Method for producing a medical device

• US 9,192,489 B2
• Filed: 04/28/2011
• Issued: 11/24/2015
• Est. Priority Date: 04/28/2010
• Status: Active Grant

• Current Assignee: Acandis GmbH
• Original Assignee: Acandis GmbH & Co. KG
• Inventors: Zamponi, Christiane, Lima De Miranda, Rodrigo
• Primary Examiner(s): Chan, Sing P
• Application Number:
  US13/695,136
• Publication Number:
  US 20130199713A1
• Time in Patent Office: 1,671 Days
• Field of Search: 156/247, 156/249, 156/278
• US Class Current: 1/1
• CPC Class Codes: A61F 2/82 Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents stent-grafts for tubular structures of the body other than blood vessels A61F2/04; stent-grafts for blood vessels A61F2/07; instruments specially adapted for placement or removal of stents or stent-grafts A61F2/95; for closing wounds, or holding wounds closed A61B17/04 - A61B17/115; dilators A61M29/00
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes

Abstract

A method for producing a medical device with a lattice structure, connected at least in some areas to a cover. The lattice structure is arranged on a substrate via the side to be connected to the cover, the lattice structure has the side arranged on the substrate pressed at least partially into the substrate, the lattice structure is coated with a first layer of a sacrificial material. At least some of the interstices of the lattice structure are covered by the first layer, and the first layer with the lattice structure on the side to be connected to the cover forms a substantially closed surface, the substrate is removed, making the side of the lattice structure accessible for connection to the cover. A second layer for forming the cover is applied to the side of the lattice structure previously pressed into the substrate, and the sacrificial material is removed.

Claims

1. A method for producing a medical device with a lattice structure which is connected at least in some areas to a cover, in which method comprising

the lattice structure is arranged on a substrate via the side that is to be connected to the cover;

the lattice structure has the side arranged on the substrate pressed at least partially into the substrate;

the lattice structure is coated with a first layer of a sacrificial material, such that at least some of the interstices of the lattice structure are covered by the first layer, and the first layer, together with the lattice structure, forms a substantially closed surface on the side to be connected to the cover;

the substrate is removed, such that the side of the lattice structure is accessible that is to be connected to the cover;

a second layer for forming the cover is applied to the side of the lattice structure previously pressed into the substrate; and

the sacrificial material is removed.

2. The method as claimed in claim 1, wherein the lattice structure is pressed into the substrate in such a way that edges or lateral roundings of the lattice structure are embedded in the substrate.

3. The method as claimed in claim 1, wherein the ratio between the part of the lattice structure pressed into the substrate and the part of the lattice structure located outside the substrate is at least 0.0005, in particular at least 0.001, in particular at least 0.005, in particular at least 0.01, in particular at least 0.03, in particular at least 0.05, in particular at least 0.07, in particular at least 0.1, in particular at least 0.15, in particular at least 0.2.

4. The method as claimed in claim 1, wherein the substrate is flexible and/or has an outer layer of a flexible material, in particular an outer layer of photoresist or a viscous polymer, which outer layer yields when the substrate is pressed into.

5. The method as claimed in claim 4, wherein, in order to remove the substrate from the lattice structure, the outer layer of the substrate is removed.

10. The method as claimed in claim 1, wherein the second layer for forming the cover is applied by a gas phase deposition method, in particular a PVD method, in particular by sputtering.

11. The method as claimed in claim 1, wherein the second layer for forming the cover is structured after application, in particular by a lithographic method.

12. The method as claimed in claim 1, wherein, before the application of the second layer, a third layer of a sacrificial material is applied to the side of the lattice structure previously pressed into the substrate.

13. The method as claimed in claim 12, wherein the third layer of a sacrificial material is structured in such a way that the lattice structure is partially covered by the third layer, wherein in particular individual elements of the lattice structure are completely covered and/or not covered and/or partially covered.

14. The method as claimed in claim 1, wherein the substrate and/or the outer layer have a three-dimensional structure, in such a way that the structure is transferred to the subsequently applied layers.

15. The method as claimed in claim 1, wherein the second layer is applied using bioresorbable materials, in particular magnesium, and/or X-ray-visible materials, in particular tantalum, or in each case alloys thereof.

16. The method as claimed in claim 1, wherein the second layer is the sole layer for forming a single-ply cover, or at least one further layer, in particular several layers, are applied to the second layer in order to form a multi-ply cover.

6. The method as claimed in claim l, wherein the lattice structure, before being coated with the first layer of a sacrificial material, is coated with a start layer.

7. The method as claimed in claim l, wherein the sacrificial material of the first layer and/or the start layer are formed from a metallic material, in particular from the same metallic material or from different metallic materials.

8. The method as claimed in claim l, wherein the coating of the lattice structure with the start layer is carried out by a gas phase deposition method, in particular a PVD method, in particular by sputtering, and/or the coating of the lattice structure with the first layer of a sacrificial material is carried out by a galvanic method.

9. The method as claimed in claim l, wherein, during the coating of the lattice structure with the first layer of a sacrificial material, the lattice structure is partially or completely embedded in the sacrificial material.