麦角乙脲(lisuride)、洛非帕明、洛莫司汀、洛哌丁胺、氯雷他定、马普替林、甲苯达唑、美贝维林、美可洛嗪、甲灭酸、甲氟喹、美洛昔康、甲吲洛尔、眠尔通、美洛培南、美沙拉嗪、甲琥胺、安乃近、二甲双胍、甲氨蝶呤、哌醋甲酯、甲基泼尼松、美噻吨、甲氧氯普胺、美托洛尔、甲硝哒唑、米赛林、咪康唑、米诺环素、米诺地尔、米索前列醇、丝裂霉素、咪唑斯汀、莫西普利、吗啡及吗啡衍生物、月见草、纳布啡、纳洛酮、替利定、萘普生、那可汀、游霉素、新斯的明、麦角溴烟酯、尼可刹米、硝苯地平、尼氟酸、尼莫地平、尼莫拉唑、尼莫司汀、尼索地平、肾上腺素及肾上腺素衍生物、氟哌酸、novamine sulfone、那可汀、制霉菌素、氧氟沙星、奥氮平、奥沙拉嗪、奥美拉唑、奥莫康唑、恩丹西酮、奥沙西罗、苯唑西林、奥昔康唑、羟甲唑啉、泮托拉唑、扑热息痛、帕罗西汀、喷昔洛韦、口服青霉素、喷他佐辛、喷替茶碱、己酮可可碱、奋乃静、哌替啶、植物提取物、安替比林、非尼拉敏、巴比妥酸衍生物、苯基丁氮酮、苯妥英、哌咪清、心得静、哌嗪、吡乙酰胺、哌仑西平、吡贝地尔、吡罗昔康、普拉克索、普伐他汀、哌唑嗪、普罗卡因、丙嗪、丙哌维林、普萘洛尔、异丙安替比林、前列腺素类、丙硫异烟胺、羟丙茶碱、喹硫平、喹那普利、喹普利拉、雷米普利、雷尼替丁、茶丙喘宁、利血平、病毒唑、利福平、利培酮、利托那韦、罗匹尼罗、罗沙替丁、罗红霉素、鲁斯可皂甙元、芦丁及芦丁衍生物、沙巴藜芦、舒喘宁、沙美特罗、东莨菪碱、司来吉兰、舍他康唑、舍吲哚、sertralion、硅酸盐、西地那非、辛伐他汀、谷甾醇、索他洛尔、司谷氨酸、司帕沙星、壮观霉素、螺旋霉素、螺普利、螺内酯、司他夫定、链霉素、硫糖铝、舒芬太尼、舒巴坦酸、磺胺、柳氮磺胺吡啶、舒必利、舒他西林、苏太明(sultiam)、舒马曲坦、氯化琥珀胆碱、他克林、他克莫司、他林洛尔(taliolol)、他莫昔芬、牛磺罗定、他扎罗汀、替马西泮、替尼泊甙、替诺昔康、特拉唑嗪、特比奈芬、特布他林、特非那定、特利加压素、特他洛尔、四环素类、四氢唑林(teryzoline)、可可碱、茶碱、butizine、甲巯咪唑、吩噻嗪、噻替哌、噻加宾、泰必利、丙酸衍生物、噻氯匹定、噻吗洛尔、替硝唑、噻康唑、硫鸟嘌呤、噻克索酮、替瑞酰胺、替扎尼定、苯甲唑啉、甲苯磺丁脲、托卡朋、托萘酯、托哌松、托泊替康、托拉塞米、抗雌激素、曲马多、曲马唑啉、群多普利、反苯环丙胺、曲匹地尔、三唑酮、去炎松及去炎松衍生物、氨苯蝶啶、三氟哌丁苯、三氟尿苷、三甲氧苄二氨嘧啶、曲米帕明、苄吡二胺、曲普利啶、trifosfamide、曲金刚胺、氨丁三醇、tropalpin、曲克芦丁、妥洛特罗、酪胺、短杆菌素、乌拉地尔、熊果脱氧胆酸、鹅脱氧胆酸、万乃洛韦、丙戊酸、万古霉素、维库氯铵(vecuronium chloride)、万艾可、文拉法辛、戊脉安、阿糖腺苷、氨己烯酸、viloazine、长春碱、长春胺、长春新碱、长春地辛、长春瑞滨、长春西汀、维喹地尔、苄丙酮香豆素、烟胺羟丙茶碱、氯磺水杨胺、扎鲁司特、扎西他滨、齐多夫定、佐米曲普坦、唑吡坦、zoplicone、佐替平等等。参见例如美国专利No.6,897,205；还参见美国专利No.6,838,528；美国专利No.6,497,729。
与本发明联用的治疗剂的实例包括雷帕霉素、40-O-(2-羟乙基)雷帕霉素(依维莫司)、40-O-苄基-雷帕霉素、40-O-(4′-羟甲基)苄基-雷帕霉素、40-O-[4′-(1，2-二羟乙基)]苄基-雷帕霉素、40-O-烯丙基-雷帕霉素、40-O-[3′-(2，2-二甲基-1，3-二氧戊环-4(S)-基)-丙-2′-烯-1′-基]-雷帕霉素、(2′：E，4′S)-40-O-(4′，5′-二羟基戊-2′-烯-1′-基)-雷帕霉素、40-O-(2-羟基)乙氧基羰基甲基-雷帕霉素、40-O-(3-羟基)丙基-雷帕霉素、4O-O-(6-羟基)己基-雷帕霉素、40-O-[2-(2-羟基)乙氧基]乙基-雷帕霉素、4O-O-[(3S)-2，2-二甲基二氧戊环-3-基]甲基-雷帕霉素、40-O-[(2S)-2，3-二羟基丙-1-基]-雷帕霉素、4O-O-(2-乙酰氧基)乙基-雷帕霉素、4O-O-(2-烟酰氧基)乙基-雷帕霉素、4O-O-[2-(N-吗啉代)乙酰氧基]乙基-雷帕霉素、4O-O-(2-N-咪唑基乙酰氧基)乙基-雷帕霉素、40-O-[2-(N-甲基-N′-哌嗪基)乙酰氧基]乙基-雷帕霉素、39-O-去甲基-39，40-O，O-亚乙基-雷帕霉素、(26R)-26-二氢-40-O-(2-羟基)乙基-雷帕霉素、28-O-甲基-雷帕霉素、4O-O-(2-氨乙基)-雷帕霉素、4O-O-(2-乙酰氨基乙基)-雷帕霉素、4O-O-(2-烟酰氨基乙基)-雷帕霉素、4O-O-(2-(N-甲基-咪唑-2′-基乙氧甲酰氨基)乙基)-雷帕霉素、4O-O-(2-乙氧基羰基氨乙基)-雷帕霉素、40-O-(2-甲苯基磺酰氨基乙基)-雷帕霉素，40-O-[2-(4′，5′-二乙氧甲酰(Dicarboethoxy)-1′，2′，3′-三唑-1’-基)-乙基]-雷帕霉素、42-Epi-(四唑基)雷帕霉素(他克莫司)和42-[3-羟基-2-(羟甲基)-2-甲基丙酸酯]雷帕霉素(西罗莫司脂化物)。
如果需要，所述活性成分也可以以其可药用盐或衍生物(是指保持本发明的化合物的生物效力和性质并且不是生物不合意或其它方面不合意的盐)形式使用，并在手性活性成分的情况下，可以使用旋光性异构体和外消旋物，或非对映体的混合物。
本文所用的“稳定性”是指在其最终产品形式中，沉积在基底上的聚合物涂层中的药物的稳定性(例如，经涂布支架中药物的稳定性)。术语稳定性是指最终产品形式中5％或更少的药物降解。
本文所用的“活性生物制剂”是指可用于预防或治疗疾病(是指哺乳动物中的任何疾病治疗，包括预防该疾病，即，使疾病的临床症状不发生；抑制该疾病，即阻止临床症状的发展；和/或缓解该疾病，即，使临床症状消退)的最初由活生物体产生的物质。本发明的活性生物制剂还可以包含两种或更多种活性生物制剂或与药剂、稳定剂或化学或生物实体结合的活性生物制剂。尽管该活性生物制剂可最初由活生物体产生，但本发明的那些也可以合成制备或通过综合生物离析和合成改性的方法制备。作为非限制性实例，核酸可以是从生物来源中离析的形式，或通过核酸合成领域技术人员已知的传统技术制备。此外，核酸可以进一步改性以含有非天然生成的部分。活性生物制剂的非限制性实例包括肽、蛋白质、酶、糖蛋白、核酸(包括它们的单链或双链形式的脱氧核糖核酸或核糖核酸聚合物，且除非另行指明，否则包括以与天然生成的核苷酸类似的方式杂交成核酸的已知天然核苷酸类似物)、反义核酸、脂肪酸、抗菌剂、维生素、激素、类固醇、脂质、多糖、碳水化合物和类似物。它们还包括，但不限于，抗再狭窄药、抗糖尿病药、镇痛药、抗炎药、抗风湿药、抗低血压药、抗高血压药、精神药物、镇静剂、止吐剂、肌肉松弛药、糖皮质激素类、治疗溃疡性结肠炎或节段性回肠炎的药物、抗过敏药、抗生素、抗癫病药、抗凝血剂、杀真菌药、镇咳药、动脉硬化药物、利尿剂、蛋白质、肽、酶、酶抑制剂、痛风药、激素类及其抑制剂、强心苷、免疫治疗剂和细胞因子、软泻剂、降脂剂、偏头痛药、矿物产品、耳科药物、抗帕金森病药、甲状腺治疗剂、解痉药、血小板聚集抑制剂、维生素、细胞抑制药和病毒转移抑制药、植物性药物、化疗剂和氨基酸类。优选地，该活性生物制剂是肽，蛋白质或酶，包括天然肽、蛋白质和酶的衍生物和类似物。
本文所用的“活性”是指药剂或活性生物制剂的预防或治疗疾病(是指哺乳动物中的任何疾病治疗，包括预防该疾病，即，使疾病的临床症状不发生；抑制该疾病，即阻止临床症状的发展；和/或缓解该疾病，即，使临床症状消退)的能力。因此，药剂或活性生物制剂的活性应该具有治疗或预防价值。
本文所用的“二级、三级和四级结构”如下定义。本发明的活性生物制剂通常具有一定程度的二级、三级和/或四级结构，该制剂的活性取决于此。作为示例性的非限制性实例，蛋白质具有二级、三级和四级结构。二级结构是指在线性序列中彼此接近的氨基酸残基的空间排列。α-螺旋和β-束是二级结构的成分。三级结构是指在线性序列中远隔的氨基酸残基的空间排列，并且是指二硫化物键型。含有多于一个多肽链的蛋白质表现出额外的结构组织化水平。这类蛋白质中的各多肽链被称作亚单元。四级结构是指亚单元的空间排列和它们的接触性质。例如，血红蛋白由两个α-和两个β链构成。公知的是，蛋白质功能源自其构象或原子的三维排列(展开的多肽链缺乏活性)。因此，本发明的一个方面是在小心保持其构象的同时操作活性生物制剂，以便不损失它们的治疗活性。
本文所用的“聚合物”是指已交联或聚合的一系列重复单体单元。可以使用任何合适的聚合物进行本发明。本发明的聚合物还可以包含两种、三种、四种或更多种不同的聚合物。在本发明的一些实施方案种，仅使用一种聚合物。在一些优选实施方案中，使用两种聚合物的组合。聚合物组合可具有不同比率以提供具有不同性质的涂层。聚合物化学领域技术人员熟悉聚合化合物的不同性质。
本文所用的“治疗所需形态”是指药剂一旦沉积到基底上后的总体形式和结构，从而提供体外储存、体内保存和/或体内释放的最佳条件。这种最佳条件可包括，但不限于，提高的贮存寿命、提高的体内稳定性、良好的生物相容性、良好的生物利用率或改进的释放速率。通常，对于本发明，药剂的所需形态是结晶或半结晶或非晶的，但是这可以根据许多因素而极大改变，这类因素包括但不限于，药剂的性质、要治疗/预防的疾病、该基底在使用之前的预期储存条件或任何生物医学植入物在体内的位置。优选至少10％、20％、30％、40％、50％、60％、70％、80％、90％或100％的药剂是结晶或半结晶形式。
本文所用的“稳定剂”是指维持或提高生物制剂稳定性的任何物质。理想地，这些稳定剂被美国食品药品管理局(FDA)归类为Generally Regarded As Safe(通常认为安全，GRAS)。稳定剂的实例包括但不限于，载体蛋白如白蛋白、凝胶、金属或无机盐。可以在相关文献(例如在Handbook of Pharmaceutical Additives：AnInternational Guide to More Than 6000 Products by Trade Name，Chemical，Function，and Manufacturer；Michael和Irene Ash(编辑)；Gower Publishing Ltd.；Aldershot，Hampshire，England，1995)中进一步找到可存在的可药用赋形剂。
本文所用的“压缩流体”是指具有明显密度(例如，＞0.2克/立方厘米)的流体，其在标准温度和压力下是气体。本文所用的“超临界流体”、“近临界流体”、“近超临界流体”、“临界流体”、“增密流体”或“增密气体”是指在温度为该流体的临界温度的至少80％且压力为该流体的临界压力的至少50％的条件下的压缩流体。
适用于本发明的表现出超临界或近临界性质的物质的实例包括但不限于，二氧化碳、异丁烯、氨、水、甲醇、乙醇、乙烷、丙烷、丁烷、戊烷、二甲醚、氙、六氟化硫、卤化和部分卤化的材料，如氯氟烃、氢氯氟烃、氢氟烃、全氟化碳(如全氟甲烷和全氟丙烷、氯仿、三氯氟甲烷、二氯二氟甲烷、二氯四氟乙烷)及其混合物。
本文所用的“烧结”是指使部分基质或整个聚合物基质变连续(例如形成连续聚合物膜)的方法。如下所述，控制该烧结过程以制造完全共形(conformal)的连续基质(完全烧结)或在基质中产生空隙(不连续点)的同时制造连续涂层区域或范围。还控制该烧结过程以便在不同聚合物(例如聚合物A和B)之间获得一定的相分离和/或在离散的聚合物颗粒之间产生相分离。通过该烧结过程，改进该涂层的粘合性质以减轻在实际操作过程中该涂层与基底的脱离。如下所述，在一些实施方案中，控制该烧结过程以提供聚合物基质的不完全烧结。在涉及不完全烧结的实施方案中，形成具有连续区域和空隙、间隙、孔隙、通道或缝隙(它们提供隔绝治疗剂的空间，该治疗剂在受控条件下释放)的聚合物基质。根据聚合物性质、聚合物颗粒的尺寸和/或其它聚合物性质，可以使用压缩气体、增密气体、近临界流体或超临界流体。在一个实例中，使用二氧化碳处理已用干粉和RESS静电涂布法涂以聚合物和药物的基底。在另一实例中，在烧结过程中使用异丁烯。在另一些实例中，使用二氧化碳和异丁烯的混合物。
在将非晶材料加热至高于其玻璃化转变温度的温度时，或在将结晶材料加热至高于相变温度的温度时，构成该材料的分子更易活动，这进而意味着它们更活性并因此更容易反应，如氧化。但是，在非晶材料保持在低于其玻璃化转变温度的温度时，其分子基本固定，因此较不容易反应。类似地，在结晶材料保持在低于其相变温度的温度下时，其分子基本固定并因此较不容易反应。相应地，在温和条件，如本文所述的沉积和烧结条件下，加工药物组分使该药物组分的交叉反应和降解最小化。通过本发明的方法最小化的一种类型的反应与避免传统溶剂的能力相关，这又通过减少其暴露在自由基、残留溶剂和自氧化引发剂中来使药物的自氧化最小化，无论该药物是非晶、半结晶还是结晶形式。
本文所用的“超临界溶液快速膨胀”或“RESS”包括聚合物溶解到压缩流体，通常超临界流体中，然后在较低压力(通常近大气条件)下快速膨胀到腔室中。超临界流体溶液快速膨胀穿过小开孔(伴随着密度下降)降低了该流体的溶解能力，并造成聚合物颗粒的成核和生长。通过保持该腔室内的气体分离“云”，使腔室气氛保持在电中性状态。使用二氧化碳或其它适当气体防止电荷从基底转移到周围环境中。
可通过本发明的方法提高的包括药剂或生物制剂的涂层的“本体性质”包括例如：粘合性、平滑度、共形性、厚度和组分混合。
本文所用的“带静电”或“电势”或“静电捕获”是指喷雾制造的颗粒收集在具有与喷雾的颗粒不同的静电势的基底上。因此，该基底相对于排出的颗粒处于吸引电势，这造成颗粒捕获在基底上，即基底与颗粒带相反电荷，并经由静电吸引增强颗粒移动以穿过捕获容器的流体介质到达基底表面上。这可以通过使颗粒带电并将基底接地或反过来使基底带电并将颗粒接地，或通过静电捕获领域技术人员容易想到的一些其它方法实现。
本发明提供了若干优点，其克服或减轻现有技术对可生物吸收支架的限制。例如，传统可生物吸收聚合材料的固有限制涉及难以成型成具有低轮廓(low profile)的强韧、挠性、可形变(例如可球囊扩张)的支架。该聚合物通常缺乏高性能金属的强度。本发明通过在基本聚合的支架中产生层压结构来克服这些限制。不希望受制于任何具体理论或类似情况，可以通过比较胶合板(plywood)的强度和薄木板的强度来理解本发明的支架提供的提高的强度。
涉及细金属支架框架的本发明的实施方案提供了包括能够克服多数聚合物的固有弹性在内的优点。通常难以在聚合物中获得高塑性形变率(例如100％)(与该材料一定程度地“回弹”回原始形状的弹性形变相比)。此外，不希望受制于任何理论，中心金属支架框架(太小太弱以致不能充当支架本身)会充当塑性可形变支架内部的线，从而基本克服该聚合物的任何“弹性记忆”。
实施例
给出下列实施例以便本领域技术人员更容易理解和实施本发明。它们不应被视为限制本发明的范围，而仅是其示例和代表。
实施例1
在此实施例中，通过使圆筒轧过片材表面，压印聚合物膜片。该聚合物片由可生物吸收的聚合物通过将不同聚合物的交替层喷到导电基底上来制备。各层的施加次序取决于所需膜机械性质。可以在每层之间或选择性地在所需层之间施加药物。使用干粉涂布技术施加药物。使圆筒形图案化棒轧过聚合物膜，以类似凹版印刷的方法产生支架。存在若干制造图案化棒的方法，如使用光致抗蚀剂蚀刻法。或者，可以将图案激光刻印到固体棒中。将平坦的聚合物片切割成宽度略大于最终支架周长的条带。然后将聚合物条带围绕充当模型的光滑未图案化圆筒(即Teflon)卷绕。然后将该物体置于压力容器中并密封。向该压力容器中加入气体如二氯氟甲烷直至该容器内的压力等于该气体在容器温度下的蒸气压。合适的气体是37℃的二氯氟甲烷。该气体使聚合物条带烧结并将接缝焊接在一起，从而产生承载在Teflon圆筒上的聚合支架。在支架烧结后，使其从支撑体上滑落。
实施例2
在此实施例中，使用可生物吸收金属，如镁作为模型，可以以分层方式在其上喷涂一种或多种可生物吸收聚合物。在该支架上喷涂并烧结一种类型的聚合物(如PLA)层。然后在带有该第一聚合物层的金属模型上喷涂另一类型的第二聚合物(如PGA)层。再次烧结该支架以产生由金属-I型聚合物-II型聚合物构成的三层结构。该过程可以用相同或其它类型的聚合物重复以构造具有所需厚度和所需机械性质的涂层。在任何两层之间，可以将药物，如雷帕霉素或泰素或其它抗再狭窄药干粉涂布到任何指定聚合物层或金属基底支架本身上。
实施例3
在承载在Teflon或类似光滑棒上的同时，将金属(如不锈钢)基底支架蚀刻成趋于0(vanishingly)的小尺寸。该棒的外径略小于支架内径并用于承载该蚀刻金属支架并掩蔽内(腔内)表面。该掩模将限制沉积在该表面上的材料量。如实施例2中那样涂布该支架以实现所需机械和涂布性质。此外，可以在任何所需层中沉积第二药物以实现所需洗脱模式。
实施例4
实施例3的一种替代方式是除去支架腔内表面的掩模。两个支架表面都用一种或多种药物和聚合物涂布。该支架靠其自身的机械强度承载在支架固定装置上。可以在聚合物涂层的任何层中或在聚合物涂层的整个厚度中沉积单种或多种药物(例如紫杉醇(Paclitaxel)或吡美莫司(Picrolimus))。
实施例5
使用压缩气体、气体或超临界气体将通过在平面上逐一喷涂聚合物层而产生的聚合物片材焊接在一起。将聚合物片材切割成略大于最终支架圆周的宽度。然后围绕外径等于最终支架内径的光滑棒(石墨、Teflon或类似材料)卷绕该片材。具体直径取决于具体支架用途。然后使该物体暴露在气体、压缩气体或超临界气体中，它们可将接缝烧结在一起以形成连续聚合物圆筒。
上文举例说明本发明而不应被视为其限制。尽管本文已经显示了描述了本发明的实施方案，但本领域技术人员显而易见的是，这类实施方案仅作为实例提供。本领域技术人员会在不背离本发明的情况下想出许多变动、修改和替换。应该理解的是，本文所述的本发明的实施方案的各种替代方案可用于实施本发明。下列权利要求旨在指定本发明的范围并由此涵盖在这些权利要求及其对等物范围内的方法和结构。

Claims (16)

1.制备层压冠状动脉支架的方法，包括：
a.提供支架框架；和
b.在所述支架框架上沉积多个层以形成所述层压冠状动脉支架；其中所述层中的至少一层包含可生物吸收聚合物、至少一种药剂或至少一种活性生物制剂；其中所述至少一种药剂是治疗所需形态的药剂，并且在所述支架框架上沉积所述多个层包括下列步骤：
i.形成包含至少一种超临界流体溶剂和至少一种药剂或至少一种活性生物制剂的超临界或近超临界流体溶液，并在足以形成所述至少一种药剂或至少一种活性生物制剂的固体颗粒的条件下经由第一孔排出所述超临界或近超临界流体溶液；
ii.形成包含至少一种超临界流体溶剂和至少一种可生物吸收聚合物的超临界或近超临界流体溶液，并在足以形成该可生物吸收聚合物的固体颗粒的条件下经由第二孔排出所述超临界或近超临界流体溶液；
iii.使该可生物吸收聚合物的固体颗粒沉积到所述框架上，其中维持该框架与该可生物吸收聚合物的固体颗粒之间的电势，并且使该药剂或活性生物制剂的固体颗粒沉积到所述框架上，其中维持所述框架与该药剂或活性生物制剂的固体颗粒之间的电势，由此形成所述层；
iv.在基本不改变所述药剂的形态或所述生物制剂的活性的条件下烧结所述层；
其中该支架框架的厚度为该层压冠状动脉支架厚度的50％或更低。
2.权利要求1的方法，其中该支架框架的制备方法包括激光切割管材、平版转印到片材上或蚀刻预先制成的金属支架。
3.权利要求1的方法，其中该支架框架是可生物吸收的。
4.权利要求1的方法，其中该支架框架由包含镁的可吸收材料制成。
5.权利要求1的方法，其中该支架框架由可生物吸收聚合物或导电聚合物制成。
6.权利要求1的方法，其中该支架框架由生物相容的不可生物吸收材料制成。
7.权利要求1的方法，其中该支架框架由不锈钢制成。
8.权利要求1的方法，其中该支架框架的厚度为该层压冠状动脉支架厚度的1％或更低。
9.权利要求1的方法，其中所述可生物吸收聚合物选自PGA聚(乙交酯)、LPLA聚(l-丙交酯)、DLPLA聚(dl-丙交酯)、PCL聚(e-己内酯)、PDO聚(二氧戊环)、85/15DLPLG p(dl-丙交酯-共-乙交酯)、75/25DLPLG、65/35DLPLG、50/50DLPLG、TMC聚(碳酸三甲酯)、PGA-TMC、p(CPP：SA)聚(1，3-双-对-(羧基苯氧基)丙烷-共-癸二酸)。
10.权利要求1的方法，包括沉积4、10、20、50、100或更多层。
11.权利要求10的方法，其中所述药剂包含大环内酯免疫抑制药。
12.权利要求11的方法，其中该大环内酯免疫抑制药包含下列的一种或多种：雷帕霉素、40-O-(2-羟乙基)雷帕霉素(依维莫司)、40-O-苄基-雷帕霉素、40-O-(4′-羟甲基)苄基-雷帕霉素、40-O-[4′-(1，2-二羟乙基)]苄基-雷帕霉素、40-O-烯丙基-雷帕霉素、40-O-[3′-(2,2-二甲基-1，3-二氧戊环-4(S)-基)-丙-2’-烯-1’-基]-雷帕霉素、(2′：E，4′S)-40-O-(4′，5′-二羟基戊-2′-烯-1′-基)-雷帕霉素、40-O-(2-羟基)乙氧基羰基甲基-雷帕霉素、40-O-(3-羟基)丙基-雷帕霉素、40-O-(6-羟基)己基-雷帕霉素、40-O-[2-(2-羟基)乙氧基]乙基-雷帕霉素、40-O-[(3S)-2,2-二甲基二氧戊环-3-基]甲基-雷帕霉素、40-O-[(2S)-2,3-二羟基丙-1-基]-雷帕霉素、40-O-(2-乙酰氧基)乙基-雷帕霉素、40-O-(2-烟酰氧基)乙基-雷帕霉素、40-O-[2-(N-吗啉代)乙酰氧基]乙基-雷帕霉素、40-O-(2-N-咪唑基乙酰氧基)乙基-雷帕霉素、40-O-[2-(N-甲基-N′-哌嗪基)乙酰氧基]乙基-雷帕霉素、39-O-去甲基-39,40-O,O-亚乙基-雷帕霉素、(26R)-26-二氢-40-O-(2-羟基)乙基-雷帕霉素、28-O-甲基-雷帕霉素、40-O-(2-氨乙基)-雷帕霉素、40-O-(2-乙酰氨基乙基)-雷帕霉素、40-O-(2-烟酰氨基乙基)-雷帕霉素、40-O-(2-(N-甲基-咪唑-2′-基乙氧甲酰氨基)乙基)-雷帕霉素、40-O-(2-乙氧基羰基氨乙基)-雷帕霉素、40-O-(2-甲苯基磺酰氨基乙基)-雷帕霉素、40-O-[2-(4′，5′-二乙氧甲酰-1′，2′，3′-三唑-1’-基)-乙基]-雷帕霉素、42-Epi-(四唑基)雷帕霉素和42-[3-羟基-2-(羟甲基)-2-甲基丙酸酯]雷帕霉素(西罗莫司脂化物)。
13.通过权利要求1的方法制成的层压冠状动脉支架。
14.制备层压冠状动脉支架的方法，包括：
a.提供支架框架；
b.在所述支架框架上沉积多个层以形成所述层压冠状动脉支架；其中所述层中的至少一层包含可生物吸收聚合物、至少一种药剂或至少一种活性生物制剂；其中所述至少一种药剂是治疗所需形态的药剂，并且在所述支架框架上沉积所述多个层中的各层包括下列步骤：
i.形成包含至少一种超临界流体溶剂和至少一种药剂或至少一种活性生物制剂的超临界或近超临界流体溶液，并在足以形成所述至少一种药剂或至少一种活性生物制剂的固体颗粒的条件下经由第一孔排出所述超临界或近超临界流体溶液；
ii.形成包含至少一种超临界流体溶剂和至少一种可生物吸收聚合物的超临界或近超临界流体溶液，并在足以形成该可生物吸收聚合物的固体颗粒的条件下经由所述第一孔或第二孔排出所述超临界或近超临界流体溶液；
iii.使该可生物吸收聚合物和药剂或活性生物制剂的固体颗粒沉积到所述框架上，其中维持所述框架与该可生物吸收聚合物和药剂或活性生物制剂的固体颗粒之间的电势，由此形成层；和
iv.在基本不改变所述药剂的形态或所述生物制剂的活性的条件下烧结所述层；
其中该支架框架的厚度为该层压冠状动脉支架厚度的50％或更低。
15.制备层压冠状动脉支架的方法，包括：
a.沉积多个层以形成包含可生物吸收聚合物的层压片材；
b.在所述片材中刻出所述冠状动脉支架的图案；和
c.卷绕所述片材以形成所述冠状动脉支架；其中沉积所述多个层中的各层包括下列步骤：
i.形成包含至少一种超临界流体溶剂和至少一种药剂或至少一种活性生物制剂的超临界或近超临界流体溶液，在足以形成所述至少一种药剂或至少一种活性生物制剂的固体颗粒的条件下经由第一孔排出所述超临界或近超临界流体溶液；
ii.形成包含至少一种超临界流体溶剂和至少一种可生物吸收聚合物的超临界或近超临界流体溶液，并在足以形成该可生物吸收聚合物的固体颗粒的条件下经由所述第一孔或经由第二孔排出所述超临界或近超临界流体溶液；
iii.沉积该可生物吸收聚合物和药剂或活性生物制剂的固体颗粒，其中在支撑体上形成所述层压片材，维持该支撑体与该可生物吸收聚合物和药剂或活性生物制剂的固体颗粒之间的电势，由此形成所述层；和
iv.在基本不改变所述药剂的形态或所述生物制剂的活性的条件下烧结所述层。
16.权利要求1的方法，其中所述至少一种药剂的治疗所需形态是结晶的或半结晶的。
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