Conical stent

• US 6,283,992 B1
• Filed: 07/09/1999
• Issued: 09/04/2001
• Est. Priority Date: 11/27/1995
• Status: Expired due to Term

• Current Assignee: Boston Scientific Corporation
• Original Assignee: Schneider (Europe) GmbH (Boston Scientific Corporation)
• Inventors: Gianotti, Marc, Hofmann, Eugen, Hankh, Susanne
• Primary Examiner(s): McDermott, Corrine
• Assistant Examiner(s): Phan, Hieu
• Application Number:
  US09/350,704
• Time in Patent Office: 788 Days
• Field of Search: 623/1.1, 623/1.12, 623/1.2, 623/1.3, 623/12, 606/195, 606/198
• US Class Current: 623/1.2
• CPC Class Codes: A61F 2/90 characterised by a net-like or mesh-like structure
• CPC Class Codes: A61F 2210/0076 multilayered, e.g. laminated structures
• CPC Class Codes: A61F 2230/0067 conical
• CPC Class Codes: A61F 2250/0037 differing in height or in length
• CPC Class Codes: A61F 2250/0039 differing in diameter
• CPC Class Codes: D04C 1/06 Braid or lace serving particular purposes
• CPC Class Codes: D10B 2509/06 Vascular grafts; stents

Abstract

The stent comprises a flexible self-expandable braided tubular wall having a proximal segment having an outer diameter, and a distal segment having an outer diameter smaller than the outer diameter of the proximal segment. An intermediate segment is formed between proximal and distal segments, which forms a truncated cone of which the base is forming the proximal end of the intermediate segment and of which the top is forming the distal end of the intermediate segment. A covering layer is arranged within the tubular wall.

Claims

1. A stent for use in a body passageway comprising:

a flexible self-expandable braided tubular wall having a longitudinal axis, the tubular wall comprising a first proximal segment adapted to provide a sufficiently high radial force to prevent migration of the stent in a body passageway, a proximal end, a distal end, and a first outer diameter, the proximal end of the first proximal segment terminating at a first free end of the stent;

a second distal segment having a proximal end, a distal end, and a second outer diameter smaller than the first outer diameter of the first proximal segment, the distal end of the second distal segment terminating at a second free end of the stent; and

a third intermediate segment having a proximal end connected to the distal end of the first segment and a distal end connected to the proximal end of the second distal segment;

wherein the braided tubular wall includes braiding with a varying steep angle with respect to the longitudinal axis of the tubular wall and wherein the radial force and flexibility over at least a portion of the flexible self-expandable braided tubular wall are not constant and wherein at least one of the first free end and the second free end is flared in a radial direction.

2. The prosthesis of claim 1 wherein the first proximal mesh segment is adapted to provide an anchor portion for securing the prosthesis in a body passageway and the intermediate mesh segment is adapted to provide transitional flexibility between the first proximal segment and the second distal segment.

3. The stent of claim 1 wherein the braided tubular wall is adapted to provide a plurality of forces to the body passageway.

4. The stent of claim 1 wherein the first proximal segment has a shorter axial length than the third intermediate segment.

5. The stent of claim 1 further comprising at least one additional segment between the first proximal segment and the second distal segment.

6. The stent of claim 1 further comprising a covering layer of an elastic material at least partially surrounding said tubular wall.

7. The stent of claim 6 wherein at least one of a proximal portion of the first proximal anchor segment and a distal portion of the second distal way-making segment is not covered by the covering layer.

8. The stent of claim 1 wherein the elastic material is adapted to prevent in growth through the stent.

9. The stent of claim 1 wherein the varying braid angle decreases from the second proximal end to the second distal end.

10. The stent of claim 1 wherein the third intermediate segment includes a plurality of consecutive truncated cones connected to one another, each of the truncated cones having a taper oriented towards the distal end of the intermediate segment.

11. The stent of claim 10 wherein at least two of the consecutive truncated cones are separated by a cylindrical segment connected thereto.

12. A stent for use in a body passageway comprising:

a flexible self-expandable braided tubular wall having a longitudinal axis, the tubular wall comprising a first proximal anchor segment adapted to provide a sufficiently high radial force to prevent migration of the stent in a body passageway, a proximal end, a distal end, and a first outer diameter, the proximal end of the first proximal anchor segment terminating at a first free end of the stent;

a second distal segment having a proximal end, a distal end, and a second outer diameter smaller than the first outer diameter of the first proximal anchor segment, the distal end of the second distal segment terminating at a second free end of the stent; and

a third intermediate segment including a plurality of consecutive truncated cones connected to one another, each of the truncated cones having a taper oriented towards the distal end of the intermediate segment, the third intermediate segment having a proximal end connected to the distal end of the first segment and a distal end connected to the proximal end of the second distal way-making segment;

wherein the braided tubular wall includes braiding with a varying steep angle with respect to the longitudinal axis of the tubular wall and wherein the radial force and flexibility over at least a portion of the flexible self-expandable braided tubular wall is not constant.

13. The stent of claim 12 wherein at least one of the first free end and the second free end of the stent is flared in an outward direction.

14. A method for manufacturing a stent comprising:

(a) forming an elongated mandrel, the elongated mandrel including;

(1) a first proximal segment having a proximal end, a distal end, and a first outer diameter;

(2) a second distal segment having a proximal end, a distal end, and a second outer diameter smaller than the first outer diameter; and

(3) a third intermediate segment having a proximal end connected to the distal end of the first segment and a distal end connected to the proximal end of the second segment;

(b) forming an elongated tubular braid having a proximal end, distal end, and an inner diameter greater than the first outer diameter of the first proximal segment of the elongated mandrel;

(c) engaging the tubular braid over the mandrel;

(d) heating the tubular braid over the mandrel; and

(e) pulling the proximal and distal ends of the tubular braid away from one another to closely radially contract the tubular braid over the segments of the mandrel during heating of the tubular braid.

15. The method for manufacturing a stent of claim 14 wherein the tubular braid includes metal.

16. The method for manufacturing a stent of claim 14 wherein the metal includes at least one of spring steel and stainless steel.

17. A method for manufacturing a stent comprising:

(a) forming an elongated tubular mandrel, the elongated tubular mandrel including;

(1) a first proximal hollow segment having a proximal end, a distal end, and a first inner diameter;

(2) a second distal hollow segment having a proximal end, a distal end, and a second inner diameter smaller than the first inner diameter; and

(3) a third intermediate hollow segment having a proximal end connected to the distal end of the first hollow segment and a distal end connected to the proximal end of the second hollow segment;

(b) forming an elongated tubular braid having a proximal end, a distal end, and an outer diameter greater than the first inner diameter of the first hollow segment of the tubular mandrel;

(c) pulling the proximal and distal ends of the elongated tubular braid away from one another to radially contract the tubular braid;

(d) engaging the contracted tubular braid into the tubular mandrel;

(e) releasing the pull on the ends of the tubular braid to radially expand the tubular braid in the mandrel; and

(f) heating the tubular braid in the mandrel to closely radially expand the tubular braid against the segments of the tubular mandrel.

18. The method for manufacturing a stent of claim 17 wherein the tubular braid includes metal.

19. The method for manufacturing a stent of claim 18 wherein the metal includes at least one of spring steel and stainless steel.

20. A body insertable stent, including:

a flexible self-expandable braided tubular wall comprising a proximal segment having a proximal segment diameter adapted to provide a sufficiently high radial force to prevent a migration of the stent in a body passageway, a proximal end of the proximal segment terminating at a first free end of the tubular wall;

a distal segment having a distal segment outer diameter less than the proximal segment outer diameter, a distal end of the distal segment terminating at a second free end of the tubular wall; and

an intermediate segment of the tubular wall disposed between the proximal and distal segments, and incorporating at least one truncated cone having a taper oriented toward the distal segment;

wherein the intermediate segment, along the at least one truncated cone, includes braiding with a steep angle that varies with respect to a longitudinal axis of the tubular wall, and wherein a radial force and flexibility of the tubular wall vary along the at least one truncated cone.

21. A stent according to claim 20, wherein said third intermediate segment is formed of a plurality of consecutive truncated cones connected to one another, each of said truncated cones having a taper oriented towards the distal end of the intermediate segment.

22. A stent according to claim 21, wherein at least two of said consecutive cones are separated by a cylindrical segment connected thereto.

23. A stent according to claim 20, wherein the proximal end of the first proximal segment is flared up.

24. A stent according to claim 20, wherein the distal end of the second distal segment is flared up.

25. A method for manufacturing a stent comprising:

(a) forming an elongated mandrel having a first proximal segment having proximal and distal ends and a first outer diameter, a second distal segment having proximal and distal ends and a second outer diameter smaller than said first outer diameter, and a third intermediate segment having a proximal end connected to the distal end of the first segment and a distal end connected to the proximal end of the second segment;

(b) forming an elongated tubular braid of spring steel having proximal and distal ends and an inner diameter greater than said first outer diameter of the first segment of the mandrel;

(c) engaging said tubular braid over said mandrel;

(d) heating the tubular braid over the mandrel; and

,

(e) pulling during said heating the proximal and distal ends of the tubular braid away from one another on the mandrel to closely radially contract the tubular braid over the segments of said mandrel.

26. A method for manufacturing a stent comprising:

(a) forming an elongated tubular mandrel having a first proximal hollow segment having proximal and distal ends and a first inner diameter, a second distal hollow segment having proximal and distal ends and a second inner diameter smaller than said first inner diameter, and a third intermediate hollow segment having a proximal end connected to the distal end of the first hollow segment and a distal end connected to the proximal end of the second hollow segment;

(b) forming an elongated tubular braid of spring steel having proximal and distal ends and an outer diameter greater than the first inner diameter of the first hollow segment of the tubular mandrel;

(c) pulling the proximal and distal ends of the elongated tubular braid away from one another to radially contract the tubular braid;

(d) engaging the contracted tubular braid into the tubular mandrel;

(e) releasing the pull on the ends of the tubular braid to radially expand it in the mandrel; and

,

(f) heating the tubular braid in the mandrel to closely radially expand the tubular braid against the segments of the tubular mandrel.