Shaped woven tubular soft-tissue prostheses and method of manufacturing the same

• US 6,596,023 B1
• Filed: 07/07/2000
• Issued: 07/22/2003
• Est. Priority Date: 05/24/1996
• Status: Expired due to Fees

• Current Assignee: Lifeshield Sciences LLC (Acacia Research Corporation)
• Original Assignee: Meadox Medicals, Inc. (Boston Scientific Corporation)
• Inventors: Schmitt, Peter J., Nuñez, Jose F.
• Primary Examiner(s): Willse, David H.
• Assistant Examiner(s): STEWART, ALVIN J
• Application Number:
  US09/611,861
• Time in Patent Office: 1,110 Days
• Field of Search: 623/1.3, 623/1.49, 623/1.5, 623/1.51, 623/1.53, 623/1.54, 623/1.52, 623/11.11, 623/23.7, 623/23.71
• US Class Current: 623/1.3
• CPC Class Codes: A61F 2/06 Blood vessels
• CPC Class Codes: A61F 2/07 Stent-grafts
• CPC Class Codes: A61F 2/90 characterised by a net-like or mesh-like structure
• CPC Class Codes: A61F 2002/065 Y-shaped blood vessels
• CPC Class Codes: A61F 2002/067 modular
• CPC Class Codes: A61F 2002/075 the stent being loosely attached to the graft material, e.g. by stitching
• CPC Class Codes: A61F 2250/0017 differing in yarn density
• CPC Class Codes: A61F 2250/0039 differing in diameter
• CPC Class Codes: D03D 3/02 Tubular fabrics
• CPC Class Codes: D03D 3/06 Fabrics of varying width
• CPC Class Codes: D10B 2509/06 Vascular grafts; stents

Abstract

Continuously flat-woven implantable tubular prostheses have seamless woven sections which gradually change the number of warp yarns to smoothly transition, i.e., taper, from one diameter to another. Multi-diameter endoluminal grafts having a variety of shapes and configurations are made using a seamless weaving process without unacceptable voids or gaps in the tubular wall.

Claims

1. A flat-woven tubular prosthesis comprising a varying diameter, single tubular wall portion having a first longitudinal expanse portion comprising a number of first warp yarns of a first polymer defining a tubular shape of a first diameter and transitioning therefrom a second longitudinal expanse portion comprising a number of second warp yarns of a second polymer defining a tubular shape of having a second diameter, wherein said first diameter is different from said second diameter.

2. The prosthesis of claim 1 wherein said polymers are thermoplastic polymers selected from the group consisting of polyesters, polypropylenes, polyethylenes, polyurethanes, polytetrafluoroethylenes and combinations thereof.

3. The prosthesis of claim 1 wherein said first and said second warp yarns are selected from the group consisting of flat yarns, textured yarns, twisted yarns, and combinations thereof.

4. The prosthesis of claim 1 wherein said first and said second warp yarns are capable of heat-setting at a temperature of about 190 to about 200°

C.

5. The prosthesis of claim 1 wherein said first diameter is substantially constant along said first expanse portion and further wherein said second diameter is substantially constant along said second expanse portion.

6. The prosthesis of claim 1 wherein said second diameter is variable along said second expanse portion.

7. The prosthesis of claim 1 wherein said second diameter increases longitudinally along said second expanse portion to define an outwardly tapered shape of said second expanse portion.

8. The prosthesis of claim 1, wherein first polymer is different from said second polymer.

9. The prosthesis of claim 1, wherein said number of first warp yarns equals said number of second warp yarns.