Methods for manufacturing secured strand end devices

• US 9,149,374 B2
• Filed: 04/23/2014
• Issued: 10/06/2015
• Est. Priority Date: 10/22/2006
• Status: Active Grant

• Current Assignee: Idev Technologies, Inc. (Abbott Laboratories)
• Original Assignee: Idev Technologies, Inc. (Abbott Laboratories)
• Inventors: Sheldon, Jeffery, Booth, Richard, Bueche, Kenneth M.
• Primary Examiner(s): Bryant, David
• Assistant Examiner(s): YOO, JUN S
• Application Number:
  US14/260,213
• Publication Number:
  US 20140230204A1
• Time in Patent Office: 531 Days
• Field of Search: 294/39, 294/33, 294/37, 294/50, 623/1.11, 623/1.12, 623/1.15, 623/1.2, 623/1.22, 623/1.51, 623/1.53
• US Class Current: 1/1
• CPC Class Codes: A46D 1/0207 Bristles characterised by the choice of material, e.g. metal
• CPC Class Codes: A61F 2/06 Blood vessels
• CPC Class Codes: A61F 2/844 folded prior to deployment
• CPC Class Codes: A61F 2/86 Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure
• CPC Class Codes: A61F 2/885 comprising a coil including a plurality of spiral or helical sections with alternate directions around a central axis
• CPC Class Codes: A61F 2/90 characterised by a net-like or mesh-like structure
• CPC Class Codes: A61F 2/91 made from perforated sheet material or tubes, e.g. perforated by laser cuts or etched holes
• CPC Class Codes: A61F 2/915 with bands having a meander structure, adjacent bands being connected to each other
• CPC Class Codes: A61F 2/95 Instruments specially adapted for placement or removal of stents or stent-grafts
• CPC Class Codes: A61F 2/966 with relative longitudinal movement between outer sleeve and prosthesis, e.g. using a push rod
• CPC Class Codes: A61F 2002/061 provided with means for allowing access to secondary lumens
• CPC Class Codes: A61F 2002/91591 Locking connectors, e.g. using male-female connections
• CPC Class Codes: A61F 2002/9534 for repositioning of stents
• CPC Class Codes: A61F 2002/9665 with additional retaining means
• CPC Class Codes: A61F 2210/0014 using shape memory or superelastic materials, e.g. nitinol
• CPC Class Codes: A61F 2220/0058 soldered or brazed or welded
• CPC Class Codes: B23K 2101/32 Wires
• CPC Class Codes: B23K 2103/14 Titanium or alloys thereof
• CPC Class Codes: B23K 26/20 Bonding soldering by means of radiant energy B23K1/005; joining of preformed plastics parts by heating using laser beam B29C65/16
• CPC Class Codes: B23K 26/244 Overlap seam welding
• CPC Class Codes: D03D 3/02 : Tubular fabrics
• CPC Class Codes: D04C 1/06 : Braid or lace serving particular purposes
• CPC Class Codes: D06C 7/00 : Heating or cooling textile fabrics
• CPC Class Codes: D10B 2509/00 : Medical; Hygiene
• CPC Class Codes: D10B 2509/06 : Vascular grafts; stents
• CPC Class Codes: Y10T 29/49849 : by wrapping around

Abstract

A woven, self-expanding stent device has one or more strands and is configured for insertion into an anatomical structure. The device includes a coupling structure secured to two different strand end portions that are substantially aligned with each other. The two different strand end portions include nickel and titanium. The coupling structure is not a strand of the device.

Claims

1. A method of forming a self-expanding stent, the method comprising:

forming a first end of the stent by forming a first bend in each of a plurality of strands, each strand including a strand section on both sides of the first bend, each strand section including an end;

weaving the strand sections;

after weaving the strand sections, heat treating the plurality of strands for a first heat treatment time;

forming a second end of the stent by forming a second bend in each of the plurality of strands;

after forming the second bends, back braiding some of the strand sections, wherein back braiding some of the strand sections comprises passing the strand sections by at least two strand crossings;

securing a first strand section end and a second strand section end, the securing comprising securing the first strand section end and the second strand section end to a coupling structure; and

positioning the coupling structure radially inward of at least one said strand crossing the coupling structure,

wherein passing the strand sections by at least two strand crossings comprises passing the strand sections radially inward of at least one strand crossing and radially outward of at least one other strand crossing.

2. The method of claim 1, further comprising, after forming the second bends, heat treating the plurality of strands for a second heat treatment time.

3. The method of claim 1, wherein securing the first strand section end and the second strand section end comprises aligning the first strand section end and the second strand section end end-to-end.

4. The method of claim 1, wherein securing the first strand section end and the second strand section end comprises welding the coupling structure to the first strand section end and the second strand section end.

5. The method of claim 4, wherein welding the coupling structure to the first strand section end and the second strand section end comprises forming at least two welded regions spaced apart from each other.

6. The method of claim 4, wherein the coupling structure includes a passageway having a diameter sized to receive one said strand.

7. The method of claim 1, further comprising, after forming the second bends, trimming at least some of the strand sections.

8. The method of claim 7, wherein, after trimming at least some of the strand sections, the ends of the strand sections are each proximate to one end of the stent.

9. The method of claim 1, wherein securing the first strand section end and the second strand section end to the coupling structure comprises spacing apart the first strand section end from the second strand section end.

10. The method of claim 1, wherein securing the first strand section end and the second strand section end comprises overlapping the first strand section end and the second strand section end.

11. The method of claim 1, wherein back braiding some of the strand sections comprises passing the strand sections by at least three strand crossings.

12. The method of claim 1, wherein back braiding some of the strand sections comprises passing the strand sections by at least four strand crossings.

13. The method of claim 1, further comprising securing each of the strand section ends to another of the strand section ends to form pairs of secured ends.

14. The method of claim 13, wherein securing the pairs of secured ends comprises aligning the pairs of secured ends along an axial direction of the stent.

15. The method of claim 13, wherein securing the pairs of secured ends comprises offsetting each of the pairs of secured ends around a circumference of the stent.

16. The method of claim 1, wherein the plurality of strands comprise a plurality of biodegradable filaments.

17. The method of claim 16, wherein the plurality of biodegradable filaments are made from poly-L-lactic acid.

18. The method of claim 1, wherein securing the first strand section end and the second strand section end comprises welding.

19. A method of forming a self-expanding stent, the method comprising:

forming a first end of the stent by forming a first bend in each of a plurality of strands, each strand including a strand section on both sides of the first bend, each strand section including an end;

weaving the strand sections;

after weaving the strand sections, heat treating the plurality of strands for a first heat treatment time;

forming a second end of the stent by forming a second bend in each of the plurality of strands;

after forming the second bends, back braiding some of the strand sections, wherein back braiding some of the strand sections comprises passing the strand sections by at least two strand crossings; and

securing each of the strand section ends to another of the strand section ends to form pairs of secured ends, the securing comprising aligning the pairs of secured ends along an axial direction of the stent,

wherein passing the strand sections by at least two strand crossings comprises passing the strand sections radially inward of at least one strand crossing and radially outward of at least one other strand crossing.

20. The method of claim 19, further comprising, after forming the second bends, heat treating the plurality of strands for a second heat treatment time.

21. The method of claim 19, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises aligning end-to-end the strand section ends of each pair of secured ends.

22. The method of claim 19, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises welding a coupling structure to each pair of secured ends.

23. The method of claim 22, wherein welding the coupling structure to each pair of secured ends comprises forming at least two welded regions spaced apart from each other.

24. The method of claim 22, wherein the coupling structure includes a passageway having a diameter sized to receive one said strand.

25. The method of claim 19, further comprising, after forming the second bends, trimming at least some of the strand sections.

26. The method of claim 25, wherein, after trimming at least some of the strand sections, the ends of the strand sections are each proximate to one end of the stent.

27. The method of claim 19, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises securing a coupling structure to each pair of secured ends.

28. The method of claim 27, wherein securing the coupling structure to each pair of secured ends comprises spacing apart the strand section ends of each pair of secured ends.

29. The method of claim 19, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises overlapping the strand section ends of each pair of secured ends.

30. The method of claim 19, wherein back braiding some of the strand sections comprises passing the strand sections by at least three strand crossings.

31. The method of claim 19, wherein back braiding some of the strand sections comprises passing the strand sections by at least four strand crossings.

32. The method of claim 19, wherein the plurality of strands comprise a plurality of biodegradable filaments.

33. The method of claim 19, wherein the plurality of biodegradable filaments are made from poly-L-lactic acid.

34. The method of claim 19, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises welding.

35. A method of forming a self-expanding stent, the method comprising:

forming a first end of the stent by forming a first bend in each of a plurality of strands, each strand including a strand section on both sides of the first bend, each strand section including an end;

weaving the strand sections;

after weaving the strand sections, heat treating the plurality of strands for a first heat treatment time;

forming a second end of the stent by forming a second bend in each of the plurality of strands;

after forming the second bends, back braiding some of the strand sections, wherein back braiding some of the strand sections comprises passing the strand sections by at least two strand crossings; and

securing each of the strand section ends to another of the strand section ends to form pairs of secured ends, the securing comprising offsetting each of the pairs of secured ends around a circumference of the stent,

wherein passing the strand sections by at least two strand crossings comprises passing the strand sections radially inward of at least one strand crossing and radially outward of at least one other strand crossing.

36. The method of claim 35, further comprising, after forming the second bends, heat treating the plurality of strands for a second heat treatment time.

37. The method of claim 35, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises aligning end-to-end the strand section ends of each pair of secured ends.

38. The method of claim 35, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises welding a coupling structure to each pair of secured ends.

39. The method of claim 38, wherein welding the coupling structure to each pair of secured ends comprises forming at least two welded regions spaced apart from each other.

40. The method of claim 38, wherein the coupling structure includes a passageway having a diameter sized to receive one said strand.

41. The method of claim 35, further comprising, after forming the second bends, trimming at least some of the strand sections.

42. The method of claim 41, wherein, after trimming at least some of the strand sections, the ends of the strand sections are each proximate to one end of the stent.

43. The method of claim 35, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises securing a coupling structure to each pair of secured ends.

44. The method of claim 43, wherein securing the coupling structure to each pair of secured ends comprises spacing apart the strand section ends of each pair of secured ends.

45. The method of claim 35, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises overlapping the strand section ends of each pair of secured ends.

46. The method of claim 35, wherein back braiding some of the strand sections comprises passing the strand sections by at least three strand crossings.

47. The method of claim 35, wherein back braiding some of the strand sections comprises passing the strand sections by at least four strand crossings.

48. The method of claim 35, wherein the plurality of strands comprise a plurality of biodegradable filaments.

49. The method of claim 35, wherein the plurality of biodegradable filaments are made from poly-L-lactic acid.

50. The method of claim 35, wherein securing each of the strand section ends to another of the strand section ends to form pairs of secured ends comprises welding.