Photocurable endoprosthesis methods of manufacture

• US 7,857,748 B2
• Filed: 10/19/2006
• Issued: 12/28/2010
• Est. Priority Date: 01/15/2003
• Status: Expired due to Fees

• Current Assignee: 2120812 Ontario Inc.
• Original Assignee: SYNE COR LLC
• Inventors: Williams, Michael S., Glenn, Richard A., Smith, Jeffrey A., DeSimone, Joseph M., Holbrook, Kevin D.
• Primary Examiner(s): PREBILIC, PAUL B
• Application Number:
  US11/584,784
• Publication Number:
  US 20070038284A1
• Time in Patent Office: 1,531 Days
• Field of Search: 623/1.21
• US Class Current: 600/36
• CPC Class Codes: A61F 2/958 Inflatable balloons for placing stents or stent-grafts
• CPC Class Codes: A61F 2002/30583 filled with hardenable fluid, e.g. curable in-situ
• CPC Class Codes: A61F 2210/0085 hardenable in situ, e.g. epoxy resins
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 35/0266 Local curing for repairing B29C73/34
• CPC Class Codes: B29C 71/04 by wave energy or particle radiation , e.g. for curing or vulcanising preformed articles during moulding, e.g. in a mould B29C35/08
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses

Abstract

Methods of manufacture of endoprostheses comprising one or more photocurable materials are disclosed. The endoprostheses may comprise regions wherein the photocurable materials are selectively disposed about the endoprosthesis and are cured according to desired parameters to achieve varying desired properties. Photolithographic masking material may be selectively disposed about an inflatable balloon and exposed to a radiation emitting catheter.

Claims

1. A method of manufacture of an endoprosthesis comprising the steps of:

providing an endoprosthesis comprising a first curable material, a first region and a second region, wherein said first curable material is curable by exposure to a radiation source;

providing a radiation emitting catheter comprising an inflatable balloon, wherein said balloon comprises a photolithographic masking coating to prevent the exposure of said first region of said endoprosthesis to radiation;

selectively curing said first curable material.

2. The method of claim 1 wherein said endoprosthesis further comprises a second curable material.

3. The method of claim 1 further comprising the steps of:

placing said endoprosthesis within a body lumen;

selectively exposing said endoprosthesis to radiation.

4. The method of claim 3 wherein said step of selectively exposing said endoprosthesis to radiation further comprises:

inflating said balloon within said endoprosthesis;

allowing said radiation emitting catheter to emit radiation, whereby said endoprosthesis is selectively exposed to radiation by the photolithographic masking coating.

5. A method of manufacture of an endoprosthesis comprising:

providing a balloon catheter comprising a balloon;

inflating said balloon to nominal pressure;

applying a photolithographic masking coating to said balloon in a predetermined pattern;

applying a photocurable film over said balloon;

introducing a radiation source within said balloon;

curing said film at a first wavelength;

removing non-cured material;

deflating said balloon;

packaging and sterilizing said endoprosthesis and balloon catheter;

inserting said endoprosthesis into the vasculature of a patient;

inflating said balloon proximate a lesion;

curing said prosthesis at a second wavelength;

deflating said balloon;

removing said balloon catheter.

6. The method of claim 5 wherein said predetermined pattern comprises a negative image of an endoprosthesis to be cured in stages on said balloon.

7. The method of claim 5 wherein said first wavelength is in a range of between 320 and 350 nm and said second wavelength is in a range of between 365 and 400 nm.

8. A method of manufacture of an endoprosthesis comprising the steps of

coextruding a first curable material and a second curable material to form a generally tubular structure;

cutting portions from said tube to define a desired pattern;

initiating curing of said first curable material and said second curable material.

9. The method of claim 8 wherein said first curable material cures by exposure to radiation at a first wavelength, and said second curable material cures by exposure to radiation at a second wavelength, and wherein the method further comprises the additional steps of selectively exposing said extruded tube to radiation at said first wavelength, and selectively exposing said extruded tube to radiation at said second wavelength.

10. The method of claim 9 wherein said first wavelength is between 320 and 350 nm and said second wavelength is between 365 and 400 nm.

11. The method of claim 9 wherein the step of selectively exposing said extruded tube to radiation at a first wavelength comprises:

placing said endoprosthesis within a body lumen;

providing a balloon catheter and inflating said balloon to nominal pressure;

introducing a radiation emitting device;

activating said radiation device to cure material at said first wavelength;

activating said radiation device to cure material at said second wavelength;

removing said catheter from said body lumen.