Surface modified expanded polytetrafluoroethylene devices and methods of producing the same

• US 6,780,497 B1
• Filed: 08/05/1999
• Issued: 08/24/2004
• Est. Priority Date: 08/05/1999
• Status: Expired due to Term

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: Gore Enterprise Holdings Incorporated (W.L. Gore and Associates)
• Inventors: Walter, James Todd
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): Vo, Hai
• Application Number:
  US09/369,231
• Time in Patent Office: 1,846 Days
• Field of Search: 428/141, 428/143, 428/158, 428/167, 428/168, 428/315.5, 428/311.51, 428/543, 204/157.15, 204/157.61
• US Class Current: 428/311.51
• CPC Class Codes: A61F 2/0077 Special surfaces of prostheses, e.g. for improving ingrowth A61F2/30767 takes precedence
• CPC Class Codes: A61L 27/16 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• 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: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 5/00 Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24579 with particulate matter
• CPC Class Codes: Y10T 428/249964 Fibers of defined composition
• CPC Class Codes: Y10T 428/249978 Voids specified as micro
• CPC Class Codes: Y10T 428/8305 Miscellaneous [e.g., treated surfaces, etc.]

Abstract

Improved processes for surface treating expanded polytetrafluoroethylene (PTFE) is disclosed and improved surface-treated devices made from the processes. The processes employ a laser to surface-modify an expanded PTFE structure to create a macro-roughened surface that has the capability to remain microporous throughout. The unique process of the present invention creates a ridge and valley structure on the surfaces of devices that includes unique gnarled nodes along valley floors.

Claims

1. A material comprising:

a surface comprising expanded PTFE having a node and fibril microstructure;

the surface having a number of node clusters, said node dusters comprising multiple nodes interconnected by fibrils, and gnarled nodes situated between the node clusters; and

said gnarled nodes having a protruding length and being substantially devoid of fibrils along the protruding length.

2. A material according to claim 1 wherein

at least one gnarled node has a protruding length measured from a valley surface;

the gnarled node is adjacent to a ridge having a height; and

the gnarled node protruding length is greater than the height of the adjacent ridge.

3. A material according to claim 1 wherein

the gnarled node has a longitudinal axis and a protruding length measured from the valley surface;

and

the longitudinal axis has at least two angular deflection points.

4. A material according to claim 1 wherein

said surface comprises a textured pattern having multiple ridges;

and

the multiple ridges are substantially parallel to each other.

5. A material according to claim 1 wherein

the material is a sheet having two opposing surfaces;

and

one opposing surface has multiple ridges and valleys.

6. A material according to claim 1 wherein

the material is a sheet having two opposing surfaces;

and

the two opposing surfaces have multiple ridges and valleys.

7. A material according to claim 1 wherein the material comprises an implantable medical device.

8. A material according to claim 7 wherein the material comprises an implantable sheet.

9. A material comprising:

a surface comprising expand d PTFE having a node and fibril microstructure;

said surface comprising a textured pattern having multiple ridges and valley surfaces, the ridges comprised of node clusters;

said node clusters comprising multiple nodes interconnected by fibrils;

the valley surfaces having gnarled nodes protruding therefrom; and

said gnarled nodes having a protruding length and being substantially devoid of fibrils along the protruding length.

10. A material according to claim 9 wherein

at least one gnarled node has a protruding length measured from a valley surface;

the gnarled node is adjacent to a ridge having a height; and

the gnarled node protruding length is greater than the height of the adjacent ridge.

11. A material according to claim 9 wherein

a gnarled node has a longitudinal axis and a protruding length measured from the valley surface;

and

the longitudinal axis has at least two angular deflection points.

12. A material according to claim 9 wherein the multiple ridges are substantial parallel to each other.

13. A material according to claim 9 wherein

the material is a sheet having two opposing surfaces;

and

one opposing surface has mu pie ridges and valleys.

14. A material according to claim 9 wherein

the material is a sheet having two opposing surfaces;

and

two opposing surfaces have multiple ridges and valleys.

15. A material according to claim 9 wherein the material comprises an implantable medical device.

16. A material according to claim 15 wherein the material comprises an implantable sheet.

17. A material comprising:

expanded PTFE having a node and fibril microstructure;

at least one node having a protruding length measured from a valley surface, the at least one node being substantially devoid of fibrils along its protruding length;

the at least one node being adjacent to a ridge having a height; and

the protruding length of the node being greater than the height of the adjacent ridge.

18. A material according to claim 17 wherein

the surface comprises a PTFE having a node and fibril microstructure; and

the surface has a number of node clusters, said node clusters comprising multiple nodes interconnected by fibrils, and the at least one node having a protruding length is situated between the node clusters.

19. A material according to claim 17 wherein

the at least one node having a protruding length node has a longitudinal axis;

and

the longitudinal axis has at least two angular deflection points.

20. A material according to claim 17 wherein

the material includes a surface having a textured pattern having multiple ridges;

and

the multiple ridges are substantially parallel to each other.

21. A material according to claim 17 wherein

the material is a sheet having two opposing surfaces;

and

one opposing surface has multiple ridges and valleys.

22. A material according to claim 17 wherein

the material is a sheet having two opposing surfaces;

and

the two opposing surfaces have multiple ridges and valleys.

23. A material according to claim 17 wherein the material comprises an implantable medical device.

24. A material according to claim 23 wherein the material comprises an implantable sheet.