U.S. patent application number 09/410329 was filed with the patent office on 2002-05-02 for a method of making an expandable fluoropolymer device.
Invention is credited to GINGRAS, PETER H., HERWECK, STEVE A., KARWOSKI, THEODORE, MARTAKOS, PAUL.
Application Number | 20020050661 09/410329 |
Document ID | / |
Family ID | 26814975 |
Filed Date | 2002-05-02 |
United States Patent
Application |
20020050661 |
Kind Code |
A1 |
HERWECK, STEVE A. ; et
al. |
May 2, 2002 |
A METHOD OF MAKING AN EXPANDABLE FLUOROPOLYMER DEVICE
Abstract
A radially expandable device having a body constructed of a
generally inelastic, expanded fluoropolymer material is described.
The body is deployable upon application of a radial expansion force
from a reduced diameter, collapsed configuration to an expanded
configuration having a pre-defined and fixed increased diameter.
The body has a singular, unitary construction of generally
homogenous material that is characterized by a seamless
construction of expanded fluoropolymer material, such as expanded
polytetrafluoroethylene (ePTFE), and is preferably constructed
through an extrusion and expansion process. The body is further
characterized by a microstructure of nodes interconnected by
fibrils in which substantially all the nodes of the body are
oriented generally perpendicularly to the longitudinal axis of the
body. The monolithic construction of the body and the orientation
of the nodes, perpendicular to the longitudinal axis of the body,
yields a radially expandable device that predictably and dependably
expands to a predefined, fixed maximum diameter that is generally
independent of the expansion force used to radially expand the
device.
Inventors: |
HERWECK, STEVE A.; (NASHUA,
NH) ; GINGRAS, PETER H.; (WINDHAM, NH) ;
MARTAKOS, PAUL; (PELHAM, NH) ; KARWOSKI,
THEODORE; (HOLLIS, NH) |
Correspondence
Address: |
LAHIVE & COCKFIELD
28 STATE STREET
BOSTON
MA
02109
US
|
Family ID: |
26814975 |
Appl. No.: |
09/410329 |
Filed: |
October 1, 1999 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60117152 |
Jan 25, 1999 |
|
|
|
Current U.S.
Class: |
264/127 ;
264/235; 264/323; 264/523; 264/540 |
Current CPC
Class: |
B29C 48/00 20190201;
A61L 29/041 20130101; B32B 2305/026 20130101; B29C 55/24 20130101;
A61M 25/10 20130101; B29L 2022/022 20130101; B29C 2049/465
20130101; B29L 2031/753 20130101; C08L 27/18 20130101; A61L 29/041
20130101; B29K 2027/18 20130101; B29C 48/09 20190201; B29C 48/10
20190201 |
Class at
Publication: |
264/127 ;
264/523; 264/540; 264/235; 264/323 |
International
Class: |
B29B 011/10; B29C
049/04 |
Claims
Having described the invention, what is claimed as new and desired
to be secured by Letters Patent is:
1. A radially expandable device comprising: a body constructed of a
fluoropolymer material, the body having a longitudinal axis and a
wall having a thickness transverse to the longitudinal axis, the
wall having a microstructure of nodes interconnected by fibrils,
substantially all the nodes being oriented generally
perpendicularly to the longitudinal axis of the body along at least
a portion of the body, the body being deployable from a reduced
diameter, collapsed configuration to an increased diameter,
expanded configuration upon application of an expansion force.
2. The device of claim 1, wherein the body is expandable to a
pre-defined and fixed increased diameter that is generally
independent of the expansion force used to expand the device to the
expanded configuration.
3. The device of claim 1, wherein the fluoropolymer material is
expanded polytetrafluoroethylene (ePTFE).
4. The device of claim 1, wherein the body is tubular in shape and
wherein the wall extends radially between an inner and an outer
surface.
5. The device of claim 4, wherein the nodes are oriented such that
spaces between the nodes form channels oriented and extending from
the inner surface to the outer surface of the wall.
6. The device of claim 1, wherein the nodes are separated by an
internodal distance, the internodal distance being approximately 1
.mu.m-150 .mu.m.
7. The device of claim 1, wherein the body is monolithic in
construction.
8. A method of manufacturing a radially expandable device, the
method comprising the steps of: forming a tube of expanded
fluoropolymer material having an initial diameter, applying a
radial expansion force to the tube to expand the tube from the
initial diameter to a second diameter, and removing the expansion
force, wherein the tube is radially expandable from a reduced
diameter configuration to the second diameter upon application of a
radial deployment force from a deployment mechanism within the
tube.
9. The method, of claim 8, wherein the step of forming the tube
comprises the steps of: creating a billet by blending a mixture of
a fluoropolymer and a lubricant and compressing the mixture,
extruding the billet to form an extruded article having a
longitudinal axis, removing the lubricant from the extruded
article, expanding the extruded article to form a tube of expanded
fluoropolymer material, and heat setting the tube.
10. The method of claim 9, wherein the fluoropolymer is
polytetrafluoroethylene (PTFE).
11. The method of claim 9, wherein the step of expanding the
extruded article further comprises bilaterally stretching the
extruded article in two opposing directions along the longitudinal
axis to yield an article which is substantially uniformly stretched
over a major portion of its length and has a microstructure of
nodes interconnected by fibrils.
12. The method of claim 11 wherein the step of expanding the
extruded article includes longitudinally stretching the extruded
article from an initial length to a stretched length at a stretch
rate.
13. The method of claim 12, further comprising selecting an amount
of radial deployment force sufficient to radially expand the tube
to the second diameter by varying a stretch ratio of the stretched
length to the initial length.
14. The method of claim 13, further comprising selecting an amount
of radial deployment force sufficient to radially expand the tube
to the second diameter by varying the stretch rate.
15. The method of claim 8, wherein the radially expandable device
is expandable to a maximum diameter generally equal to the second
diameter.
16. The method of claim 15, wherein the maximum diameter is
generally independent of a deployment force applied by the
deployment mechanism.
17. The method of claim 8, wherein the deployment mechanism is a
fluid.
18. The method of claim 8, wherein the step of applying a radial
expansion force includes inserting a balloon into the tube, and
expanding the balloon to apply the radial expansion force to the
tube.
19. The method of claim 18, wherein the balloon is expanded by
inflation with a fluid.
20. The method of claim 19, wherein the balloon is constructed of
an inelastic material.
21. The method of claim 20, wherein the balloon is expandable to a
predefined size and shape.
22. The method of claim 21, wherein the balloon expands the tube to
the predetermined size and shape.
23. The method of claim 22, further comprising providing a mold
having an internal cavity, positioning the tube within the internal
cavity, and radially expanding the balloon within the tube while
the tube remains positioned in the internal cavity.
24. The method of claim 23, wherein the internal cavity has a size
and shape analogous to the predefined size and shape of the
balloon.
25. The method of claim 18, wherein the balloon and the tube are
heated to approximately 35.degree. C.-60.degree. C. during the step
of radial expanding.
26. The method of claim 8, wherein the step of radially expanding
the tube plastically deforms the tube beyond its elastic limit.
27. The method of claim 8, wherein the step of applying a radial
expansion force includes inserting a second tube of extruded
material into the tube, and expanding the second tube to apply the
radial expansion force to the tube.
28. The method of claim 27, wherein the tube and the second tube
are heated to the glass transition temperature of the extruded
material during the step of radial expansion.
29. The method of claim 27, further comprising providing a mold
having an internal cavity, positioning the tube and the second tube
within the internal cavity, and radially expanding the tube within
the internal cavity.
30. The method of claim 29, further comprising heating the tube and
the second tube to the glass transition temperature of the extruded
material during the step of radially expanding the tube within the
internal cavity of the mold.
31. The method of claim 8, further comprising heat setting the tube
after the step of applying a radial expansion fore to the tube.
32. A radially expandable medical treatment device comprising: a
tubular body constructed of a generally inelastic, expanded
fluoropolymer material and having a longitudinal axis and a wall
having a radial thickness transverse to the longitudinal axis and
extending between an inner and an outer surface, the wall having a
microstructure of nodes interconnected by fibrils, substantially
all the nodes being oriented generally perpendicularly to the
longitudinal axis of the tube, the body being deployable upon
application of an expansion force from a reduced diameter,
collapsed configuration to an increased diameter expanded
configuration.
33. The treatment device of claim 32, wherein the medical treatment
device is a catheter balloon suitable for deployment within a body
vessel by a catheter.
34. The treatment device of claim 32, wherein the tubular body of
the medical treatment device is sized and shaped to facilitate
passage through an obstruction in the body vessel.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Provisional Application
Ser. No. 60/117,152, filed Jan. 25, 1999, and incorporated herein
by reference.
BACKGROUND OF THE INVENTION
[0002] Radially expandable devices are utilized in a wide range of
applications including a number of biological applications.
Radially expandable devices in the form of inflatable balloons have
been proposed for treatment of body passages occluded by disease
and for maintenance of the proper position of catheter delivered
medical devices within such body passages. Such expandable devices
can be constructed of elastomeric materials such as latex. A number
of general problems are associated with such elastomeric balloons.
Balloons and other expansion devices constructed of elastomeric
materials can lack a maximum inflation or expansion diameter in
that the prolonged application of an inflation medium will cause
the balloon to continuously expand until the balloon bursts. Thus,
over inflation of an elastomeric balloon may result in damage to
the body vessel or organ being treated or may result in the balloon
bursting within the body. Elastomeric balloons frequently do not
inflate symmetrically and may not inflate to the desired size and
shape. Asymmetrical expansion, as well as failure of the balloon to
properly inflate, can lead to incomplete treatment of the body
vessel. The high coefficient of friction of most elastomeric
materials, such as latex, can result in damage to one or more
cellular layers of the wall of the body vessel or organ being
treated. Additionally, elastomeric expansion devices generally have
insufficient strength for a number of applications, such as
compressing deposits formed on vascular walls and positioning
catheter delivered medical devices.
SUMMARY OF THE INVENTION
[0003] The present invention provides a radially expandable device
having a body constructed a fluoropolymer material, such as
expanded polytetrafluoroethylene (ePTFE). The use of fluoropolymer
materials provides a radial expandable device having a
biocompatible and inelastic construction that is suitable for
numerous uses including the treatment of body vessels, organs, and
implanted grafts. The body of the radially expandable device has a
longitudinal axis and a wall having a thickness transverse to the
longitudinal axis. The wall of the body is characterized by a
microstructure of nodes interconnected by fibrils. The body of the
radially expandable device is deployable from a reduced diameter,
collapsed configuration to an increased diameter, expanded
configuration upon application of an expansion force to the
radially expandable device. Along at least a portion of the body,
substantially all the nodes of the microstructure are oriented
generally perpendicularly to the longitudinal axis of the body.
This orientation of the nodes, perpendicular to the longitudinal
axis of the body, yields a radially expandable device that
predictably and dependably expands to the increased diameter
configuration.
[0004] According to one aspect of the present invention, the body
of the radially expandable device has a monolithic construction.
The term "monolithic", as used herein, includes structures having a
singular, unitary construction of generally homogenous material.
The monolithic body of the radially expandable device of the
present invention is characterized by a seamless construction of
fluoropolymer material, such as expanded polytetrafluoroethylene
(ePTFE), preferably constructed through an extrusion and expansion
process. Because the cross section of the monolithic body is
singular or unitary, the expandable device lacks seams or internal
interfaces between adjacent layers that can result in unreliable
expansion of the device. The monolithic construction of the body of
the present invention contributes to the dependable and predictable
expansion of the body to a predefined, fixed maximum diameter that
is generally independent of the expansion force used to radially
expand the device.
[0005] In accordance with a further aspect of the present
invention, a method is provided for manufacturing a radially
expandable device constructed of a fluoropolymer material such as,
for example, ePTFE. The method includes the step of forming a tube
of fluoropolymer material having an initial diameter. A radial
expansion force is applied to the tube to expand the tube from the
initial diameter to a second diameter. The expansion force is then
removed. The resultant tube is radially expandable from a reduced
diameter to the second diameter upon application of a radial
deployment force from a deployment mechanism within the tube. The
deployment mechanism can be, for example, a fluid injected into the
tube or a radial expansion element inserted into the tube.
[0006] A radially expandable device constructed in accordance with
the method of the present invention can be dependably and
predictably expanded to the second diameter upon the application of
a radially deployment force within the tube. The second diameter
can be predefined and fixed to a maximum expansion diameter through
the manufacturing process of the present invention, resulting in an
expansion device having a maximum expansion diameter that is
generally independent of the radial deployment force applied to the
device.
[0007] The fluoropolymer tube can be constructed through an
extrusion and expansion process including the step of creating a
billet by blending a mixture of a fluoropolymer and a lubricant and
compressing the mixture. The fluoropolymer is preferably PTFE. The
billet can then be extruded to form an extruded article. The
lubricant is removed and the extruded article is expanded to form a
monolithic tube of inelastic, expanded fluoropolymer material. The
stretched tube is then heat set to lock in the microstructure of
the tube and maintain the tube in the stretched state.
[0008] The extruded article is preferably bilaterally stretched in
two opposing directions along the longitudinal axis of the article.
Bilaterally stretching the extruded article yields an article that
is substantially uniformly stretched over a major portion of its
length and has a microstructure of nodes interconnected by fibrils.
The bilateral stretching step can be carried out by displacing the
ends of the extruded article either simultaneously or sequentially.
The longitudinal stretch ratio of the expanded tube, i.e., the
ratio of the final stretched length of the tube to the initial
length, and the diametric stretch ratio, i.e., the ratio of the
final diameter, after longitudinal stretching, and the initial
diameter, can be varied to yield an expansion device having
differing radial expansion properties. For example, the magnitude
of the deployment force necessary to expand the expansion device of
the present invention can be pre-selected and manipulated by
varying the stretch ratios of the fluoropolymer tube. Additionally,
the stretch rate can be varied to selectively provide the expansion
device with improved expansion characteristics.
[0009] In accordance with another aspect of the present invention,
the step of applying a radial expansion force to the fluoropolymer
tube is carried out by inserting a balloon into the tube and
expanding the balloon to apply the radial expansion force to the
tube. Preferably, the balloon is constructed from an inelastic
material such as, for example, polyethylene terephthalate (PET) or
nylon. In a preferred embodiment, the balloon is constructed to be
expandable to a predefined size and shape by inflation with a
fluid. Radial expansion of the fluoropolymer tube with such an
inelastic balloon imparts the predetermined size and shape of the
balloon to the expanded fluoropolymer balloon.
[0010] In accordance with a further aspect of the present
invention, the step of radially expanding the fluoropolymer tube
plastically deforms the tube beyond its elastic limit to the second
diameter. Plastically deforming the fluoropolymer tube to the
second diameter contributes to expansion device dependably
expanding to the second diameter upon application of the radial
deployment force.
[0011] The step of radially expanding the fluoropolymer tube can
also include the steps of positioning the tube within the internal
cavity of a mold fixture and radially expanding the balloon within
the tube while the tube remains positioned in the internal mold
cavity. The internal mold cavity preferably has a size and shape
analogous to the predefined size and shape of the balloon. The
internal cavity of the mold facilitates concentric radial expansion
of the balloon and the fluoropolymer tube.
[0012] In accordance with another aspect of the present invention,
the step of applying a radial expansion force to the fluoropolymer
tube is carried out by inserting a second tube constructed from an
extruded inelastic material, such as extruded PET, into the
fluoropolymer tube and expanding the second tube to apply the
radial expansion force to the tube. Preferably, the fluoropolymer
tube and the second tube are heated to a temperature less than or
equal to the glass transition temperature of the extruded material
forming the second tube during the radial expansion step. The
heating of the tubes can be accomplished by submerging the tubes
into a hot water bath. Alternatively, the fluoropolymer tube can be
expanded by the second tube within a heated mold.
[0013] In accordance with a further aspect of the present
invention, the radially expandable device of the present invention
is particularly suited for treatment of body passages occluded by
disease. The expandable device can be utilized in the manner of a
catheter balloon suitable for deployment within a body vessel by a
catheter. Exemplary treatment applications of the present
application include dilation of stenoic blood vessels in a
percutaneous transluminal angioplasty procedure (PTA), removal of
thrombi and emboli from obstructed blood vessels, urethra dilation
to treat prostatic enlargement due to benign prostate hyperplasia
(BPH) or prostatic cancer, and generally restoring patency to
implanted grafts or body passages such as blood vessels, the
urinary tract, the intestinal tract, the kidney ducts, or other
body passages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other features and advantages of the present
invention will be more fully understood by reference to the
following detailed description in conjunction with the attached
drawings in which like reference numerals refer to like elements
through the different views. The drawings illustrate principles of
the invention and, although not to scale, show relative
dimensions.
[0015] FIG. 1 is a side elevational view in cross-section of a
radially expandable device according to the teachings of the
present invention, illustrating the device in a first, reduced
diameter configuration;
[0016] FIG. 2 is a side elevational view in cross-section of the
radially expandable device of FIG. 1, illustrating the device in a
second, increased diameter configuration;
[0017] FIG. 3 is a schematic representation of the microstructure
of a section of the wall of an expanded fluoropolymer tube used
during the manufacturing process of the present invention to yield
the radially expandable device of the present invention;
[0018] FIG. 4A is a side elevational view in cross-section of an
inelastic balloon positioned within an expanded fluoropolymer tube,
illustrating the inelastic balloon in a deflated condition in
accordance with a method of manufacturing a radially expandable
device according to the teachings of the present invention;
[0019] FIG. 4B is a side elevational view in cross-section of the
inelastic balloon and the expanded fluoropolymer tube of FIG. 4A,
illustrating the inelastic balloon in an inflated condition in
accordance with a method of manufacturing a radially expandable
device according to the teachings of the present invention;
[0020] FIG. 4C is a side elevational view in cross-section of the
inelastic balloon and the expanded fluoropolymer tube of FIG. 4A,
illustrating the removal of the deflated inelastic balloon from the
expanded fluoropolymer tube in accordance with a method of
manufacturing a radially expandable device according to the
teachings of the present invention;
[0021] FIG. 5 is a side elevational view of an inelastic balloon
and an expanded fluoropolymer tube positioned within the internal
cavity of a mold fixture, illustrating the inelastic balloon in a
inflated condition in accordance with a method of manufacturing a
radially expandable device according to the teachings of the
present invention;
[0022] FIG. 6A is a flow chart illustrating the steps of
manufacturing a radially expandable device according to the
teachings of the present invention;
[0023] FIG. 6B is a flow chart illustrating the steps of an
alternative method of manufacturing a radially expandable device
according to the teachings of the present invention;
[0024] FIG. 7A is a side elevational view in cross section of a
generally pear-shaped radially expandable device in accordance with
the teaching of the present invention;
[0025] FIG. 7B is a side elevational view in cross section of a
generally hour glass shaped radially expandable device in
accordance with the teaching of the present invention;
[0026] FIG. 7C is a side elevational view in cross section of two
coaxially aligned, adjacent radially expandable devices in
accordance with the teaching of the present invention; and
[0027] FIG. 8 is a side elevational view in cross section of a
catheter deployed dilation balloon according to the teaching of the
present invention, illustrating the dilation balloon expanded
within a body vessel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] A radially expandable device 10 having a body 12 constructed
of a generally inelastic, expanded fluoropolymer material is
illustrated in FIGS. 1 and 2. Expandable devices provided by the
present invention are suitable for a wide range of applications
including, for example, a range of medical treatment applications.
Exemplary biological applications include use as a catheter balloon
for treatment of implanted grafts and body passages such as blood
vessels, the urinary tract, the intestinal tract, kidney ducts,
etc. Specific examples include as a device for the removal of
obstructions such as emboli and thrombi from blood vessels, as a
dilation device to restore patency to an occluded body passage as
an occlusion device to selectively obstruct a body passage, and as
a centering mechanism for transluminal instruments and catheters.
The expandable device of the present invention can also be used as
a sheath for covering conventional catheter balloons to control the
expansion of the conventional balloon.
[0029] The body 12 of the radially expandable device 10 is
deployable upon application of an expansion force from a first,
reduced diameter configuration, illustrated in FIG. 1, to a second,
increased diameter configuration, illustrated in FIG. 2. The body
12 of the expansion device 10 of the present invention preferably
features a monolithic construction, i.e., the body 12 is a
singular, unitary article of generally homogeneous material. The
body 12 is manufactured in accordance with the methods of
manufacturing of the present invention, an extrusion and expansion
process described in detail below, to yield a body 12 characterized
by a seamless construction of inelastic, expanded fluoropolymer
having a predefined size and shape in the second, increased
diameter configuration. The body 12 can be dependably and
predictably expanded to the predefined, fixed maximum diameter and
to the predefined shape independent of the expansion force used to
expand the device.
[0030] Referring specifically to FIG. 2, the body 12 of the radial
expansion device 10 of the present invention is preferably
generally tubular in shape when expanded, although other cross
sections, such as rectangular, oval, elliptical, or polygonal, can
be utilized. The cross section of the body 12 is preferably
continuous and uniform along the length of the body. However, in
alternative embodiments, the cross section can vary in size and/or
shape along the length of the body. FIG. 1 illustrates the body 12
relaxed in the first, reduced diameter configuration. The body 12
has a central lumen 13 extending along a longitudinal axis 14
between a first end 16 and second end 18.
[0031] A deployment mechanism in the form of an elongated hollow
tube 20 is shown positioned within the central lumen 13 to provide
a radial deployment or expansion force to the body 12. The radial
deployment force effects radial expansion of the body 12 from the
first configuration to the second increased diameter configuration
illustrated in FIG. 2. The first end 16 and the second end 18 are
connected in sealing relationship to the outer surface of the
hollow tube 20. The first and second ends 16 and 18 can be
thermally bonded, bonded by means of an adhesive, or attached by
other means suitable for inhibiting fluid leakage from the first
and second ends 16 and 18 between the walls of the body 12 and the
tube 20.
[0032] The hollow tube 20 includes an internal, longitudinal
extending lumen 22 and a number of side-holes 24 that provide for
fluid communication between the exterior of the tube 20 and the
lumen 22. The tube 20 can be coupled to a fluid source (not shown)
to selectively provide fluid, such as water, saline, or air, to the
lumen 13 of the body 12 through the lumen 22 and side-holes 24. The
pressure from the fluid provides a radial expansion force on the
body 12 to radial expand the body 12 to the second, increased
diameter configuration. Because the body 12 is constructed from an
inelastic material, uncoupling the tube 20 from the fluid source or
otherwise substantially reducing the fluid pressure within the
lumen 13 of the body 12, does not generally result in the body 12
returning to the first, reduced diameter configuration. However,
the body 12 will collapse under its own weight to a reduced
diameter. Application of negative pressure, from, for example, a
vacuum source, can be used to completely deflate the body 12 to the
initial reduced diameter configuration.
[0033] One skilled in the art will appreciate that the expansion
device 10 of the present invention is not limited to use with
deployment mechanisms employing a fluid deployment force, such as
hollow tube 20. Other known deployment mechanisms can be used to
radially deploy the expansion device 10 including, for example,
mechanical operated expansion elements, such as mechanically
activated members or mechanical elements constructed from
temperature activated materials such as nitinol.
[0034] Various fluoropolymer materials are suitable for use in the
present invention. Suitable fluoropolymer materials include, for
example, polytetrafluoroethylene (PTFE) or copolymers of
tetrafluoroethylene with other monomers may be used. Such monomers
include ethylene, chlorotrifluoroethylene,
perfluoroalkoxytetrafluoroethylene, or fluorinated propylenes such
as hexafluoropropylene. PTFE is the preferred material of choice.
Accordingly, while the radial expansion device 10 can be
manufactured from various fluoropolymer materials, and the
manufacturing methods of the present invention can utilize various
fluoropolymer materials, the description set forth herein refers
specifically to PTFE.
[0035] A method of manufacturing a radially expandable device in
accordance with the present invention will be described in
connection with FIGS. 4A-4C and the flow chart shown in FIG. 6A.
The radially expandable device 10 of the present invention is
produced from a tube 110 constructed of expanded fluoropolymer
material, which is preferably produced through an extrusion and a
longitudinal expansion process. The preferred fluoropolymer
material is expanded PTFE (ePTFE), which is a hydrophobic,
biocompatible, inelastic material having a low coefficient of
friction, although, as discussed above, other inelastic,
biocompatible fluoropolymer materials may be used.
[0036] To produce the ePTFE tube, a billet comprising a PTFE resin
mixed with an organic lubricant is utilized. Various organic
lubricants are suitable such as naphtha, ISOPAR-G and ISOPAR-H
available from Exxon Corporation. The blended resin is compressed
at low pressure to yield a tubular billet of PTFE resin and
lubricant, step 210 of FIG. 6A. The tubular billet is then extruded
through an extruder, for example a ram extruder, to reduce the
cross section of the billet and to yield a tubular extrudate, step
212. The organic lubricant can be removed from the extrudate by
drying the extrudate in a heated oven, step 214.
[0037] Once the tubular extrudate is produced, the extrudate is
expanded by longitudinal stretching, step 216. Preferably, the
extrudate is bilaterally stretched. Bilateral stretching is
accomplished by displacing both ends of the extrudate, sequentially
or simultaneously, away from the center of the extrudate. Bilateral
stretching provides a material that is homogeneously stretched over
the majority of its length. After the extrudate has been stretched,
it is heat set to lock in the microstructure of the material, step
218 of FIG. 6A, and to complete the process of the forming the tube
110 of ePTFE.
[0038] FIG. 3 is a schematic representation of the microstructure
of the walls of the ePTFE tube 110 as formed by the extrusion and
expansion process described above. For purposes of description, the
microstructure of the tube 110 has been exaggerated. Accordingly,
while the dimensions of the microstructure are enlarged, the
general character of the illustrated microstructure is
representative of the microstructure prevailing within the tube
110.
[0039] The microstructure of the ePTFE tube 110 is characterized by
nodes 130 interconnected by fibrils 132. The nodes 130 are
generally oriented perpendicular to the longitudinal axis 114 of
the tube 110. This microstructure of nodes 130 interconnected by
fibrils 132 provides a microporous structure having microfibrillar
spaces which define through-pores or channels 134 extending
entirely from the inner wall 136 and the outer wall 138 of the tube
110. The through-pores 134 are perpendicularly oriented (relative
to the longitudinal axis 114), internodal spaces that traverse from
the inner wall 136 to the outer wall 138. The size and geometry of
the through- pores 134 can be altered through the extrusion and
stretching process, as described in detail in Applicants' copending
U.S. patent application Ser. No. ______ (Attorney Docket No.
ATA-257), filed on the same date as the present application, which
is incorporated herein by reference, to yield a microstructure that
is impermeable, semi-impermeable, or permeable.
[0040] In a preferred embodiment, the ePTFE tube 110, and the
resultant expandable device 10, has a fine nodal structure that is
uniform throughout the cross section and length of the ePTFE tube.
The preferred uniform fine nodal structure provides the expandable
device 10 with improved expansion characteristics as the expandable
device dependably and predictably expands to the second diameter.
The preferred fine nodal structure is characterized by nodes having
a size and mass less than the nodes found in conventional ePTFE
grafts, preferably in the range of 25 .mu.m-30 .mu.m. Additionally,
the spacing between the nodes, referred to as the internodal
distance, and the spacing between the fibers, referred to as the
interfibril distance, is also preferably less than found in
conventional ePTFE grafts, preferably in the range of 1 .mu.m-5
.mu.m. Moreover, the internodal distance and the interfibril
distance in the preferred embodiment is preferably uniform
throughout the length and the cross section of the ePTFE tube. The
preferred uniform nodal structure can be created by forming the
billet with a uniform lubricant level throughout its cross section
and length. Stretching the tubular extrudate at higher stretch
rates, for example at rates greater than 1 in/s, yields the
preferred fine nodal structure. Preferably, the extrudate is
stretched at a rate of approximately 10 in/s or greater.
[0041] Continuing to describe the manufacturing method of the
present invention and referring again to FIGS. 4A and 6A, the ePTFE
tube 110, having an initial diameter d, is pulled over a balloon
112 to position the balloon 112 within the lumen 114 of the tube
110, step 220 of FIG. 6A. The balloon 112 is preferably constructed
of an inelastic material such as, for example, PET or nylon, such
that the balloon 112, when inflated, attains a predetermined size
and shape. The balloon 112 can be bonded or otherwise coupled to a
rigid catheter or hypo-tube 116 to facilitate placement and removal
of the ePTFE tube as described below. The catheter 116 has a
central inflation lumen 118 and a plurality of side-holes 120 to
provide for the delivery of an inflation fluid to inflate the
balloon 112.
[0042] Referring specifically to FIG. 4B, the balloon 112 can be
inflated by introduction of a pressurized fluid to the lumen 114 of
the ePTFE tube 110. The overlying ePTFE tube 110 expands with the
inelastic balloon 122 until both the balloon 112 and the ePTFE tube
110 obtain the predetermined size and shape of the inflated balloon
112, step 222 of FIG. 6A. The inflated balloon 112 thus imparts its
predetermined size and shape to the ePTFE tube 110. This radially
expansion process is referred to as blow-molding. The PTFE tube 110
shown in FIG. 4B is radially expanded from the initial diameter d
(FIG. 4A) to an increased diameter D. This radial expansion process
may take place in an air, water, or steam-heated chamber that is
heated to a temperature between 35.degree. C. and 60.degree. C.,
preferably 50.degree. C. The elevated temperature can contribute to
uniform expansion, both circumferentially and longitudinally, of
the ePTFE balloon, as well as uniform wall thickness.
[0043] It is preferable for the ePTFE tube 110 to be plastically
deformed by the radial expansion of the inelastic balloon 112, step
222 of FIG. 6A. The terms "plastic deformation" and "plastically
deform," as used herein, is intended to include the radial
expansion of the ePTFE tube 110 beyond the elastic limit of the
ePTFE material such that the ePTFE material is permanently
deformed. Once plastically deformed, the ePTFE material forming the
tube 110 becomes substantially inelastic, i.e., the ePTFE tube
generally will not, on its own, return to its pre-expansion size
and shape.
[0044] The ePTFE tube 110 can be removed from the balloon 112 by
sliding the ePTFE tube 110 relative to balloon 112 and catheter
116, i.e. in the direction of arrows A in FIG. 4C, step 224 of FIG.
6A. The tube 110 can be heat set at a temperature above the sinter
point of the material forming the tube, 360.degree. C. for ePTFE,
to lock in the structure of the tube 110, step 225 of FIG. 6A.
[0045] The resultant radially expanded ePTFE tube 110, produced in
accordance with the above described method, provides a radially
expandable device, such as expandable device 10 illustrated in
FIGS. 1 and 2 and described above, that is radially expandable from
a relaxed, collapsed diameter to the second, increased diameter D
upon application of a radial deployment force from a deployment
mechanism, e.g., hollow tube 20, within the tube 110. The ePTFE
tube 110 further provides an expansion device 10 having monolithic
construction, that is, a singular, unitary construction of
generally homogenous material, ePTFE, that lacks seams or other
internal interfaces. The ePTFE tube 110 can be dependably and
predictably expanded to the second diameter D upon the application
of the radially deployment force within the tube. In particular,
the plastically deformed, monolithic microstructure of the ePTFE
tube 110, once radially expanded by the inelastic balloon 120, will
readily return to the increased diameter D upon application of a
radial deployment force and generally will not expand beyond the
increased diameter D. The increased diameter D is effectively the
maximum expansion diameter for the ePTFE tube, as the increased
diameter D is generally independent of the radial deployment force
applied to the tube.
[0046] Referring to FIG. 5, an alternative method of manufacturing
a radially expandable device employing a mold 202 is illustrated.
The mold 202 includes two interconnected sections 204 and 206
forming an internal mold cavity 208 for receiving the ePTFE tube
110 with the balloon 112 positioned therein. The mold 202 is
preferably constructed of a rigid, unyielding material such as a
metal or metal alloy. Suitable metals or metal alloys include brass
and steel alloys. The internal mold cavity 208 preferably has a
size and shape analogous to that of the inflated balloon 112 to
ensure that the inflated balloon 112, and the overlying ePTFE tube
110 concentrically expand.
[0047] Referring to the flow chart illustrated in FIG. 6B, a
further alternative method of manufacturing a radially expandable
device according to the teachings of the present invention will be
described. A tube constructed of ePTFE is formed in accordance with
the methods described above, step 410. A tube formed of an extruded
inelastic material such as PET is used in place of balloon 112 to
radially expand the ePTFE tube. The extruded tube is positioned
within the ePTFE tube 110, step 412. The extruded tube is then
sealed at one end and attached to an inflation system at the other
end, step 414. The extruded tube can then be inflated by an
inflation medium to radially expand the ePTFE tube, step 416. The
extruded tube and ePTFE tube are preferably heated to the glass
transition temperature of the extruded tube, approximately
80.degree. C.-100.degree. C. for PET, as the extruded tube is
inflated within the ePTFE tube. It is preferable to limit the
temperature of the extruded tube to a temperature less than or
equal to the glass transition temperature of the material forming
the extruded tube to facilitate removal of the extruded tube from
the ePTFE tube. Heating the extruded tube to a temperature above
the glass transition temperature will cause the extruded tube to
heat set in an expanded configuration, which makes removing the
extruded tube from the ePTFE tube difficult. A suitable inflation
system employing a hot water chamber for heating the tubes is
described in Applicants copending U.S. patent application Ser. No.
______ (Attorney Docket No. ATA-257), filed on the same date as the
present application, which is incorporated herein by reference.
[0048] After the extruded tube and ePTFE tube are expanded to
desired size and shape, the extruded tube is deflated and removed
from the ePTFE tube, step 418. The ePTFE tube is then heat set to
lock in the structure of the ePTFE tube, step 420.
[0049] A mold, such as mold 202, can be employed during radial
expansion of the ePTFE tube using the PET tube. The mold is
preferably heated within the hot water chamber of the inflation
system or by other means such as a hot oil bath or through a steam,
hot air, electric, radio frequency or infra red heat source. The
mold can be constructed of a material having good heat transfer
characteristics, such as metal or metal alloy, for example brass.
The mold includes a mold cavity having a size and shape analogous
to the desired size and shape of the radially expandable device 10
in the second diameter configuration.
[0050] Expansion devices of a wide variety of sizes and shapes may
be constructed by altering the geometry of the inelastic balloon
112 or the mold 202. Accordingly, an ePTFE expansion device having
a size and shape tailored to a particular function can be
manufactured in accordance with the manufacturing methods of the
present invention by selecting an inelastic balloon having the
desired size and shape. Exemplary expandable fluoropolymer medical
treatment devices of different size and shapes are illustrated in
FIGS. 7A-7C.
[0051] FIG. 7A illustrates a radially expandable treatment device
10A having a generally pear-shaped configuration when inflated. The
pear shaped configuration is particularly suited for removal of
obstructions, such as thrombi and emboli, from a body passage. The
expandable treatment device 10A has an increased diameter section
226 that tapers to a reduced diameter section 228. The diameter of
the increased diameter section 226 is preferably equal to or
slightly less than the diameter of the body passage. The increased
diameter section 226 is the primary mechanism for removing
obstructions from the body passage and, thus, preferably
substantially fills the entire diameter of the body passage to
facilitate complete removal of all obstructions from the body
passage. The pear-shaped configuration provides the expandable
treatment device 10A with a limited, reduced surface area, the
increased diameter section 226, which can engage the walls of the
body passage and thus minimizes potential damage to the walls of
the body passage.
[0052] FIGS. 7B and 7C illustrate alternative exemplary embodiments
of the expandable device of the present invention, each providing
the device with a reduced surface area for contacting the walls of
a body passage. In particular, FIG. 7B illustrates a substantially
hour-glass shaped expandable treatment device 10B including, when
inflated, a first increased diameter section 229 that tapers to a
reduced diameter section 230 that expands to a second increased
diameter section 231. As in the case of the exemplary embodiment
described above and illustrated in FIG. 7A, the first and second
increased diameter sections 229 and 231 preferably have a diameter
equal to or slightly less than the diameter of a body passage to be
treated to facilitate complete removal of obstructions from the
body passage.
[0053] FIG. 7C illustrates a third exemplary embodiment in which
two axially aligned expandable devices 10C and 10D are provided. As
is the case of the second exemplary embodiment described above, the
dual expandable devices 10C and 1 OD together provide a
substantially hour-glass configuration that provides the devices
with two increased diameter sections 232 and 236.
[0054] One feature of the manufacturing processes of the present
invention is that the properties of the ePTFE tube 110 forming the
expandable device 10 can be manipulated, by varying the extrusion
and expansion process parameters, to produce a radially expandable
device 10 having different expansion characteristics. For example,
the longitudinal stretch ratio of the ePTFE tube 110, i.e., the
ratio of final stretched length of the tube to the initial length,
and the diametric stretch ratio of the ePTFE tube 110, i.e., the
ratio of the final diameter, after longitudinal stretching, and the
initial diameter, and the stretch rate can be varied to yield an
expansion device having different radial expansion properties.
Applicants determined that larger longitudinal stretch ratios, in
the order of 2:1 to 3:1, can result in a ePTFE tube having a
microstructure characterized by increased internodal distances and
interstitial space. Suitable longitudinal stretch ratios can be
from 1.1:1 to 10:1. As discussed above, Applicants determined that
increased stretch rates yield an ePTFE tube having a fine nodal
structure conducive to radial expansion. Expansion devices
constructed from ePTFE tubes having such larger longitudinal and/or
diametric stretch ratios and which are stretched at increased rates
generally require less radial deployment force to expand from the
collapsed, reduced diameter configuration to the expanded,
increased diameter configuration. Thus, the magnitude of the radial
deployment force necessary to expand the ePTFE tube 110 can be
pre-selected and manipulated by varying the stretch ratios and
stretch rate of the ePTFE tube 110 during the manufacturing
process.
[0055] In addition to the longitudinal and diametric stretch ratios
and the stretch rate, further process parameters can be varied to
produce an ePTFE tube 110 having different characteristics. For
example, the ePTFE tube 110 can be manufactured to have a porosity
that allows for the fluid utilized to radially deploy the ePTFE
tube to the expanded configuration to permeate through the walls of
the ePTFE tube at a desired flow rate. The process for producing
such a microporous ePTFE tube is described in detail in Applicants'
copending U.S. patent application Ser. No. ______ (Attorney Docket
No. ATA-257), filed on ______, which is incorporated herein by
reference.
[0056] FIG. 8 illustrates an exemplary embodiment of the expandable
device of the present invention in which the expandable device 10E
is utilized as a catheter deployed dilation balloon 300 for the
treatment of a blood vessel 310 partially occluded by plaque
deposits 312 adhered to the walls 314 of the blood vessel. The
dilation balloon 300 can be manufactured in accordance with the
methods of the present invention and is shown in the expanded
configuration. The ends 302 of the dilation balloon 300 are bonded
to a catheter tube 320, which is used to provide an inflation fluid
to the balloon 300 to effect expansion of the balloon 300 to a
predefined and fixed maximum diameter.
[0057] It will thus be seen that the invention efficiently attains
the objects made apparent from the preceding description. Since
certain changes may be made in the above constructions without
departing from the scope of the invention, it is intended that all
matter contained in the above description or shown in the
accompanying drawings be interpreted as illustrative and not in a
limiting sense.
[0058] It is also to be understood that the following claims are to
cover all generic and specific features of the invention described
herein, and all statements of the scope of the invention which, as
a matter of language, might be said to fall therebetween.
* * * * *