METHOD OF MANUFACTURING A TUBULAR MEDICAL IMPLANT

• US 20140277580A1
• Filed: 03/11/2014
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: SMed TA/TD, LLC. (Sites Medical LLC)
• Original Assignee: SMed TA/TD, LLC. (Sites Medical LLC)
• Inventors: Knapp, Troy D., Stalcup, Gregory C., Nebosky, Paul S., Jurick, Joseph W.
• Granted Patent: US 9,681,966 B2
• Time in Patent Office: Days
• US Class Current: 623/23.74
• CPC Class Codes: A61F 2/2846 Support means for bone substitute or for bone graft implants, e.g. membranes or plates for covering bone defects nets or sleeves applied to surface of endoprostheses A61F2/30907; bone plates A61B17/80; bone regeneration in dental surgery A61C8/0006
• 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 2/852 Two or more distinct overlapping stents
• CPC Class Codes: A61F 2002/30235 tubular, e.g. sleeves
• CPC Class Codes: A61F 2002/3092 having an open-celled or open-pored structure
• CPC Class Codes: A61F 2002/30971 Laminates, i.e. layered products
• CPC Class Codes: A61F 2210/0076 multilayered, e.g. laminated structures
• CPC Class Codes: A61F 2250/0023 differing in porosity

Abstract

A method of manufacturing a tubular medical implant is provided. The method includes forming a hollow first tube with a first diameter and a first plurality of pores formed thereon and a hollow second tube with a second unstretched diameter and a second plurality of pores formed thereon. The second unstretched diameter is greater than the first diameter. At least a portion of the first tube slides within the second tube to create an overlapped area of the first tube and the second tube. The first tube and second tube are then bonded together in the overlapped area.

Claims

1. A method of manufacturing a tubular medical implant, comprising the steps of:

forming a hollow first tube having a first diameter and a first plurality of pores formed thereon;

forming a hollow second tube having a second unstretched diameter and a second plurality of pores formed thereon, said second unstretched diameter being greater than said first diameter;

sliding at least a portion of said first tube within said second tube to create an overlapped area of said first tube and said second tube; and

bonding said first tube to said second tube in said overlapped area.

2. The method according to claim 1, wherein said first plurality of pores forms a first pore pattern and said second plurality of pores forms a second pore pattern.

3. The method according to claim 2, wherein said first pore pattern and said second pore pattern are different patterns.

4. The method according to claim 2, wherein said first pore pattern and said second pore pattern are the same pattern.

5. The method according to claim 2, wherein said bonding step is accomplished using at least one of diffusion bonding, sintering, laser welding, heat staking, thermal processing, ultrasonic welding and adhesive bonding.

6. The method according to claim 2, wherein said bonding step is accomplished by pressing said first tube and said second tube together at a bonding temperature and a bonding pressure.

7. The method according to claim 6, further comprising the step of providing a support rod within said first tube prior to said bonding step.

8. The method according to claim 2, wherein said second tube is in a substantially non-deformed state when sliding over said first tube.

9. The method according to claim 2, further comprising the step of aligning said first pore pattern relative to said second pore pattern prior to said bonding step to form an implant pore pattern.

10. The method according to claim 9, wherein said first tube is composed of at least one of a polymer, a metal and a ceramic and said second tube is composed of at least one of a polymer, a metal and a ceramic.

11. The method according to claim 10, wherein said implant pore pattern includes at least one pore formed through said implantable tubular structure.

12. The method according to claim 10, wherein said first tube and said second tube are aligned such that said first pore pattern and said second pore pattern have no overlap.

13. The method according to claim 2, wherein said first pore pattern and said second pore pattern are created by using at least one of chemical etching, photochemical etching, laser cutting, electron-beam machining, conventional machining, stamping, extrusion, rolling and knurling.

14. A tubular medical implant, comprising:

a first hollow tube including a first tube wall with a first plurality of pores formed thereon, said first hollow tube defining a first diameter;

a second hollow tube surrounding said first hollow tube to form an overlapped area and including a second tube wall with a second plurality of pores formed thereon, said second hollow tube defining a second unstretched diameter that is greater than said first diameter; and

a bonding interface between said first hollow tube and said second hollow tube at said overlapped area.

15. The tubular medical implant of claim 14, wherein said first plurality of pores forms an inner pore pattern and said second plurality of pores forms an outer pore pattern.

16. The tubular medical implant of claim 15, wherein said inner pore pattern and said outer pore pattern together form a plurality of implant pores forming a tubular implant pore pattern.

17. The tubular medical implant of claim 16, wherein a plurality of said implant pores extend entirely through said porous tubular implant.

18. The tubular medical implant of claim 17, wherein at least one of said plurality of implant pores is formed by a partial overlap of one of said first plurality of pores and one of said second plurality of pores.

19. The tubular medical implant of claim 18, wherein said bonding interface is at least one of an adhesive, a deformed material and a melted material.