Durable multi-layer high strength polymer composite suitable for implant and articles produced therefrom

• US 10,022,219 B2
• Filed: 05/28/2015
• Issued: 07/17/2018
• Est. Priority Date: 04/01/2011
• Status: Expired due to Fees

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Inventors: Bruchman, William C., Gassler, Paul D., Hartman, Cody L., Walsh, Peter J.
• Primary Examiner(s): Sharma, Yashita
• Assistant Examiner(s): PRESTON, REBECCA STRASZHEIM
• Application Number:
  US14/724,672
• Publication Number:
  US 20150257876A1
• Time in Patent Office: 1,146 Days
• CPC Class Codes: A61F 2/2403 with pivoting rigid closure members check valves with hinged closure members in general F16K15/03
• CPC Class Codes: A61F 2/2415 Manufacturing methods
• CPC Class Codes: A61F 2210/0076 multilayered, e.g. laminated structures
• CPC Class Codes: A61F 2230/00 Geometry of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: A61F 2240/005 Templates
• CPC Class Codes: A61L 2420/04 Coatings containing a composite material such as inorganic/organic, i.e. material comprising different phases
• CPC Class Codes: A61L 2420/08 Coatings comprising two or more layers
• CPC Class Codes: A61L 2430/20 for reconstruction of the heart, e.g. heart valves
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 27/48 with macromolecular fillers
• CPC Class Codes: A61L 27/507 for artificial blood vessels apparatus for applying cells on a blood vessel prosthesis A61F2/062
• CPC Class Codes: A61L 27/56 Porous materials, e.g. foams or sponges
• CPC Class Codes: C08L 27/18 Homopolymers or copolymers or tetrafluoroethene
• CPC Class Codes: Y10T 29/49412 with assembly, disassembly or composite article making

Abstract

A thin, biocompatible, high-strength, composite material is disclosed that is suitable for use in various implanted configurations. The composite material maintains flexibility in high-cycle flexural applications, making it particularly applicable to high-flex implants such as a prosthetic heart valve leaflet. The composite material includes at least one porous expanded fluoropolymer layer and an elastomer present in the pores of the porous expanded fluoropolymer.

Claims

1. A prosthetic valve, comprising:

a leaflet comprising more than one layer of a composite material having at least one fluoropolymer layer having a plurality of pores and an elastomer substantially filling the pores of the at least one fluoropolymer layer, the composite material comprising less than about 80% fluoropolymer by weight, the more than one layer of composite material being coupled together via the elastomer.

2. The prosthetic valve as set forth in claim 1, the leaflet having a ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 5.

3. The prosthetic valve as set forth in claim 2, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 3.

4. The prosthetic valve as set forth in claim 2, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 1.

5. The prosthetic valve as set forth in claim 2, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 0.5.

6. The prosthetic valve as set forth in claim 1, wherein the leaflet encompasses a radiopaque element.

7. The prosthetic valve as set forth in claim 1, wherein the leaflet has a bending modulus of less than about 100 MPa.

8. The prosthetic valve as set forth in claim 1, wherein the leaflet is operatively coupled to a support frame and movable between closed and open configurations relative to the support frame.

9. The prosthetic valve as set forth in claim 8, wherein the support frame is selectively diametrically adjustable for endovascular delivery and deployment at a treatment site.

10. The prosthetic valve as set forth in claim 1, wherein the composite material comprises less than about 70% fluoropolymer by weight.

11. The prosthetic valve as set forth in claim 1, wherein the composite material comprises less than about 60% fluoropolymer by weight.

12. The prosthetic valve as set forth in claim 1, wherein the composite material comprises less than about 50% fluoropolymer by weight.

13. The prosthetic valve as set forth in claim 1, wherein the elastomer is a TFE/PMVE copolymer.

14. The prosthetic valve as set forth in claim 13, wherein the TFE/PMVE copolymer comprises essentially of between about 40 and 80 weight percent perfluoromethyl vinyl ether and complementally 60 and 20 weight percent tetrafluoroethylene.

15. The prosthetic valve as set forth in claim 1, wherein the leaflet has a thickness of less than about 350 μ

m.

16. The prosthetic valve as set forth in claim 1, wherein the leaflet has a thickness of less than about 300 μ

m.

17. The prosthetic valve as set forth in claim 1, wherein the leaflet has a thickness of less than about 200 μ

m.

18. The prosthetic valve as set forth in claim 1, wherein the leaflet has a thickness of less than about 100 μ

m.

19. The prosthetic valve as set forth in claim 1, wherein the leaflet has a thickness of less than about 50 μ

m.

20. The prosthetic valve as set forth in claim 1, wherein the leaflet has a thickness of less than about 25 μ

m.

21. The prosthetic valve as set forth in claim 1, wherein the elastomer is a fluoroelastomer.

22. The prosthetic valve as set forth in claim 21, wherein the fluoropolymer layer is PTFE.

23. The prosthetic valve as set forth in claim 22, wherein the PTFE is ePTFE.

24. The prosthetic valve as set forth in claim 23, wherein the at least one fluoropolymer layer has a matrix tensile strength in at least one direction greater than about 96 MPa.

25. A prosthetic valve, comprising:

a leaflet comprising more than one layer of a composite material having at least one fluoropolymer layer having a plurality of pores and TFE/PMVE copolymer substantially filling the pores of the at least one fluoropolymer layer, the composite material comprising less than about 80% fluoropolymer by weight, the more than one layer of composite material being coupled together via the TFE/PMVE copolymer.

26. The prosthetic valve as set forth in claim 25, the leaflet having a ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 5.

27. The prosthetic valve as set forth in claim 26, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 3.

28. The prosthetic valve as set forth in claim 26, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 1.

29. The prosthetic valve as set forth in claim 26, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 0.5.

30. The prosthetic valve as set forth in claim 25, wherein the leaflet encompasses a radiopaque element.

31. The prosthetic valve as set forth in claim 25, wherein the leaflet has a bending modulus of less than about 100 MPa.

32. The prosthetic valve as set forth in claim 25, wherein the leaflet is operatively coupled to a support frame and movable between closed and open configurations relative to the support frame.

33. The prosthetic valve as set forth in claim 32, wherein the support frame is selectively diametrically adjustable for endovascular delivery and deployment at a treatment site.

34. The prosthetic valve as set forth in claim 25, wherein the composite material comprises less than about 70% fluoropolymer by weight.

35. The prosthetic valve as set forth in claim 25, wherein the composite material comprises less than about 60% fluoropolymer by weight.

36. The prosthetic valve as set forth in claim 25, wherein the composite material comprises less than about 50% fluoropolymer by weight.

37. The prosthetic valve as set forth in claim 25, wherein the TFE/PMVE copolymer comprises essentially of between about 40 and 80 weight percent perfluoromethyl vinyl ether and complementally 60 and 20 weight percent tetrafluoroethylene.

38. The prosthetic valve as set forth in claim 25, wherein the leaflet has a thickness of less than about 350 μ

m.

39. The prosthetic valve as set forth in claim 25, wherein the leaflet has a thickness of less than about 300 μ

m.

40. The prosthetic valve as set forth in claim 25, wherein the leaflet has a thickness of less than about 200 μ

m.

41. The prosthetic valve as set forth in claim 25, wherein the leaflet has a thickness of less than about 100 μ

m.

42. The prosthetic valve as set forth in claim 25, wherein the leaflet has a thickness of less than about 50 μ

m.

43. The prosthetic valve as set forth in claim 25, wherein the leaflet has a thickness of less than about 25 μ

m.

44. The prosthetic valve as set forth in claim 25, wherein the fluoropolymer layer is PTFE.

45. The prosthetic valve as set forth in claim 44, wherein the PTFE is ePTFE.

46. The prosthetic valve as set forth in claim 45, wherein the at least one fluoropolymer layer has a matrix tensile strength in at least one direction greater than about 96 MPa.

47. A prosthetic valve, comprising:

a leaflet comprising more than one layer of a composite material having at least one fluoropolymer layer having a plurality of pores and an elastomeric material substantially filling the pores of the at least one fluoropolymer layer, the composite material comprising less than about 80% fluoropolymer by weight, the more than one layer of composite material being coupled together via the elastomeric material.

48. The prosthetic valve as set forth in claim 47, the leaflet having a ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 5.

49. The prosthetic valve as set forth in claim 48, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 3.

50. The prosthetic valve as set forth in claim 48, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 1.

51. The prosthetic valve as set forth in claim 48, wherein the ratio of leaflet thickness (μ

m) to number of fluoropolymer layers of less than about 0.5.

52. The prosthetic valve as set forth in claim 47, wherein the leaflet encompasses a radiopaque element.

53. The prosthetic valve as set forth in claim 47, wherein the leaflet has a bending modulus of less than about 100 MPa.

54. The prosthetic valve as set forth in claim 47, wherein the leaflet is operatively coupled to a support frame and movable between closed and open configurations relative to the support frame.

55. The prosthetic valve as set forth in claim 54, wherein the support frame is selectively diametrically adjustable for endovascular delivery and deployment at a treatment site.

56. The prosthetic valve as set forth in claim 47, wherein the composite material comprises less than about 70% fluoropolymer by weight.

57. The prosthetic valve as set forth in claim 47, wherein the composite material comprises less than about 60% fluoropolymer by weight.

58. The prosthetic valve as set forth in claim 47, wherein the composite material comprises less than about 50% fluoropolymer by weight.

59. The prosthetic valve as set forth in claim 47, wherein the leaflet has a thickness of less than about 350 μ

m.

60. The prosthetic valve as set forth in claim 47, wherein the leaflet has a thickness of less than about 300 μ

m.

61. The prosthetic valve as set forth in claim 47, wherein the leaflet has a thickness of less than about 200 μ

m.

62. The prosthetic valve as set forth in claim 47, wherein the leaflet has a thickness of less than about 100 μ

m.

63. The prosthetic valve as set forth in claim 47, wherein the leaflet has a thickness of less than about 50 μ

m.

64. The prosthetic valve as set forth in claim 47, wherein the leaflet has a thickness of less than about 25 μ

m.

65. The prosthetic valve as set forth in claim 47, wherein the fluoropolymer layer is PTFE.

66. The prosthetic valve as set forth in claim 65, wherein the PTFE is ePTFE.

67. The prosthetic valve as set forth in claim 66, wherein the at least one fluoropolymer layer has a matrix tensile strength in at least one direction greater than about 96 MPa.

68. The prosthetic valve as set forth in claim 47, wherein the elastomeric material is a TFE/PMVE copolymer.