Polymer stents and methods of manufacture

• US 9,801,980 B2
• Filed: 12/20/2011
• Issued: 10/31/2017
• Est. Priority Date: 12/20/2010
• Status: Active Grant

• Current Assignee: Microvention Incorporated (Terumo Corporation)
• Original Assignee: Microvention Incorporated (Terumo Corporation)
• Inventors: Karino, Wataru, Plotkin, Steve, Cruise, Gregory M.
• Primary Examiner(s): Daniels, Matthew
• Assistant Examiner(s): Stewart, Kimberly A
• Application Number:
  US13/332,048
• Publication Number:
  US 20120187604A1
• Time in Patent Office: 2,142 Days
• Field of Search: None
• CPC Class Codes: A61L 31/048 obtained by reactions only involving carbon-to-carbon unsaturated bonds A61L31/041 takes precedence
• CPC Class Codes: A61L 31/14 Materials characterised by their function or physical properties , e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 39/006 Monomers or prepolymers by reaction injection moulding B29C67/246
• CPC Class Codes: B29C 39/02 for making articles of definite length, i.e. discrete articles

Abstract

Methods of forming and/or manufacturing polymeric stents are disclosed. Polymeric stents are also disclosed.

Claims

1. A method of forming a polymeric stent comprising:

preparing a prepolymer solution comprising a macromer, a monomer and a crosslinker, wherein the macromer includes ethoxylated trimethylol propane triacrylate;

forcing the prepolymer solution onto a textured surface of a first tube wherein the forcing is accomplished by injecting the prepolymer solution into voids created by the textured surface of the first tube and an inner surface of a second tube when the first tube fits inside the second tube and the textured surface of the first tube fits against the inner surface of the second tube;

initiating polymerization of the prepolymer solution to form a polymeric tube on the textured surface; and

modifying the polymeric tube into a desired shape or pattern, wherein the formed polymeric stent has a hydrated radial force of about 1 gf to about 50 gf.

2. The method according to claim 1 wherein the textured surface has a cross-hatched pattern.

3. The method according to claim 1 wherein the first tube substantially fits within the second tube.

4. The method according to claim 1 wherein the modifying comprises laser cutting the polymeric stent to an appropriate length.

5. The method according to claim 1 wherein initiating polymerization of the prepolymer solution is accomplished using heat.

6. The method according to claims 1 wherein initiating polymerization of the prepolymer solution is accomplished using ultraviolet light.

7. The method according to claim 1 wherein the prepolymer solution comprises at least one of alkyl methacrylate, ethylene glycol dimethacrylate, ethoxylated trimethylol propane triacrylate, pentaerythritol triacrylate, di(trimethylol propane) tetraacrylate, hydroxyethyl methacrylate, divinyl benzene, isopropyl alcohol or a combination thereof.

8. A method of forming a polymeric stent comprising:

preparing a prepolymer solution comprising a macromere, a monomer and a cross linker, wherein the macromere includes ethoxylated trimethylol propane triacrylate;

distributing the prepolymer solution onto an outer textured surface of a tube by injecting the prepolymer solution between the outer textured surface and the inner surface of a second tube fit substantially around the outer textured surface wherein the outer textured surface of the tube fits against the inner surface of the second tube;

initiating polymerization of the prepolymer solution using heat;

forming a polymeric stent on the outer textured surface; and

removing the polymeric stent from the tube, wherein the formed polymeric stent has a hydrated radial force of about 1 gf to about 50 gf.

9. A method of forming a polymeric stent comprising:

preparing a prepolymer solution comprising a macromere, a monomer and a cross linker, wherein the macromere includes ethoxylated trimethylol propane triacrylate;

distributing the prepolymer solution onto an inner textured surface of a tube by injecting the prepolymer solution between the inner textured surface and an outer surface of a second tube fit substantially inside the inner textured surface wherein the inner textured surface fits against the outer surface of the second tube;

initiating polymerization of the prepolymer solution using heat;

forming a polymeric stent on the inner textured surface; and

removing the polymeric stent from the tube, wherein the formed polymeric stent has a hydrated radial force of about 1 gf to about 50 gf.