Sintered structures for vascular graft

• US 20060149366A1
• Filed: 12/31/2004
• Published: 07/06/2006
• Est. Priority Date: 12/31/2004
• Status: Abandoned Application

• Current Assignee: Lifeshield Sciences LLC (Acacia Research Corporation)
• Original Assignee: Lifeshield Sciences LLC (Acacia Research Corporation)
• Inventors: Henderson, Jamie
• Application Number:
  US11/026,609
• Publication Number:
  US 20060149366A1
• Time in Patent Office: Days
• US Class Current: 623/1.490
• CPC Class Codes: A61F 2/06 Blood vessels
• CPC Class Codes: A61F 2250/0028 differing in fibre orientations
• CPC Class Codes: A61F 2250/0048 differing in mechanical expandability, e.g. in mechanical, self- or balloon expandability
• CPC Class Codes: B29C 35/0266 Local curing for repairing B29C73/34
• CPC Class Codes: B29C 55/005 characterised by the choice of materials
• CPC Class Codes: B29K 2027/18 PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29L 2031/7534 Cardiovascular protheses

Abstract

The vascular graft is for implantation within a body and has a PTFE tube structure including a length and inner and outer wall surfaces. The tube structure has a non-expanded portion formed from sintering a PTFE green tube extrudate and an expanded portion formed subsequent to the sintering. The expanded and non-expanded portions are of the same extrudate. The expanded portion has a region which adjoins the non-expanded portion wherein a degree of expansion of the region is limited by the non-expanded portion. The limiting of the expansion by the non-expanded portion is attenuated at a location of the region which is remote from the non-expanded portion. A method for making the vascular graft facilitates the formation of the non-expanded and expanded portions of the PTFE tube structure.

Claims

1. A vascular graft for implantation within a body, said vascular graft comprising

a PTFE tube structure having a length and inner and outer wall surfaces,

said tube structure having a non-expanded portion formed from sintering a PTFE green tube extrudate and an expanded portion formed subsequent to the sintering,

said expanded and non-expanded portions being of the same extrudate,

said expanded portion having a region which adjoins said non-expanded portion wherein a degree of expansion of said region is limited by said non-expanded portion, said limiting of said expansion by said non-expanded portion being attenuated at a location of said region which is remote from said non-expanded portion.

2. A vascular graft according to claim 1, wherein said expanded portion has a node and fibril microstructure.

3. A vascular graft according to claim 1, wherein said non-expanded portion comprises a first non-expanded portion, said vascular graft further comprising three additional non-expanded portions formed from sintering the PTFE green tube extrudate, said first non-expanded and three additional non-expanded portions each being elongate and having a longitudinal central axis contained in respective longitudinal cross-sectional planes of said PTFE tube structure, said expanded and first and three additional non-expanded portions being of the same extrudate, adjacent pairs of said first and additional non-expanded portions being separated from one another circumferentially relative to said PTFE tube structure by an angular dimension equal to 90 degrees, said first and additional non-expanded portions each having respective proximal and distal ends, said proximal ends having the same longitudinal positions relative to said PTFE tube structure, said distal ends having the same longitudinal position relative to said PTFE tube structure,

said first and additional non-expanded portions being contained within a first longitudinal region of said PTFE tube structure such that application of a uniform longitudinal tensile force to said PTFE tube structure causes longitudinal elongation of said first longitudinal region and longitudinal elongation of a second longitudinal region of said PTFE tube structure, the longitudinal elongation of said first longitudinal region being less than the longitudinal elongation of said second longitudinal region.

4. A vascular graft according to claim 3, wherein the uniform longitudinal tensile force causes the longitudinal elongation of said first longitudinal region to be 200% and the longitudinal elongation of said second longitudinal region to be 800%.

5. A vascular graft according to claim 1, wherein said limiting of said expansion by said non-expanded portion is increasingly attenuated at locations of said region which are increasingly remote from said non-expanded portion.

6. A vascular graft according to claim 1, wherein said non-expanded portion is elongate and has a longitudinal central axis contained in a longitudinal cross-sectional plane of said PTFE tube structure.

7. A vascular graft according to claim 1, wherein said non-expanded portion is elongate and has a longitudinal central axis contained in a transverse cross-sectional plane of said PTFE tube structure.

8. A vascular graft according to claim 7, wherein said non-expanded portion encircles said inner wall surface such that said non-expanded portion is annular.

9. A vascular graft according to claim 1, wherein said non-expanded portion is elongate and has a longitudinal central axis which is inclined relative to a transverse cross-sectional plane of said PTFE tube structure.

10. A vascular graft according to claim 9, wherein said non-expanded portion constitutes a first non-expanded portion,

said vascular graft comprising a second non-expanded portion formed from sintering the PTFE green tube extrudate, said expanded and second non-expanded portions being of the same extrudate,

said second non-expanded portion being elongate and having a longitudinal central axis which is inclined relative to a transverse cross-sectional plane of said PTFE tube structure, said inclination of said second non-expanded portion being opposite to said inclination of said first non-expanded portion, said first and second non-expanded portions intersecting one another.

11. A vascular graft according to claim 1, wherein said non-expanded portion has an elongate saw-tooth configuration.

12. A vascular graft according to claim 11, wherein said non-expanded portion has a longitudinal principal axis which bisects said saw-tooth configuration, said principal axis being contained in a transverse cross-sectional plane of said PTFE tube structure.

13. A vascular graft according to claim 11, wherein said non-expanded portion has a longitudinal principal axis which bisects said saw-tooth configuration, said principal axis being contained in a longitudinal cross-sectional plane of said PTFE tube structure.

14. A vascular graft according to claim 1, wherein said non-expanded portion constitutes a transverse non-expanded portion, said vascular graft further comprising another transverse non-expanded portion formed from sintering the PTFE green tube extrudate, said expanded and transverse non-expanded portions being of the same extrudate,

said transverse non-expanded portions each being elongate and having a longitudinal central axis which is contained in a corresponding transverse cross-sectional plane of said PTFE tube structure, said transverse non-expanded portions being separated from one another longitudinally relative to said PTFE tube structure,

said vascular graft further comprising longitudinal non-expanded portions formed from sintering the PTFE green tube extrudate, said longitudinal non-expanded portions each being elongate and having a longitudinal central axis which is contained in a corresponding longitudinal cross-sectional plane of said PTFE tube structure, said expanded and longitudinal non-expanded portions being of the same extrudate and separated from one another transversely relative to said PTFE tube structure,

said longitudinal non-expanded portions intersecting said transverse non-expanded portions.

15. A vascular graft according to claim 1, wherein said non-expanded portion constitutes a first transverse non-expanded portion, said vascular graft further comprising a second transverse non-expanded portion formed from sintering the PTFE green tube extrudate,

said first and second transverse non-expanded portions each being elongate and having a longitudinal central axis which is contained in a corresponding transverse cross-sectional plane of the PTFE tube structure, said expanded and first and second transverse non-expanded portions being of the same extrudate, said first and second transverse non-expanded portions being separated from one another longitudinally relative to said PTFE tube structure,

said vascular graft further comprising an annular non-expanded portion which is formed from sintering the PTFE green tube extrudate, said expanded and annular non-expanded portions being of the same extrudate, said annular non-expanded portion being located between said first and second transverse non-expanded portions in tangential relation thereto.

16. A vascular graft according to claim 15, wherein said annular non-expanded portion constitutes a first annular non-expanded portion, said vascular graft further comprising a third transverse non-expanded portion formed from sintering the PTFE green tube extrudate, said third transverse non-expanded portion being elongate and having a longitudinal central axis which is contained in a corresponding transverse cross-sectional plane of said PTFE tube structure, said expanded and third transverse non-expanded portions being of the same extrudate, said third transverse non-expanded portion being elongate and separated from said first and second transverse non-expanded portions longitudinally relative to the PTFE tube structure such that said third transverse non-expanded portion is longitudinally separated from said first annular non-expanded portion,

said vascular graft further comprising a second annular non-expanded portion which is formed from sintering the PTFE green tube extrudate, said expanded and second annular non-expanded portions being of the same extrudate, said second annular non-expanded portion being located between said third transverse non-expanded portion and one of said first and second transverse non-expanded portions in tangential relation thereto.

17. A vascular graft according to claim 1, wherein said non-expanded portion comprises a lattice structure.

18. A vascular graft according to claim 1, wherein said non-expanded portion constitutes a first non-expanded portion which is elongate and has a longitudinal central axis which is contained in a first longitudinal cross-sectional plane of said PTFE tube structure,

said vascular graft further comprising a second non-expanded portion formed from sintering the PTFE green tube extrudate, said second non-expanded portion being elongate and having a longitudinal central axis which is contained in a second longitudinal cross-sectional plane of said PTFE tube structure, said second non-expanded portion being separated from said first non-expanded portion circumferentially relative to said PTFE tube structure, said expanded and second non-expanded portion being of the same extrudate,

said first and second non-expanded portions having longitudinally offset positions relative to one another wherein said first and second non-expanded portions are longitudinally displaced relative to one another during the formation of said expanded portion.

19. A vascular graft according to claim 18, wherein said longitudinally offset positions provide for partial longitudinal overlap of said first and second non-expanded portions in which parts thereof have the same longitudinal positions relative to said tube structure and other parts of said non-expanded portions have different longitudinal positions relative to said tube structure.

20. A vascular graft according to claim 18, wherein said expanded portion has a node and fibril microstructure in which nodes extend between said first and second non-expanded portions, said nodes having an inclined orientation relative to a longitudinal plane of said PTFE tube structure subsequent to the formation of said expanded portion.

21. A vascular graft according to claim 18, and further comprising a plurality of first supplemental non-expanded portions formed from sintering the PTFE green tube extrudate, said first supplemental non-expanded portions being elongate and having a longitudinal central axis which is contained in said first longitudinal cross-sectional plane, said first supplemental and first non-expanded portions having the same longitudinal dimension and being of the same extrudate, said first supplemental and first non-expanded portions being separated longitudinally from adjacent ones of said first supplemental and first non-expanded portions by uniform dimensions,

said vascular graft further comprising a plurality of second supplemental non-expanded portions formed from sintering the PTFE green tube extrudate, said second supplemental non-expanded portions being elongate and having a longitudinal central axis which is contained in said second longitudinal cross-sectional plane, said second supplemental and second non-expanded portions having the same longitudinal dimensions and being of the same extrudate, said second supplemental and second non-expanded portions being separated longitudinally from adjacent ones of said first supplemental and first non-expanded portions by uniform dimensions which are the same as said uniform dimensions of said separation of said first supplemental and first non-expanded portions,

said first supplemental and first non-expanded portions being longitudinally symmetrical relative to said second supplemental and second non-expanded portions both before and after the formation of said expanded portion,

said dimension of said separation between said first supplemental and first non-expanded portions, and said dimension of said separation between said second supplemental and second non-expanded portions being increased during the formation of said expanded portion.

22. A vascular graft according to claim 21, wherein said expanded portion has a node and fibril microstructure in which nodes extend between said first and second non-expanded portions, said node and fibril microstructure having nodes which extend between said first and second supplemental non-expanded portions, said nodes which extend between said first and second non-expanded portions and said nodes which extend between said first and second supplemental non-expanded portions having an inclined orientation relative to a longitudinal plane of said PTFE tube structure subsequent to the formation of said expanded portion, said inclination of nodes which extend between said first and second non-expanded portions being symmetrical relative to said inclination of nodes which extend between said first and second supplemental non-expanded portions about a transverse plane of said PTFE tube structure.

23. A vascular graft according to claim 1, wherein said non-expanded portion is oriented relative to a transverse cross-sectional plane of said PTFE tube structure such that said non-expanded portion provides a corresponding resistance to compression of said PTFE tube structure in said transverse cross-sectional plane.

24. A method for making a vascular graft comprising:

providing a PTFE green tube extrudate which is un-sintered;

pre-sintering a section of the extrudate to produce a pre-sintered portion such that a section of the extrudate is unsintered to constitute an unsintered portion;

expanding the unsintered portion, said expansion of the region of the unsintered portion which adjoins the non-expanded portion being limited by the non-expanded portion, the limiting of said expansion by the non-expanded portion being attenuated in a region of the extrudate which is remote from the non-expanded portion.

25. A method according to claim 24, wherein the rate of said expansion is controlled to vary said expansion of the section of the extrudate which contains the non-expanded portion relative to said expansion of the region of the extrudate which is remote from the non-expanded portion.