Method of manufacturing a tubular medical implant

• US 10,449,065 B2
• Filed: 06/12/2017
• Issued: 10/22/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Smed-Ta/Td LLC
• Original Assignee: Smed-Ta/Td LLC
• Inventors: Knapp, Troy D., Stalcup, Gregory C., Jurick, Joseph, Nebosky, Paul S.
• Primary Examiner(s): Ulsh, George J
• Application Number:
  US15/620,226
• Publication Number:
  US 20170273808A1
• Time in Patent Office: 862 Days
• Field of Search: 623 115
• CPC Class Codes: A61F 2/2846 Support means for bone substitute or for bone graft implants, e.g. membranes or plates for covering bone defects nets or sleeves applied to surface of endoprostheses A61F2/30907; bone plates A61B17/80; bone regeneration in dental surgery A61C8/0006
• CPC Class Codes: A61F 2/82 Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents stent-grafts for tubular structures of the body other than blood vessels A61F2/04; stent-grafts for blood vessels A61F2/07; instruments specially adapted for placement or removal of stents or stent-grafts A61F2/95; for closing wounds, or holding wounds closed A61B17/04 - A61B17/115; dilators A61M29/00
• CPC Class Codes: A61F 2/852 Two or more distinct overlapping stents
• CPC Class Codes: A61F 2002/30235 tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2210/0076 multilayered, e.g. laminated structures
• CPC Class Codes: A61F 2250/0023 differing in porosity

Abstract

A method of manufacturing a tubular medical implant is provided. The method includes forming a hollow first tube with a first diameter and a first plurality of pores formed thereon and a hollow second tube with a second unstretched diameter and a second plurality of pores formed thereon. The second unstretched diameter is greater than the first diameter. At least a portion of the first tube slides within the second tube to create an overlapped area of the first tube and the second tube. The first tube and second tube are then bonded together in the overlapped area.

Claims

1. A tubular medical implant, comprising:

a first hollow tube including a first tube wall with a first plurality of pores formed thereon, said first hollow tube defining a first diameter;

a second hollow tube surrounding and press fit to said first hollow tube to form an overlapped area and including a second tube wall with a second plurality of pores formed thereon, said second hollow tube defining a second unstretched diameter that is greater than said first diameter, at least one of said first plurality of pores and at least one of said second plurality of pores overlapping within said overlapped area to form an implant pore extending completely through said first tube wall and said second tube wall;

a non-porous rod supporting an interior of said first hollow tube, wherein said non-porous rod is hollow; and

a third hollow tube placed within said non-porous rod and including a third tube wall with a third plurality of pores formed thereon.

2. The tubular medical implant of claim 1, wherein said first plurality of pores forms an inner pore pattern and said second plurality of pores forms an outer pore pattern.

3. The tubular medical implant of claim 2, wherein said inner pore pattern and said outer pore pattern together form a plurality of implant pores forming a tubular implant pore pattern.

4. The tubular medical implant of claim 1, wherein said at least one of said first plurality of pores and said at least one of said second plurality of pores partially overlap.

5. The tubular medical implant of claim 1, wherein said press fit of said second hollow tube to said first hollow tube does not deform said first plurality of pores and said second plurality of pores.

6. The tubular medical implant of claim 1, wherein said first hollow tube is composed of at least one of a polymer, a metal, and a ceramic and said second hollow tube is composed of at least one of a polymer, a metal, and a ceramic.

7. The tubular medical implant of claim 1, wherein said first hollow tube defines a first tube thickness and said second hollow tube defines a second tube thickness which is equal to said first tube thickness.

8. A tubular medical implant comprising:

a first hollow tube including a first tube wall with a first plurality of pores formed thereon, said first hollow tube defining a first diameter;

a second hollow tube surrounding and press fit to said first hollow tube to form an overlapped area and including a second tube wall with a second plurality of pores formed thereon, said second hollow tube defining a second unstretched diameter that is greater than said first diameter, at least one of said first plurality of pores and at least one of said second plurality of pores overlapping within said overlapped area to form an implant pore extending completely through said first tube wall and said second tube wall; and

a third hollow tube at least partially surrounding said second hollow tube and including a third tube wall with a third plurality of pores formed thereon.

9. The tubular medical implant of claim 8, wherein said third hollow tube is press fit to said second hollow tube.

10. The tubular medical implant of claim 8, wherein at least one of said third plurality of pores overlaps with said implant pore.