WO1998000090A2 - Stented, radially expandable, tubular ptfe grafts - Google Patents
Stented, radially expandable, tubular ptfe grafts Download PDFInfo
- Publication number
- WO1998000090A2 WO1998000090A2 PCT/US1997/011106 US9711106W WO9800090A2 WO 1998000090 A2 WO1998000090 A2 WO 1998000090A2 US 9711106 W US9711106 W US 9711106W WO 9800090 A2 WO9800090 A2 WO 9800090A2
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- WO
- WIPO (PCT)
- Prior art keywords
- stent
- graft
- stented
- ptfe
- tubular
- Prior art date
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Classifications
-
- 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
- A61F2/02—Prostheses implantable into the body
- A61F2/04—Hollow or tubular parts of organs, e.g. bladders, tracheae, bronchi or bile ducts
- A61F2/06—Blood vessels
- A61F2/07—Stent-grafts
-
- 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
- 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
-
- 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
- A61F2/02—Prostheses implantable into the body
- A61F2/04—Hollow or tubular parts of organs, e.g. bladders, tracheae, bronchi or bile ducts
- A61F2/06—Blood vessels
- A61F2/07—Stent-grafts
- A61F2002/072—Encapsulated stents, e.g. wire or whole stent embedded in lining
-
- 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
- A61F2/02—Prostheses implantable into the body
- A61F2/04—Hollow or tubular parts of organs, e.g. bladders, tracheae, bronchi or bile ducts
- A61F2/06—Blood vessels
- A61F2/07—Stent-grafts
- A61F2002/075—Stent-grafts the stent being loosely attached to the graft material, e.g. by stitching
-
- 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
- A61F2240/00—Manufacturing or designing of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
- A61F2240/001—Designing or manufacturing processes
-
- 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
- A61F2250/00—Special features of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
- A61F2250/0058—Additional features; Implant or prostheses properties not otherwise provided for
- A61F2250/0067—Means for introducing or releasing pharmaceutical products into the body
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
- B29K2027/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2227/00—Use of polyvinylhalogenides or derivatives thereof as reinforcement
- B29K2227/12—Use of polyvinylhalogenides or derivatives thereof as reinforcement containing fluorine
- B29K2227/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/753—Medical equipment; Accessories therefor
- B29L2031/7532—Artificial members, protheses
- B29L2031/7534—Cardiovascular protheses
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S623/00—Prosthesis, i.e. artificial body members, parts thereof, or aids and accessories therefor
- Y10S623/901—Method of manufacturing prosthetic device
Definitions
- the present invention pertains generally to medical devices and their methods of manufacture, and more particularly to tubular, polytetrafluoroethylene (PTFE) grafts having integral, radially expandable stents, for implantation in a cavities or passageways (e.g. , ducts or blood vessels) of the body.
- PTFE polytetrafluoroethylene
- the prior art has included a number of radially expandable stents which may be initially deployed in a radially collapsed state suitable for transluminal insertion via a delivery catheter, and subsequently transitioned to a radially expanded state whereby the stent will contact and engage the surrounding wall or the anatomical duct or body cavity within which the stent has been positioned.
- Such stents have been used to support and maintain the patency of blood vessel lumens (e.g., as an adjuvant to balloon angioplasty) and to structurally support and/or anchor other apparatus, such as a tubular endovascular grafts, at desired locations within a body cavity or passageway (e.g., to anchor a tubular endovascular graft within a blood vessel such that the graft forms an internal conduit through an aneurysm or site of traumatic injury to the blood vessel wall) .
- stents of the prior art have been formed of individual member (s) such as wire, plastic, metal strips, or mesh which have been bent, woven, interlaced or otherwise fabricated into a generally cylindrical configuration. These stents of the prior art have generally been classified into two major categories —a) “self-expanding” stents, and b) “pressure expandable” stents. i) self-expanding Stents
- Self-expanding stents are typically formed of spring metal, shape memory alloy, or other material which is resiliently biased toward it's fully radially expanded configuration or otherwise capable of self-expanding to it's fully radially expanded configuration without the need for the exertion of outwardly directed radial force upon the stent by some extraneous expansion apparatus (e.g., a balloon or mechanical expander tool).
- These self-expanding stents may be initially radially compressed and loaded into a small diameter delivery catheter or alternatively mounted upon the outer surface of a delivery catheter equipped with some means for restraining or maintaining the stent in it's radially compressed state.
- the delivery catheter is inserted into the body and is advanced to a position where the stent is located at or near the site at which it is to be implanted. Thereafter, the stent is expelled out of (or released from) the delivery catheter and allowed to self-expand to it's full radial diameter. Such expansion of the stent causes the stent to frictionally engage the surrounding wall of the body cavity or passageway within which the stent has been positioned. The delivery catheter is then extracted, leaving the self-expanded stent at it's intended site of implantation.
- the pressure-expandable stents of the prior art are typically formed of metal wire, metal strips, or other malleable or plastically deformable material, fabricated into a generally cylindrical configuration.
- the pressure-expandable stent is initially disposed in a collapsed configuration having a diameter which is smaller than the desired final diameter of the stent, when implanted in the blood vessel.
- the collapsed stent is then loaded into or mounted upon a small diameter delivery catheter.
- the delivery catheter is then advanced to its desired location within the vasculature, and a balloon or other stent-expansion apparatus (which may be formed integrally of or incorporated into the delivery catheter) is utilized to exert outward radial force on the stent, thereby radially expanding and plastically deforming the stent to it's intended operative diameter whereby the stent frictionally engages the surrounding blood vessel wall.
- the material of the stent undergoes plastic deformation during the pressure- expansion process. Such plastic deformation of the stent material causes the stent to remain in its radially expanded operative configuration.
- the balloon or other expansion apparatus is then deflated/collapsed and is withdrawn from the body separately from, or as part of, the delivery catheter, leaving the pressure-expanded stent at it's intended site of implantation.
- pressure-expandable stents of the prior art include those described in United States Patent Nos. 5,135,536 (Hillstead) ; 5,161,547 (Tower); 5,292,331 (Boneau) ; 5,304,200 (Spaulding) and 4,733,665 (Palmaz) .
- 5,135,536 Hillstead
- Tower Tower
- 5,292,331 Boneau
- 5,304,200 Spaulding
- 4,733,665 Palmaz
- Fluoropolymers such as polytetrafluoroethylene, have been heretofore used for the manufacture of various types of prosthetic vascular grafts. These vascular grafts are typically of tubular configuration so as to be useable to replace an excised segment of blood vessel.
- tubular PTFE vascular grafts of the prior art have traditionally been implanted, by open surgical techniques, whereby a diseased or damaged segment of blood vessel is surgically excised and removed, and the tubular bioprosthetic graft is then anastomosed into the host blood vessel as a replacement for the previously removed segment thereof.
- tubular prosthetic vascular grafts have also been used as bypass grafts wherein opposite ends of the graft are sutured to a host blood vessel so as to form a bypass conduit around a diseased, injured or occluded segment of the host vessel.
- tubular prosthetic vascular grafts of the prior art have been formed of extruded, porous PTFE tubes.
- a PTFE tape is wrapped about and laminated to the outer surface of a tubular base graft to provide reinforcement and additional burst strength.
- some of the prior tubular prosthetic vascular grafts have included external support member (s) , such as a PTFE beading, bonded or laminated to the outer surface of the tubular graft to prevent the graft from becoming compressed or kinked during implantation.
- external support member such as a PTFE beading
- tubular vascular graft is formed of a PTFE tube having a PTFE filament helically wrapped around, and bonded to, the outer surface of the PTFE tube.
- IMPRA Flex m Graft IMPRA, Inc., Tempe, Az
- One other commercially available, externally-supported, tubular vascular graft comprises a regular walled, PTFE tube which has PTFE reinforcement tape helically wrapped around, and bonded to, the outer surface of the PTFE tube and individual rings of Fluorinated Ethylene Propylene (FEP) rings disposed around, and bonded to, the outer surface of the reinforcement tape.
- FEP Fluorinated Ethylene Propylene
- stented grafts typically comprise a-self- expanding or pressure-expandable stent which is affixed to or formed within a pliable tubular graft. Because of their radial compressibility/expandability, these stented grafts are particularly useable in applications wherein it is desired to insert the graft into an anatomical passageway (e.g., blood vessel) while the graft is in a radially compact state, and to subsequently expand and anchor the graft to the surrounding wall of the anatomical passageway.
- anatomical passageway e.g., blood vessel
- tubular prosthetic vascular grafts within the lumen of a blood vessel, by percutaneous or minimal incision means.
- endovascular implantation initially involves translumenal delivery of the graft, in a compacted state, by way of a catheter or other transluminally advancable delivery apparatus. Thereafter, the graft is radially expanded and anchored to the surrounding blood vessel wall, thereby holding the graft at its intended site of implantation within the host blood vessel.
- An affixation apparatus such as a stent, is typically utilized to anchor at least the opposite ends of the tubular graft to the surrounding blood vessel wall.
- endovascular grafts of this type are in the treatment of vascular aneurysms without requiring open surgical access and resection of the aneurysmic blood vessel.
- stented grafts may also be useable to treat occlusive vascular disease—especially in cases where the stented graft is constructed in such a manner that the tubular graft material forms a complete barrier between the stent and the blood which is flowing through the blood vessel.
- tubular graft material may serve as a smooth, biologically compatible, inner "covering" for the stent, thereby preventing a) turbulent blood-flow as the blood flows over the wire members or other structural material of which the stent is formed, b) immunologic reaction to the metal or other material of which the stent is formed, and c) a barrier to separate a diseased or damaged segment of blood vessel from the blood-flow passing therethrough.
- turbulent blood-flow and/or immunologic reaction to the stent material is believed to be desirable as both of these phenomena are believed to be associated with thrombus formation and/or restenosis of the blood vessel.
- stented grafts may include restoring patency to, or re-canalizing, other anatomical passageways such as ducts of the biliary tract, digestive tract and/or genito-urinary tract.
- Many of the stented grafts known in the prior art have utilized woven or knitted material, such as polyester fiber, as the graft material.
- the present invention is directed to stented, tubular, PTFE grafts and their methods of manufacture.
- the present invention may exist in any of three (3) separate embodiments, depending upon whether the stent component of the graft is formed integrally (i.e., within) the tubular PTFE graft, externally (i.e., on the outer surface of) the tubular PTFE graft, or internally (i.e., on the inner lu enal surface) of the PTFE tubular graft.
- Each of these three separate embodiments of the invention may be self expanding (i.e., incorporating a self-expanding stent) or pressure- expandable (i.e., incorporating a pressure-expandable stent.
- an integrally stented PTFE graft which comprises a tubular PTFE base graft preferably of a density less than 1.6 g/cc, a radially expandable stent surrounding the outer surface of the tubular base graft, and an outer PTFE layer having a density of less than 1.6 g/cc.
- the tubular outer layer is fused to the tubular base graft through lateral openings or perforations formed in the stent.
- a polymer coating, such as a PTFE coating may be disposed on the stent to further facilitate fusing or boding of the stent to the base tube and/or outer tubular layer.
- an externally stented, tubular PTFE graft which comprises a radially compressible/expandable stent having a ePTFE tube of less than 1.6 g/cc density coaxially disposed within the stent, with the outer surface of the tubular ePTFE graft being fused or attached to the stent.
- a polymer coating such as PTFE or any other plastic which may be fused or adhered to PTFE, may be applied to or formed on the stent to facilitate the desired fusion or attachment of the tube graft to the stent, and/or to improve the biocompatibility of the stent.
- an internally stented, tubular PTFE graft comprising a tubular outer layer formed of ePTFE having a density of less than 1.6 g/cc, and a radially expandable stent.
- the stent is coaxially disposed within the lumen of the tubular outer layer, and fused or attached thereto.
- the stent may be covered with a polymer coating, such as PTFE or other biocompatable plastic capable of adhering or fusing to PTFE, to facilitate the desired fusion or attachment of the stent to the outer tubular layer, and/or to improve the biocompatability of the stent.
- PTFE particles may be disposed between the tubular outer layer and the tubular base graft to facilitate adhering or fusing of these two layers to one another, and/or to the stent.
- Such PTFE particles may be disposed between the inner base graft and outer tubular layer by applying or depositing PTFE liquid dispersion therebetween, or by depositing dry PTFE resin powder therebetween.
- any of above-summarized three (3) separate embodiments of the invention may be manufactured by a method which comprises the steps of: a) initially positioning a generally cylindrical stent of either the self-expanding or pressure-expandable variety in contacting coaxial relation with the tubular ePTFE base graft and/or the tubular ePTFE outer layer, upon a cylindrical mandrel or other suitable support surface, and b) subsequently fusing the fuse (i.e., heating to a lamination temperature) assembled components (i.e., the stent in combination with the inner base graft and/or outer tubular layer) of the stented graft into a unitary stented graft structure.
- tubular ePTFE base graft and the tubular ePTFE outer layer are present, such heating will additionally cause the tubular outer layer to fuse to the inner tubular base graft, through lateral openings or perforations which exist in the stent.
- the stent may be surface treated, abraded, or coated with a plastic capable of adhering or fusing to ePTFE to facilitate attachment of the stent to the adjacent outer layer and/or inner base graft upon subsequent heating, application of solvent or other suitable adhesion promoting technique.
- a plastic coating is formed on the stent
- such coating may be in the nature of a tube or film which is applied to the stent prior to assembly and mounting of the stented graft components on the mandrel or other support surface.
- aqueous PTFE dispersion, powdered PTFE resin or other flowable plastic material may be deposited between the outer tubular layer and inner tubular base graft at the time of assembly (prior to heating) to further facilitate fusion of the outer tubular layer and/or inner tubular base graft to the stent and/or to one another.
- the stented PTFE grafts of the present invention are capable of radially expanding and contracting without excessive puckering, wrinkling or invagination of the PTFE graft material.
- the manufacturing methods and materials of the present invention render the PTFE sufficiently strong and sufficiently firmly laminated or fused so as to permit such relative movement of the individual members of the stent without tearing or rupturing of the tubular PTFE graft.
- Figure 1 is a perspective view of an integrally stented PTFE tubular graft of the present invention, wherein a portion of the graft has been inserted into a tubular catheter.
- Figure la is an enlarged perspective view of a segment of Figure 1.
- Figure 2 is an enlarged, cut-away, elevational view of a preferred, integrally stented, tubular PTFE graft of the present invention.
- Figure 3a is an enlarged perspective view of a portion of the stent incorporated in the graft of Figure 2.
- Figure 3b is an enlarged cross-sectional view through line 3b-3d of Figure 3a.
- Figures 4a-4f are a step-by-step illustration of a preferred method for manufacturing an integrally stented PTFE graft of the present invention.
- Figure 5 is a schematic illustration of an alternative electron beam deposition method which is usable for depositing PTFE coating on the stent portion of the integrally stented PTFE grafts of the present invention.
- Figure 6 is a perspective view of an alternative heating apparatus which is useable in the manufacture of the integrally stented PTFE grafts of the present invention.
- FIG. 1 A. The Structure of an Integrally Stented PTFE Graft With reference to Figures l-3b, there is shown an integrally stented tubular PTFE graft 10 of the present invention.
- the preferred integrally stented graft 10 comprises a tubular PTFE base graft 12, a PTFE-coated stent 14 and an outer layer of PTFE 16.
- This particular stent 14 is formed of individual elements or wires 18 which have been coated with a PTFE coating 20. Gaps or lateral openings 19 exist between adjacent ones or bundles of the wires 18.
- this particular stent 14 is composed of rigid but resiliently flexible thread elements or wires 18. These thread elements or wires 18 are formed of metal, such as an alloy of cobalt, chromium, nickel or molybdenum, wherein the alloying residue is iron.
- wires 18 of the stent 14 are arranged in helical configuration about a common longitudinal axis LA. A number of the wires 18 are positioned in substantially parallel relation to one another, but are axially displaced relative to each other.
- wires 18 are wound in a first helical direction, while others are wound in a second or opposite helical direction such that they cross on opposite sides of adjacent ones of the wires wound in the first helical direction so as to form a helically braided wire stent as shown in the Figures.
- this stent 14 may be radially compressed to a smaller diameter D, and radial constraint, as may be applied by the surrounding wall of the tubular delivery catheter 22 shown in Figure 1, may be applied to hold the stent 14 in such radially compressed state (diameter D.,) . Thereafter, when the radial constraint is removed from the stent 14, the stent 14 will resiliently spring back to its radially expanded diameter D 2 .
- the individual, helically wound wires 18 of this particular braided stent 14 move and articulate such that the angular dispositions of the wires 18, relative to one another, will change radial expansion and compression of the stent 14.
- the longitudinal length of the stent 14 will increase as the stent 14 is radially compressed toward its radially compact configuration D, , and such length will shorten as the stent 14 expands toward its radially expanded configuration D 2 .
- the optional PTFE coating 20 is applied to the wires 18 of the stent 14, such coating (described in detail herebelow) is preferably flexible enough to withstand the flexing and movement of the individual wires 18 without cracking or degrading.
- the tubular base graft 12 is initially coaxially positioned within the hollow inner bore of the tubular stent 14 while the stent 14 is in it's radially expanded configuration, after the stent 14 has been coated with the PTFE coating 20, if desired. Thereafter, the outer PTFE layer 16 is formed by any suitable means, such as by wrapping PTFE tape 17 upon the outer surface of the PTFE coated stent 14 to form the generally tubular outer PTFE layer 16. Thereafter, heat or other means are utilized to fuse the outer PTFE layer 16 to the inner base graft 12, through the gaps or openings 19 which exist in the stent 14.
- the optional PTFE coating 20 has been applied to the stent 14
- such heating will also facilitate bonding of the PTFE coating 20 of the stent 14 to the adjacent base graft 12 and outer PTFE layer 16.
- the stent 14 forms an integral structural framework within the tubular graft 10, and the fused PTFE body of the graft is low enough in density and sufficiently pliable to allow the stent 14 incorporated into the graft 10 to continue to undergo substantially the same range of radial expansion and contraction that such stent 14 was capable of before disposition of the PTFE graft thereon.
- the internally stented graft 10 is radially compressible to the stent's first diameter D 1 and may be may be inserted into the lumen of a small diameter tubular catheter 22.
- the external constraint provided by the wall of the catheter 22 will maintain the stented graft 10 in it's radially compressed configuration of diameter D 1 until such time as the graft 10 is expelled or ejected out of the catheter 22.
- the graft will self-expand to a diameter which is substantially equal to the original expanded diameter D 2 of the stent 14.
- the manufacture of the tubular base graft begins with the step of preparing a PTFE paste dispersion for subsequent extrusion.
- This PTFE paste dispersion may be prepared by known methodology whereby a fine, virgin PTFE powder (e.g. , F-104 or F-103 Virgin PTFE Fine Powder, Dakin America, 20 Olympic Drive, Orangebury, NY 10962) is blended with a liquid lubricant, such as odorless mineral spirits (e.g., Isopar®, Exxon Chemical Company, Houston, TX 77253-3272) , to form a PTFE paste of the desired consistency.
- odorless mineral spirits e.g., Isopar®, Exxon Chemical Company, Houston, TX 77253-3272
- the PTFE-lubricant blend dispersion is subsequently passed through a tubular extrusion dye to form a tubular extrudate. iii.) Drying
- the wet tubular extrudate is then subjected to a drying step whereby the liquid lubricant is removed.
- This drying step may be accomplished at room temperature or by placing the wet tubular extrudate in an oven maintained at an elevated temperature at or near the lubricant's dry point for a sufficient period of time to result in evaporation of substantially all of the liquid lubricant. iv. ) Expansion
- the dried tubular extrudate is longitudinally expanded or longitudinally drawn at a temperature less than 327 °c and typically in the range of 250-326°c.
- This longitudinal expansion of the extrudate may be accomplished through the use of known methodology, and may be implemented by the use of a device known as a batch expander.
- the tubular extrudate is longitudinally expanded by an expansion ratio of more than two to one (2:1) (i.e., at least two (2) times its original length) .
- the base graft 12 is formed of expanded, sintered PTFE having a density of less than 1.6 grams per cubic centimeter. v.) Sintering
- the expanded PTFE tube is subjected to a sintering step whereby it is heated to a temperature above the sintering temperature of PTFE (i.e., 350-370°c) to effect amorphous-locking of the PTFE polymer.
- a sintering step whereby it is heated to a temperature above the sintering temperature of PTFE (i.e., 350-370°c) to effect amorphous-locking of the PTFE polymer.
- Completion of the sintering step marks the completion of the preparation of the expanded, sintered PTFE base graft 12.
- the PTFE tape 16 may be manufactured by any suitable method, including the general method for manufacturing expanded PTFE tape, as follows: C. Preparation of PTFE Tape i. ) Preparation of Paste Dispersion
- the usual manufacture of an expanded, sintered PTFE tape 17 useable to form the outer PTFE layer 16 of the stented graft 10 begins with the preparation of a PTFE paste dispersion.
- This PTFE paste dispersion may be prepared in the same manner as described hereabove for preparation of the PTFE paste dispersion used to form the tubular base graft. ii. ) Extrusion of Film
- the PTFE paste dispersion is subsequently passed through the film extrusion dye to form a wet film extrudate.
- the wet film extrudate is taken up or wound upon a rotating core so as to form a roll of the wet film extrudate.
- iii.) Calendaring The wet film extrudate is subsequently unrolled and subjected to an initial cold (i.e., ⁇ 100°c) calendaring step by passing the film through at least one set of opposing stainless steel calendaring rollers having an adjustable gap thickness therebetween.
- the calendaring rollers are preferably maintained at a temperature between room temperature and 60°c. The width of the wet extrudate is held constant as it passes through these calendaring rollers.
- the thickness of the wet film extrudate is reduced to its desired final thickness (e.g., 0.004-0.005 inches) while the width of the film is maintained constant. It will be appreciated that, since the width of the film is maintained constant, the passage of the film through the calendaring machine will result in a longitudinal lengthening of the film. The amount of longitudinal lengthening will be a function of the decrease in film thickness which occurs as the film passes between the calendaring rollers.
- the wet film is subjected to a drying step.
- This drying step may be accomplished by permitting or causing the liquid lubricant to evaporate from the matrix of the film.
- Such evaporation of the liquid lubricant may be facilitated by passing the film over a drum or roller which is maintained in an elevated temperature sufficient to cause the liquid lubricant to fully evaporate from the film matrix,
- v) Expansion Separately, or concurrently with the drying step the film is subjected to an expansion step.
- Such expansion step comprises expanding the PTFE film in at least one direction (e.g., longitudinally).
- Such expansion of the film serves to a) increase the porosity of the film, b) increase the strength of the film, and c) orient the PTFE fibrils in the direction of the axis of expansion.
- This expansion step is typically carried out with some heating of the film during such expansion, but such heating does not exceed the crystalline melting point of the PTFE polymer.
- the film is subjected to a sintering step wherein the film is heated to a temperature above the melting point of PTFE to accomplish sintering or amorphous locking of the PTFE polymer.
- This sintering step may be carried out by passing the film over a drum or roller which is maintained at a high surface temperature (e.g., 350-420°c) to cause the desired heating of the PTFE film above the melting point of the PTFE polymer for a sufficient period of time to effect the desired sintering of the film.
- the film After the film has been dried, the film is cut into strips, each strip typically having a width of 0.25-0.50 inches, thereby creating strips of expanded, sintered PTFE tape 14.
- the stent 14 may be coated with a polymer coating 20.
- the polymer coating formed on the stent 14 may be any suitable type of polymer which will adhere to PTFE.
- polymers which may be used for such polymer c o a t i n g o r c o v e r i n g i n c l u d e polytetrafluoroethylene(PTFE) , fluorinated ethylene propylene (FEP) , polytetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) , polyvinyl chloride (PVC) , polypropylene (PP) , polyethylene terephthalate (PET) polyuinylidene fluoride (PVDF) and other biocompatable plastics.
- PTFE fluorinated ethylene propylene
- PFA polytetrafluoroethylene-perfluoroalkyl vinyl ether copolymer
- PVC polyvinyl chloride
- PP polypropylene
- PET polyethylene terephthalate
- PVDF polyuinylidene fluor
- FIG 4a One manner in which such coating of the stent 14 may be carried out is illustrated in Figure 4a.
- the stent 14 may be immersed in a vessel 30 containing an aqueous dispersion of PTFE 32.
- aqueous PTFE dispersion which may be useable for coating of the stent 14 is DuPont T-30 Aqueous PTFE Dispersion, available commercially from the E.I. DuPont de Numoris Co., (Wilmington, Delaware).
- PTFE dispersion 32 which may be utilized for coating of the stent is Daikin-Polyflon TFE Dispersion, available from Daikin Industries, Ltd., Chemical Division (Umeda Center Bldg., 4-12 chome, Nakazaki-nishi, Kita-ku, Osaka, Japan) .
- the time in which the stent 14 must remain immersed in the liquid PTFE dispersion 32 may vary, depending on the construction of the stent 14 and the chemical composition of the PTFE dispersion 32. However, in most cases, an immersion time of 10-15 seconds will be sufficient to obtain uniform deposition of the PTFE coating 20 on the wire members 18 of the stent 14.
- the stent 14 After the stent 14 has been removed from the liquid PTFE dispersion 32, it will be permitted to air dry such that a dry PTFE coating 20 remains deposited upon the outer surface of each wire 18 of the stent 14.
- the PTFE coated stent 14 may be placed in an oven at 350°c for approximately 10 minutes to sinter the PTFE coating and/or to enhance the bonding of the PTFE coating 20 to wire members 18 of the stent 14. Sintering of the PTFE coating renders the coating more resistant to abrasion or peeling during the subsequent handing of the stent and/or the ensuing manufacture and use of the stented graft 10.
- PTFE coating 20 may be used for depositing the PTFE coating 20 on the stent 14.
- One alternative method is electron beam deposition, as illustrated in Figure 5.
- the stent 14 is positioned within a closed vacuum chamber 36 wherein a mass of PTFE 38 is located.
- An electron beam apparatus 40 is then utilized to project electron beam radiation onto the PTFE 38 within the chamber 36 so as to cause sublimation of the PTFE and resultant deposition of the layer 20 of PTFE on the outer surface of the stent 14.
- the apparatus and specific methodology useable to perform this electron beam deposition of the PTFE coating 20 are well known to those of skill in the relevant art.
- the stent 14 whereupon the PTFE coating 20 has been deposited may be subjected to optional heating at 350 °c for a period of approximately ten minutes in order to sinter the PTFE coating and/or to enhance the bonding of the PTFE coating 20 to the wire members 18 of the stent 14.
- such PTFE aqueous dispersion may be painted onto the outer surface of the base graft 12, or the inner surface of the outer tubular layer 16, or may be otherwise disposed between the base graft 12 and outer tubular layer 16 to facilitate fusion or bonding of the inner base graft 12 to the outer tubular layer 16.
- such PTFE aqueous dispersion may be sprayed or otherwise applied to the outer surface of the outer tubular layer 16 provided that the PTFE present in the dispersion are small enough to migrate inwardly through pores in the outer tubular layer 16, thereby becoming deposited between the outer tubular layer 16 and the inner base graft 12.
- Another alternative or additional means by which adherence or fusion of the base graft 12, outer tubular layer 16 and/or stent 14 may be facilitated or enhanced includes the deposition of raw PTFE resin powder between the outer tubular layer 16 and inner base graft 12, and/or upon the stent 14.
- the stent 14 when the stent 14 is of the self-expanding variety it will, in most cases, automatically assume it's fully radially expanded configuration of diameter D 2 and no such volitional or purposeful pre-expansion of the stent 14 will be required.
- Figures 4b-4f show, in step-wise fashion, the preferred method for assembling and constructing the integrally stented PTFE graft 10.
- the tubular base graft 12 is initially disposed on a rod or mandrel 50.
- rod or mandrel 50 may comprise a stainless steel rod having an outer diameter which is only slightly smaller than the inner diameter of the tubular base graft 12.
- the tubular base graft 12 may be slidably advanced onto the outer surface of the mandrel 50 without undue effort or damage to the base graft 12.
- the PTFE-coated stent 14 is axially advanced onto the outer surface of the tubular base graft 12, as shown in Figure 4c.
- PTFE liquid dispersion or powdered PTFE resin may be additionally (optionally) applied to the stent 14 and/or outer surface of the base graft 12 to promote further bonding and fusion of the base graft 12 to the stent 14 and/or subsequently applied outer layer 16.
- the mandrel-borne tubular base graft 12 and stent 14 may be rolled in powdered PTFE resin to accomplish the desired deposition of PTFE powder thereon.
- the above- described PTFE liquid dispersion may be painted sprayed or otherwise applied to the surface of the stent 14 and/or outer surface of the tubular base graft 12 prior to subsequent application of the outer tubular layer 16.
- the tape 17 is initially helically wrapped in overlapping fashion, on the outer surface of the stent 14, in a first direction.
- tape of 1/2 inch width is used.
- the tape is helically wrapped about the stent at a pitch angle whereby 6 to 8 revolutions of the tape are applied per linear inch of the stent 14.
- both wrappings of the tape 17 combine to form a tubular, outer PTFE layer 16 which preferably has a thickness of less than 0.1 inches, and which may be formed of 1 to 10 consecutive (e.g., laminated) layers of the tape 17.
- the first helical wrap may deposit four consecutive layers of tape 17
- the second helical wrap may deposit an additional 4 layers of tape 17, thereby resulting in an outer tubular layer 16 which is made up of a total of 8 layers of such tape 17.
- liquid PTFE dispersion may be sprayed, painted or otherwise applied to and dried upon the tape 17 prior to wrapping, or such liquid PTFE dispersion may be deposited by any suitable means (spraying, painting, etc.) between the outer tubular layer 16 formed by the helically wrapped tape 17 and the inner base graft 12.
- liquid PTFE dispersion may be sprayed onto or otherwise applied to the outer surface of the helically wrapped tape 17 such the small particles of PTFE contained within the liquid dispersion will migrate inwardly through pores in the layers of tape 17, and will thereby become deposited between the outer tubular layer 16 and the inner base graft 12 prior to subsequent heating of the assembly, as described herebelow.
- Another alternative (and optional) method for depositing polymer (e.g., PTFE) particles between the base graft 12 and outer tubular layer 16 is by rolling the mandrel 50, having the base graft 12 and stent 14 disposed thereon, in dry, powdered polymer resin (e.g., the above-described PTFE resin) to cause such dry polymer resin to become deposited on the outer surface of the base graft 12 and/or stent 14 prior to application of the tape 17 as shown in Figures 4d and
- dry, powdered polymer resin e.g., the above-described PTFE resin
- ligatures 52 of stainless steel wire are tied about the opposite ends of the graft 10 so as to securely hold the base graft 12, PTFE-coated stent 14 and outer layer 16 on the mandrel 50.
- the mandrel, having the graft 10 disposed thereon is then heated to a temperature of 363° ⁇ 2°c for thirty minutes. Such heating will cause the outer PTFE layer 16 to heat fuse to the inner base graft 12 through the openings 19 which exist in the stent 14, and will further facilitate bonding or fusing of the PTFE coating 20 of the stent 14 to the adjacent base graft 12 and outer tape layer 16. In this manner, the desired integrally-stented PTFE tubular graft 10 is formed.
- the heating step illustrated schematically in Figure 4f may be carried out by any suitable means.
- the mandrel 50 having the graft 10 and ligatures 52 disposed thereon may be placed in an oven preheated to the desired temperature, for the desired period of time.
- the mandrel, having the graft 10 and ligatures 52 disposed thereon may be rolled on a hot plate or heated surface to accomplish the desired heat fusing or bonding of the outer layer 16, base graft 12 and PTFE coating 20 of the stent 14.
- FIG. 6 Another alternative apparatus which may be utilized for the heating step shown schematically in Figure 4f, is the U-shaped aluminum block heater shown in Figure 6.
- This aluminum block heater is formed of a solid aluminum plate or block 54 formed into a generally U-shaped configuration, and having a plurality of bore holes 60 formed longitudinally therein and extending at least part way therethrough.
- Elongate, cylindrical, electric heaters 62 such as those commercially available from the Watlow Electric Company, 12001 Lackland Road, St. Louis, MO 63146, are inserted into the bore holes 60, and such heaters 62 are heated to a temperature which will cause the inner surface of the U-shaped aluminum heater block 54 to be maintained at approximately 300 °c or greater.
- other types of heating apparatus such as electrical strip heaters mounted on the outer surface of the U-shaped block 54 , may be useable as an alternative to the bore holes 60 and cylindrical heaters 62 described herein.
- the mandrel 50 After the U-shaped block 54 has been heated to the desired temperature, the mandrel 50, having the graft 10 and ligatures 52 disposed thereon, is inserted into the U-shaped inner region of the block 54, and is rotated, therein so as to accomplish the desired heat fusing of the tubular base graft 12, outer tape layer 16 and PTFE coating 20 of the stent 14.
- the stented graft 10 is removed from the mandrel 50 and is held in a heated environment, such as in the inner space of the U-shaped heater device shown in Figure 6. Thereafter, the opposite ends of the stent 14 are pulled longitudinally away from each other to thereby radially contract the stented graft 10 to it's minimal radially compressed diameter D,. Thereafter, the stented graft 10 is allowed to self-expand.
- the stented graft 10 may then be re-advanced onto the mandrel 50 to thereby force the stented graft 10 to reassume it's full radially expanded configuration of diameter D 2 .
- the inner base graft 12 may be eliminated or excluded, thereby providing a modified version of the stented graft
- the above- described manufacturing method is performed as described without the tubular base graft 12, thereby forming a modified version of the stented graft 10 wherein the outer tubular layer 16 of PTFE is fused only to the stent 14.
- the stent 14 is coated with a polymer coating such as PTFE, the presence of such coating on the stent 14 will provide lubricity and biocompatability, which may render such internally stented graft suitable for use in applications wherein the exposed stent 14 will come in direct contact with biological fluid or blood flowing through the graft, thereby avoiding the need for use of the internal base graft 12.
- a polymer coating such as PTFE
- this first alternative embodiment of the present invention includes all possible embodiments wherein only the outer tubular layer 16 is utilized in conjunction with the stent 14, to provide an internally stented graft 10 which is devoid of any internal tubular base graft 12.
- the outer tubular layer 16 may be excluded or eliminated, thereby providing an externally stented PTFE tube graft which comprises only the stent 14 and the inner-base tube 12.
- the above- described manufacturing method is performed as described without the outer tubular layer 16.
- the stent 14 is coated with a polymer coating, such as PTFE
- the presence of such coating on the stent 14 will provide for enhanced biocompatability, which may render such externally stented graft suitable for implantation in blood vessels or other tubular anatomical passageways wherein the exposed exterior of the coated stent 14 comes in direct contact with vascular tissue or other tissue of the body, thereby avoiding the need for use of the outer tubular layer 16.
- this second alternative embodiment of the present invention includes all possible embodiments wherein only the inner base graft 12 is utilized in conjunction with the stent 14, to provide an externally stented graft 10 which is devoid of any outer tubular layer 16.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002259543A CA2259543C (en) | 1996-07-03 | 1997-06-26 | Stented, radially expandable, tubular ptfe grafts |
BR9710100-1A BR9710100A (en) | 1996-07-03 | 1997-06-26 | Tubular graft with a stent and process for the manufacture of a tubular graft. |
AU35056/97A AU712190B2 (en) | 1996-07-03 | 1997-06-26 | Stented, radially expandable, tubular PTFE grafts |
EP97931425A EP0959813B1 (en) | 1996-07-03 | 1997-06-26 | Stented, radially expandable, tubular ptfe grafts |
DE69736987T DE69736987T2 (en) | 1996-07-03 | 1997-06-26 | Supported, radially expandable tubular PTFE grafts |
JP10504286A JP2000508216A (en) | 1996-07-03 | 1997-06-26 | Radially expandable tubular PTFE graft with stent |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/675,644 | 1996-07-03 | ||
US08/675,644 US5928279A (en) | 1996-07-03 | 1996-07-03 | Stented, radially expandable, tubular PTFE grafts |
Publications (2)
Publication Number | Publication Date |
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WO1998000090A3 WO1998000090A3 (en) | 1998-01-08 |
WO1998000090A2 true WO1998000090A2 (en) | 1998-01-08 |
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Application Number | Title | Priority Date | Filing Date |
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PCT/US1997/011106 WO1998000090A2 (en) | 1996-07-03 | 1997-06-26 | Stented, radially expandable, tubular ptfe grafts |
Country Status (10)
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US (3) | US5928279A (en) |
EP (1) | EP0959813B1 (en) |
JP (2) | JP2000508216A (en) |
CN (1) | CN1160027C (en) |
AT (1) | ATE345748T1 (en) |
AU (1) | AU712190B2 (en) |
BR (1) | BR9710100A (en) |
CA (1) | CA2259543C (en) |
DE (1) | DE69736987T2 (en) |
WO (1) | WO1998000090A2 (en) |
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Also Published As
Publication number | Publication date |
---|---|
AU712190B2 (en) | 1999-10-28 |
US6786920B2 (en) | 2004-09-07 |
DE69736987D1 (en) | 2007-01-04 |
CN1228690A (en) | 1999-09-15 |
JP3927545B2 (en) | 2007-06-13 |
JP2004167277A (en) | 2004-06-17 |
EP0959813B1 (en) | 2006-11-22 |
AU3505697A (en) | 1998-01-21 |
US5928279A (en) | 1999-07-27 |
DE69736987T2 (en) | 2007-03-08 |
US6790225B1 (en) | 2004-09-14 |
ATE345748T1 (en) | 2006-12-15 |
CA2259543A1 (en) | 1998-01-08 |
US20020026231A1 (en) | 2002-02-28 |
JP2000508216A (en) | 2000-07-04 |
CN1160027C (en) | 2004-08-04 |
CA2259543C (en) | 2004-09-21 |
BR9710100A (en) | 1999-12-07 |
WO1998000090A3 (en) | 1998-01-08 |
EP0959813A1 (en) | 1999-12-01 |
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