U.S. patent application number 10/682278 was filed with the patent office on 2004-04-15 for coating for a stent and a method of forming the same.
Invention is credited to Hossainy, Syed Faiyaz Ahmed.
Application Number | 20040073298 10/682278 |
Document ID | / |
Family ID | 25285712 |
Filed Date | 2004-04-15 |
United States Patent
Application |
20040073298 |
Kind Code |
A1 |
Hossainy, Syed Faiyaz
Ahmed |
April 15, 2004 |
Coating for a stent and a method of forming the same
Abstract
A coating for a stent and methods for coating a stent are
provided. The coating may be used for the sustained delivery of an
active ingredient or a combination of active ingredients.
Inventors: |
Hossainy, Syed Faiyaz Ahmed;
(Fremont, CA) |
Correspondence
Address: |
Paul J. Meyer, Jr.
Squire, Sanders & Dempsey L.L.P.
Suite 300
1 Maritime Plaza
San Francisco
CA
94111
US
|
Family ID: |
25285712 |
Appl. No.: |
10/682278 |
Filed: |
October 8, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10682278 |
Oct 8, 2003 |
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09841798 |
Apr 24, 2001 |
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Current U.S.
Class: |
623/1.46 |
Current CPC
Class: |
A61L 2400/18 20130101;
A61L 31/10 20130101 |
Class at
Publication: |
623/001.46 |
International
Class: |
A61F 002/06 |
Claims
What is claimed is:
1. A method of coating a stent, comprising: (a) forming a first
layer supported by a stent substrate; and (b) patterning said first
layer by removing portions of said first layer.
2. A coated stent produced in accordance with the method of claim
1.
3. The method of claim 1, wherein said patterning comprises: (a)
forming a second layer on the surface of said stent prior to
forming said first layer; (b) patterning said second layer to form
vias in said second layer, wherein said first layer is formed on
the remaining portions of said second layer and in said vias; and
(c) patterning said second layer to remove portions of said the
first layer disposed on the remaining portion of said second layer
to pattern said first layer.
4. The method of claim 1, additionally comprising forming a primer
layer on the surface of said stent substrate prior to forming said
first layer, wherein said patterning comprises: (a) forming a
second layer on said primer layer prior to forming said first
layer; (b) patterning said second layer to form vias in said second
layer, wherein said primer layer remains essentially undisturbed on
the surface of said stent substrate, and wherein said first layer
is formed on the remaining portions of said second layer and in
said vias on said primer layer; and (c) removing the remaining
portions of said second layer to remove portions of said first
layer disposed on the remaining portions of said second layer to
pattern said first layer.
5. The method of claim 1, additionally comprising forming a second
layer on the remaining portions of said first layer.
6. The method of claim 5, wherein said first layer contains a first
substance and said second layer contains a second substance
different than said first substance.
7. The method of claim 6, wherein said first or second substances
are selected from a group of therapeutic agents, radiopaque
elements and radioactive isotopes.
8. The method of claim 1, wherein said patterning comprises: (a)
forming a second layer on the surface of said stent prior to
forming said first layer; (b) patterning said second layer to
expose portions of the surface of said stent; (c) forming depots in
said stent between the remaining portions of said second layer,
wherein said first layer fills said depots; and (d) removing the
remaining portions of said second layer to remove portions of said
first layer disposed on the remaining portions of said second
layer, wherein said first layer remains in said depots.
9. The method of claim 8, additionally comprising reducing the
profile of said first layer such that said first layer does not
protrude out from said depots.
10. The method of claim 8, additionally comprising forming a third
layer over said first layer and on the surface of said stent.
11. The method of claim 10, wherein said first layer contains a
first substance and said third layer contains a second substance
different from said first substance.
12. The method of claim 1, wherein said patterning comprises: (a)
forming a second layer on said first layer; (b) patterning said
second layer to form vias in said second layer to expose portions
of said first layer; (c) removing the exposed portions of said
first layer, wherein portions of said first layer positioned
underneath the remaining portions of said second layer remain
essentially undisturbed; and (d) removing the remaining portions of
said second layer to form a patterned first layer.
13. The method of claim 12, additionally comprising forming a third
layer on the remaining portions of said first layer.
14. The method of claim 13, additionally comprising reducing the
profile of said third layer so as to create an alternating pattern
of said first layer and said third layer.
15. The method of claim 13, wherein said first layer contains a
first substance and said third layer contains a second substance
different from said first substance.
16. The method of claim 12, wherein the coating comprises a
discontinuous first layer interrupted by a second layer.
17. A coating for a stent comprising: a first layer; and a
discontinuous second layer separated by said first layer.
18. The coating of claim 17, wherein said first layer is a
discontinuous layer separated by said second layer so as to create
an alternating pattern of said first layer and said second layer
disposed on the surface of the stent.
19. The coating of claim 17, additionally comprising: a primer
layer disposed on the surface of the stent, wherein said first
layer is a discontinuous layer separated by said second layer so as
to create an alternating pattern of said first layer and said
second layer disposed on said primer layer.
20. The coating of claim 17, wherein said first layer contains a
first substance and said second layer contains a second substance,
and wherein the release rate of said first substance is different
than the release rate of said second substance.
21. The coating of claim 17, wherein said first substance is
different than said second substance.
22. The coating of claim 17, wherein the stent is a radially
expandable stent.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to implantable devices or endoluminal
prostheses, such as stents. More particularly, this invention
relates to a coating for a stent and methods for making the
same.
[0003] 2. Description of the Background
[0004] Percutaneous transluminal coronary angioplasty (PTCA) is a
procedure for treating heart disease. A catheter assembly having a
balloon portion is introduced percutaneously into the
cardiovascular system of a patient via the brachial or femoral
artery. The catheter assembly is advanced through the coronary
vasculature until the balloon portion is positioned across the
occlusive lesion. Once in position across the lesion, the balloon
is inflated to a predetermined size to radially press against the
atherosclerotic plaque of the lesion for remodeling of the vessel
wall. The balloon is then deflated to a smaller profile to allow
the catheter to be withdrawn from the patient's vasculature.
[0005] A problem associated with the above procedure includes
formation of intimal flaps or torn arterial linings, which can
collapse and occlude the conduit after the balloon is deflated.
Vasospasms and recoil of the vessel wall also threaten vessel
closure. Moreover, thrombosis and restenosis of the artery may
develop over several months after the procedure, which may
necessitate another angioplasty procedure or a surgical by-pass
operation. To reduce the partial or total occlusion of the artery
by the collapse of arterial lining and to reduce the chance of the
development of thrombosis and restenosis, an expandable,
intraluminal prosthesis, one example of which is a stent, is
implanted in the lumen to maintain the vascular patency.
[0006] Stents act as scaffoldings, functioning to physically hold
open and, if desired, to expand the wall of the passageway.
Typically stents are capable of being compressed, so that they can
be inserted through small cavities via catheters, and then expanded
to a larger diameter once they are at the desired location.
Examples in the patent literature disclosing stents that have been
applied in PTCA procedures include U.S. Pat. No. 4,733,665 issued
to Palmaz, U.S. Pat. No. 4,800,882 issued to Gianturco, and U.S.
Pat. No. 4,886,062 issued to Wiktor. Mechanical intervention via
stents has reduced the rate of restenosis as compared to balloon
angioplasty. Yet, restenosis is still a significant clinical
problem with rates ranging from 20-40%. When restenosis does occur
in the stented segment, its treatment can be challenging, as
clinical options are more limited as compared to lesions that were
treated solely with a balloon.
[0007] Stents are used not only for mechanical intervention but
also as vehicles for providing biological therapy. Biological
therapy can be achieved by medicating the stents. Medicated stents
provide for the local administration of a therapeutic substance at
the diseased site. In order to provide an efficacious concentration
to the treated site, systemic administration of such medication
often produces adverse or even toxic side effects for the patient.
Local delivery is a preferred method of treatment in that smaller
total levels of medication are administered in comparison to
systemic dosages, but are concentrated at a specific site. Local
delivery thus produces fewer side effects and achieves more
favorable results. This invention provides for a stent coating
capable of sustained local delivery of therapeutic substances and
methods of forming the coating.
SUMMARY OF THE INVENTION
[0008] A method of coating a stent is provided. The method includes
forming a first layer supported by a stent substrate and patterning
the first layer by removing portions of the first layer.
[0009] In some embodiments, the method additionally includes
forming a primer layer on the surface of the stent substrate prior
to forming the first layer.
[0010] In other embodiments, the method includes forming a second
layer on the remaining portions of the first layer. The first layer
may contain a first substance and the second layer may contain a
second substance different than the first substance. The first and
second substances may be active ingredients, radiopaque elements,
or radioactive isotopes.
[0011] In other embodiments, the act of patterning the first layer
includes forming a second layer on the surface of the stent prior
to forming the first layer. The second layer is patterned to form
vias in the second layer. Such patterning may be performed by
applying a laser discharge to selected areas of the second layer.
The first layer is formed on the remaining portions of the second
layer and in the vias. The second layer is patterned to remove
portions of the first layer disposed on the remaining portion of
the second layer to pattern the first layer.
[0012] In still other embodiments, the act of patterning the first
layer includes forming a second layer on the surface of the stent
prior to forming the first layer and patterning the second layer to
expose portions of the surface of the stent. The act of patterning
the first layer also includes forming depots in the stent between
the remaining portions of the second layer, wherein the first layer
fills the depots, and removing the remaining portions of the second
layer to remove portions of the first layer disposed on the
remaining portions of the second layer, wherein the first layer
remains in the depots. A third layer may be formed on the surface
of the stent and over the first layer in the depots.
[0013] In still other embodiments, the act of patterning the first
layer includes forming a second layer on the first layer and
patterning the second layer to form vias in the second layer to
expose portions of the first layer. The act of patterning the first
layer also includes removing the exposed portions of the first
layer, wherein portions of the first layer positioned underneath
the remaining portions of the second layer remain essentially
undisturbed, and removing the remaining portions of the second
layer to form a patterned first layer. A third layer may be formed
on the remaining portions of the first layer.
[0014] A coated stent produced in accordance with the various
methods is also provided. The coated stent includes a first layer
and a discontinuous second layer separated by the first layer. The
first layer is a discontinuous layer separated by the second layer
so as to create an alternating pattern of the first and second
layers on the surface of the stent. In accordance with another
embodiment, the discontinuous first and second layers can be
disposed on a primer layer.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIG. 1 illustrates a stent.
[0016] FIGS. 2A-2G illustrate a method of coating a stent in
accordance with several embodiments of the invention.
[0017] FIGS. 3A-3F illustrate a method of coating a stent in
accordance with several other embodiments of the invention.
[0018] FIGS. 4A-4F illustrate a method of coating a stent in
accordance with several other embodiments of the invention.
[0019] FIGS. 5A-5H illustrate a method of coating a stent in
accordance with several other embodiments of the invention.
DETAILED DESCRIPTION
[0020] "Polymer," "poly," and "polymeric" are defined as compounds
that are the product of a polymerization reaction and are inclusive
of homopolymers, copolymers, terpolymers etc., including random,
alternating, block, and graft variations thereof. Representative
examples of polymers that can be used with the embodiments of the
present invention include ethylene vinyl alcohol copolymer
(commonly known by the generic name EVOH or by the trade name
EVAL), polyhydroxy alkanoates such as (poly(hydroxyvalerate)),
(poly(hydroxybutyrate)), and (poly(hydroxybutyrate-co-valerate));
poly(L-lactic acid), polycaprolactone; poly(lactide-co-glycolide);
polydioxanone; polyorthoester; polyanhydride; poly(glycolic acid);
poly(D,L-lactic acid); poly(glycolic acid-co-trimethylene
carbonate); polyphosphoester; polyphosphoester urethane; poly(amino
acids); cyanoacrylates; poly(trimethylene carbonate);
poly(iminocarbonate); copoly(ether-esters) (e.g. PEO/PLA);
polyalkylene oxalates; polyphosphazenes and biomolecules such as
fibrin, fibrinogen, cellulose, starch, collagen and hyaluronic
acid; polyurethanes; silicones; polyesters; polyolefins;
polyisobutylene and ethylene-alphaolefin copolymers; acrylic
polymers and copolymers; vinyl halide polymers and copolymers, such
as polyvinyl chloride; polyvinyl ethers, such as polyvinyl methyl
ether; polyvinylidene halides, such as polyvinylidene fluoride and
polyvinylidene chloride; polyacrylonitrile; polyvinyl ketones;
polyvinyl aromatics, such as polystyrene; polyvinyl esters, such as
polyvinyl acetate; copolymers of vinyl monomers with each other and
olefins, such as ethylene-methyl methacrylate copolymers,
acrylonitrile-styrene copolymers, ABS resins, and ethylene-vinyl
acetate copolymers; polyamides, such as Nylon 66 and
polycaprolactam; alkyd resins; polycarbonates; polyoxymethylenes;
polyimides; polyethers; epoxy resins; polyurethanes; rayon;
rayon-triacetate; cellulose; cellulose acetate; cellulose butyrate;
cellulose acetate butyrate; cellophane; cellulose nitrate;
cellulose propionate; cellulose ethers; and carboxymethyl
cellulose.
[0021] "Solvent" is defined as a liquid substance or composition
which is compatible with the polymer and is capable of dissolving
the polymer at the concentration desired in the composition.
Examples of solvents include, but are not limited to,
dimethylsulfoxide (DMSO), chloroform, acetone, water (buffered
saline), xylene, methanol, ethanol, 1-propanol, tetrahydrofuran,
1-butanone, dimethylformamide, dimethylacetamide, cyclohexanone,
ethyl acetate, methylethylketone, propylene glycol monomethylether,
isopropanol, isopropanol admixed with water, N-methyl
pyrrolidinone, toluene, and combinations thereof.
[0022] The Figures have not been drawn to scale, and the dimensions
such as depth and thickness of the various regions and layers have
been over or under emphasized for illustrative purposes. Referring
to FIG. 1, a stent 10 is illustrated, which is broadly defined to
include any inter- or intraluminal device used for the release of
an active ingredient, for upholding the luminal patency, and/or for
the incorporation of radiopaque or radioactive materials. Examples
of stents include self-expandable stents, balloon-expandable
stents, and stent-grafts. Stent 10 can be made of a metallic
material or an alloy such as, but not limited to, stainless steel
(316L), "MP35N," "MP20N," ELASTINITE (Nitinol), tantalum,
nickel-titanium alloy, platinum-iridium alloy, gold, magnesium, or
combinations thereof. "MP35N" and "MP20N" are trade names for
alloys of cobalt, nickel, chromium and molybdenum available from
standard Press Steel Co., Jenkintown, Pa. "MP35N" consists of 35%
cobalt, 35% nickel, 20% chromium, and 10% molybdenum. "MP20N"
consists of 50% cobalt, 20% nickel, 20% chromium, and 10%
molybdenum. Stents made from bioabsorbable or biostable polymers
could also be used with the embodiments of the present
invention.
[0023] FIGS. 2A-2G illustrate a method for coating stent 10 in
accordance with several embodiments of the invention. FIG. 2A
illustrates a segment of the body or substrate 12 of stent 10,
wherein reference number 14 denotes the outer surface or the tissue
contacting surface of stent 10. The illustrations have been
simplified for ease of understanding and describing the embodiments
of the present invention. FIG. 2B illustrates a first layer 16
formed on substrate 12. First layer 16 can be of any suitable
thickness. The thickness of first layer 16 can be from about 0.1
micron to about 20 microns, more narrowly from about 2 microns to
about 10 microns. By way of example, first layer 16 can have a
thickness of about 3 microns. First layer 16 can be made from a
polymeric material. Polymers having a high coefficient of
extinction, which allows the material to burn quickly and easily,
can be used. The coefficient of extinction k is defined by Equation
1.
k={Ln(I.sub.0/I.sub.f)}/h (Equation 1)
[0024] Where k=coefficient of extinction (cm.sup.-1)
[0025] I.sub.0=initial intensity
[0026] I.sub.f=final intensity
[0027] h=distance at final intensity (cm)
[0028] A suitably high coefficient of extinction k can be greater
than or equal to 1.times.10.sup.4 cm.sup.-1. Examples of polymers
having such a coefficient of extinction include polyimide,
segmented polyurethane, and polycarbonate. Such polymers may be
particularly suitable for preventing melting defects when the
patterning of first layer 16 is accomplished using a laser
discharge as described below.
[0029] First layer 16 can be deposited by any conventional method
such as immersing substrate 12 in or spraying substrate 12 with a
first composition containing a dissolved mixture of a first solvent
with a first polymer and allowing the first solvent to evaporate
from first layer 16. The polymer-solvent combination should be
capable of forming first layer 16 as a uniform film, rather than in
a powdered form, on substrate 12.
[0030] First layer 16, as illustrated in FIG. 2C, is patterned by
removing or etching portions of first layer 16 to form vias 18 to
expose surface 14 of substrate 12 not covered by first layer 16.
Vias 18 can be formed by, for example, exposing first layer 16 to a
laser discharge such as that produced by an excimer laser. The
width of vias 18 is dependent on a variety of factors, such as the
size of stent struts and the coating pattern that is desired. By
way of example, vias 18 can be from about 5 microns to about 500
microns, for example about 100 microns wide.
[0031] Referring to FIG. 2D, a second layer 20, containing a first
substance, is deposited on substrate 12 to cover the remaining
portions of first layer 16 and vias 18. Second layer 20 can be made
of any suitable polymeric material and can be of any suitable
thickness. The thickness of second layer 20 can be from about 0.1
micron to about 15 microns, more narrowly from about 1 micron to
about 10 microns. By way of example, second layer 20 can have a
thickness of about 5 microns. The polymeric material for second
layer 20 should possess good adhesive qualities to surface 14 of
stent 10. If a radially expandable stent 10 is used, the polymeric
material should be capable of expanding with stent 10 without
significant detachment or fragmenting of the material from surface
14 of stent 10. The polymeric material should be a biocompatible
polymer, either bio-stable or bio-absorbable in nature. One example
of such a polymer is ethylene vinyl alcohol co-polymer.
[0032] Second layer 20 can be deposited by immersing substrate 12
in or spraying substrate 12 with a second composition containing a
second solvent, a second polymer, and the first substance and
allowing the second solvent to evaporate. The polymer-solvent
combination selected should be capable of forming second layer 20
as a uniform film, rather than in a powdered form, on substrate 12.
The second solvent should be capable of placing the polymer of the
second layer 20 into solution but should not be capable of removing
the remaining portions of first layer 16. In other words, the
second solvent should not dissolve first layer 16 during the
application of the second composition.
[0033] Following the application of second layer 20, the remaining
portions of first layer 16 can be removed, as illustrated in FIG.
2E, to pattern second layer 20. The remaining portions of first
layer 16 can be removed by the application of a solvent, such as
the first solvent used to form first layer 16. The solvent should
be capable of removing or dissolving the remaining portions of
first layer 16. The polymeric material from which second layer 20
is made should not be capable of being dissolved during the
application of the solvent. Removal of the remaining portions of
first layer 16 also causes the portions of second layer 20 that are
disposed over first layer 16 to be physically removed or
broken-off. Portions of second layer 20 that are in contact with
surface 14 remain attached to substrate 12.
[0034] Referring to FIG. 2F, a third layer 22, containing a second
substance, can be deposited on substrate 12 to cover the patterned
second layer 20 and the exposed portions of surface 14. The second
substance can be the same as or different than the first substance.
Third layer 22 can be deposited by applying a composition
containing a third solvent, the second substance, and a polymeric
material to stent 10. The polymer-solvent combination selected
should be capable of forming third layer 22 as a uniform film,
rather than in a powdered form. The third solvent should not remove
second layer 20 or adversely affect the first substance contained
in the second layer 20. As an optional step, as illustrated in FIG.
2G, the profile of third layer 22 can be reduced so as to create an
alternating pattern of second layer 20 and third layer 22. The
resulting stent 10 includes a low profile coating defined by
discontinuous second layer 20 interrupted by third layer 22. The
discontinuous second layer 20 and third layer 22 can carry a first
and a second substance, respectively, for release of the substances
at different rates in situ.
[0035] The first and second substances can be any active ingredient
capable of exerting a therapeutic or prophylactic effect in the
practice of the present invention. Examples of such active
ingredients include antiproliferative, antineoplastic,
antiinflammatory, antiplatelet, anticoagulant, antifibrin,
antithrombin, antimitotic, antibiotic, and antioxidant substances
as well as combinations thereof.
[0036] A suitable example of an antiproliferative substance is
actinomycin D, or derivatives and analogs thereof. Synonyms of
actinomycin D include dactinomycin, actinomycin IV, actinomycin
I.sub.1, actinomycin X.sub.1, and actinomycin C.sub.1. Examples of
suitable antineoplastics include paclitaxel and docetaxel. Examples
of suitable antiplatelets, anticoagulants, aritifibrins, and
antithrombins include sodium heparin, low molecular weight heparin,
hirudin, argatroban, forskolin, vapiprost, prostacyclin and
prostacyclin analogs, dextran, D-phe-pro-arg-chloromethy- lketone
(synthetic antithrombin), dipyridamole, glycoprotein IIb/IIIa
platelet membrane receptor antagonist, recombinant hirudin,
thrombin inhibitor (available from Biogen), and 7E-3B.RTM. (an
antiplatelet drug from Centocore). Examples of suitable antimitotic
agents include methotrexate, azathioprine, vincristine,
vinblastine, fluorouracil, adriamycin, and mitamycin. Examples of
suitable cytostatic or antiproliferative agents include angiopeptin
(a somatostatin analog from Ibsen), angiotensin converting enzyme
inhibitors such as CAPTOPRIL (available from Squibb), CILAZAPRIL
(available from Hoffman-LaRoche), or LISINOPRIL (available from
Merck); calcium channel blockers (such as Nifedipine), colchicine,
fibroblast growth factor (FGF) antagonists, fish oil (omega 3-fatty
acid), histamine antagonist, LOVASTATIN (an inhibitor of HMG-CoA
reductase, a cholesterol lowering drug from Merck), monoclonal
antibodies (such as PDGF receptors), nitroprusside,
phosphodiesterase inhibitors, prostaglandin inhibitor (available
form Glazo), Surmin (a PDGF antagonist), serotonin blockers,
steroids, thioprotease inhibitors, triazolopyrimidine (a PDGF
antagonist), and nitric oxide. Other therapeutic substances or
agents which may be appropriate include alpha-interferon,
genetically engineered epithelial cells, and dexamethasone.
Exposure of the composition to the active ingredient is not
permitted to adversely alter the active ingredient's composition or
characteristic. Accordingly, the particular active ingredient is
selected for compatibility with the blended polymer-solvent.
[0037] The dosage or concentration of the active ingredient
required to produce a favorable therapeutic effect should be less
than the level at which the active ingredient produces toxic
effects and greater than the level at which non-therapeutic results
are obtained. The dosage or concentration of the active ingredient
required can depend upon factors such as the particular
circumstances of the patient; the nature of the trauma; the nature
of the therapy desired; the time over which the ingredient
administered resides at the treatment site; and if other bioactive
substances are employed, the nature and type of the substance or
combination of substances. Therapeutic effective dosages can be
determined empirically, for example by infusing vessels from
suitable animal model systems and using immunohistochemical,
fluorescent or electron microscopy methods to detect the agent and
its effects, or by conducting suitable in vitro studies. Standard
pharmacological test procedures to determine dosages are understood
by one of ordinary skill in the art.
[0038] In accordance with another embodiment, the first and/or
second substances can be radiopaque elements or radioactive
isotopes. Examples of radiopaque elements include, but are not
limited to, gold, tantalum, and platinum. An example of a
radioactive isotope is P.sup.32. Sufficient amounts of such
substances may be dispersed in the composition. By dispersed it is
meant that the substances are not present in the composition as
agglomerates or flocs. Certain substances will disperse with
ordinary mixing, such as by stirring with a stir bar, vortexing,
and similar perturbation techniques. Otherwise, the substances can
be dispersed by high shear processes such as ball mill, disc mill,
sand mill, attritor, rotor stator mixer, or ultrasonication--all
such high shear dispersion techniques being well known to one of
ordinary skill in the art. Agents in the form of surfactants,
emulsifiers, or stablilizers may also be added to the composition
to assist in dispersion.
[0039] Referring to FIGS. 3A-3F, an optional primer layer 24, free
from any substances, can be formed on surface 14 of substrate 12
prior to the formation of first layer 16. The presence of a
substance in second layer 20 can interfere with the ability of
second layer 20 to adhere effectively to surface 14 of substrate
12. High drug loadings of 10-40% by weight in the matrix may
significantly hinder the retention of second layer 20 on surface 14
of substrate 12. The primer layer 24 serves as a functionally
useful intermediary layer between surface 14 of substrate 12 and
the substance-containing second layer 20. The primer layer 24
provides for an adhesive tie which, in effect, would also allow for
the quantity of the substance in the second layer 20 to be
increased without compromising the ability of second layer 20 to be
effectively contained on substrate 12 during delivery and, if
applicable, expansion of stent 10.
[0040] With the use of thermoplastic polymers such as, but not
limited to, ethylene vinyl alcohol copolymer, polycaprolactone,
poly(lactide-co-glycolide), and poly(hydroxybutyrate), the
deposited primer composition should be exposed to a heat treatment
at a temperature range greater than about the glass transition
temperature (T.sub.g) and less than about the melting temperature
(T.sub.m) of the selected polymer. Unexpected results have been
discovered with treatment of the composition under this temperature
range, specifically strong adhesion or bonding of the coating to
the metallic surface of a stent 10. The prosthesis should be
exposed to the heat treatment for any suitable duration of time
that will allow for the formation of primer layer 24 on surface 14
of substrate 12 and for the evaporation of the solvent
employed.
[0041] FIGS. 3A-3F correspond to the above-described FIGS. 2B-2G,
respectively, but for the initial formation of primer layer 24
directly onto surface 14 of substrate 12. Briefly, FIG. 3A
illustrates the formation of first layer 16 on primer layer 24.
First layer 16 is patterned to form vias 18, as depicted in FIG.
3B. The underlying primer layer 24 should remain essentially
undisturbed on surface 14 of substrate 12. In FIG. 3C, second layer
20, containing a first substance, is deposited on the substrate 12
to cover the remaining portions of first layer 16 and vias 18. The
polymeric material selected for second layer 20 should possess good
adhesive qualities to primer layer 24. Following the application of
second layer 20, the remaining portions of first layer 16 are
removed, as illustrated in FIG. 3D, to pattern second layer 20.
Referring to FIG. 3E, a third layer 22, containing a second
substance, can be deposited on second layer 20. The second
substance can be the same as or different than the first substance.
As an optional step, as illustrated in FIG. 3F, the profile of
third layer 22 can be reduced so as to create an alternating
pattern of second layer 20 and third layer 22, being adhesively
tied to stent 10 via primer layer 24, and containing a combination
of first and second substances that are capable of being released
at different rates in situ.
[0042] FIGS. 4A-4F illustrate a method of coating stent 10 in
accordance with several other embodimerits of the present
invention. FIG. 4A illustrates first layer 16 formed on substrate
12. First layer 16 may be made from any suitable material and can
be of any suitable thickness. The thickness of first layer 16 can
be from about 0.5 micron to about 10 microns, more narrowly from
about 2 microns to about 8 microns. By way of example, first layer
16 can have a thickness of about 3 microns. First layer 16 can be
made from a polymeric material. Polymers having a high coefficient
of extinction, as discussed above, are suitable. First layer 16 can
be deposited by any conventional method such as immersing substrate
12 in or spraying substrate 12 with a first composition containing
a dissolved mixture of a first solvent with the polymer and
allowing the first solvent to evaporate from first layer 16.
[0043] First layer 16, as illustrated in FIG. 4B, is patterned by
removing or etching portions of first layer 16 to form vias 18.
Additionally, portions of substrate 12 underlying the removed
portions of first layer 16 are removed or etched to form depots 26.
Depots 26 can be formed by, for example, exposing first layer 16
and the underlying substrate 12 to a laser discharge such as that
produced by an excimer laser.
[0044] Referring to FIG. 4C, a second layer 20, containing a first
substance, is deposited on the substrate 12 to fill depots 26 and
vias 18 and to cover the remaining portions of first layer 16.
Second layer 20 can be made of a polymeric material having good
adhesive qualities to substrate 12. One example of such a polymer
is ethylene vinyl alcohol co-polymer.
[0045] Following the application of second layer 20, the remaining
portions of first layer 16 are removed, as illustrated in FIG. 4D,
to pattern second layer 20. The remaining portions of first layer
16 can be removed by the application of a solvent, such as the
first solvent used to form first layer 16. The polymeric material
from which second layer 20 is made should not be capable of being
removed or dissolved during the application of the solvent. Removal
of the remaining portions of first layer 16 also causes the
portions of second layer 20 that are disposed over first layer 16
to be physically removed or broken-off. Portions of second layer 20
that are within depots 26 remain attached to substrate 12. As
illustrated in FIG. 4E, the profile of second layer 20 can be
reduced so as to remove the portions of second layer 20 extending
above surface 14.
[0046] Referring to FIG. 4F, in accordance with another embodiment,
a third layer 22 containing a second substance, can be deposited on
substrate 12 to cover second layer 20 within depots 26 as well as
surface 14. The second substance can be the same as or different
than the first substance. Third layer 22 can be made of any
suitable polymeric material and can be of any suitable thickness.
The thickness of third layer 22 can be from about 0.2 microns to
about 10 microns, more narrowly from about 2 microns to about 8
microns. By way of example, third layer 22 can have a thickness of
about 5 microns. The resulting stent 10 includes a first substance
within depots 26 and a second substance in third layer 22, each of
which is capable of being released at a different rate in situ.
[0047] FIGS. 5A-5H illustrate a method of coating stent 10 in
accordance with other embodiments of the present invention. FIG. 5A
illustrates a first layer 28, containing a first substance. The
thickness of first layer 28 can be from about 0.2 micron to about
10 micron, more narrowly from about 2 microns to about 8 microns.
By way of example, first layer 28 can have a thickness of about 5
microns. FIG. 5B illustrates a second layer 30 formed on substrate
12 to cover first layer 28. The thickness of second layer 30 can be
from about 1 micron to about 10 microns, more narrowly from about 2
microns to about 8 microns. By way of example, second layer 30 can
have a thickness of about 4 microns. Second layer 30 can be made
from a polymeric material such as, but not limited to,
polyurethanes or parylene.
[0048] Second layer 30, as illustrated in FIG. 5C, is patterned by
removing portions of second layer 30 to form vias 18, to expose
portions of first layer 28 not covered by second layer 30. Vias 18
can be formed by, for example, exposing second layer 30 to a laser
discharge. First layer 28 is patterned by removing portions of
first layer 28 not covered by the remaining portions of second
layer 20, as illustrated in FIG. 5D. First layer 28 can be
patterned by exposing the uncovered portions of first layer 28 to a
solvent so as to remove or dissolve the selected portions of first
layer 28.
[0049] The remaining portions of second layer 30 can be removed, as
illustrated in FIG. 5E by, for example, exposing second layer 30 to
a laser discharge. Alternatively, the remaining portions of second
layer 30 can be removed by the application of a solvent. The
solvent should be capable of removing or dissolving the remaining
portions of second layer 20, but should not remove the polymeric
material from which first layer 28 is made or adversely affect the
first substance.
[0050] Referring to FIG. 5F, a third layer 32, containing a second
substance, is deposited on substrate 12 to cover the remaining
portion of first layer 28 and vias 18. Third layer 32 can be made
of any suitable polymeric material and can be of any suitable
thickness. The solvent used to form third layer 32 should be
capable of placing the polymer of the third layer 32 into solution,
but should not be capable of removing the remaining portions of
first layer 28. In other words, the solvent should not dissolve
first layer 28 during the application of the third solution.
[0051] Following the application of third layer 32, the profile of
third layer 32 can optionally be reduced so as to create an
alternating pattern of first layer 28 and third layer 32 having
essentially the same thickness, as depicted in FIG. 5G. As another
optional step, a fourth layer 34 can be deposited on the
alternating pattern of first layer 28 and third layer 32, as
illustrated in FIG. 5H. In some embodiments, fourth layer 34
functions as a diffusion barrier for the first and second
substances in first layer 28 and third layer 32, respectively.
Fourth layer 34 can also contain a third substance. The third
substance can be the same as or different than the first and second
substances. The resulting stent 10 includes a low profile coating
having a combination of first, second and third substances that are
capable of being released at different rates in situ. In yet
another embodiment, a primer layer (not shown) can also be
employed.
[0052] In the above-described embodiments, high temperature heating
in a furnace (e.g., 700-800.degree. C.) may be employed to
incinerate all polymers on substrate 12. This polymer removal
technique is particularly suitable when gold or platinum has been
deposited as the first substance.
[0053] In accordance with the above-described methods, one or more
active ingredient can be applied to a device, e.g., a stent,
retained on the stent during delivery and expansion of the stent,
and released at a desired control rate and for a predetermined
duration of time at the site of implantation. A stent having the
above-described coating is useful for a variety of medical
procedures, including, by way of example, treatment of obstructions
caused by tumors in bile ducts, esophagus, trachea/bronchi and
other biological passageways. A stent having the above-described
coating is particularly useful for treating occluded regions of
blood vessels caused by abnormal or inappropriate migration and
proliferation of smooth muscle cells, thrombosis, or restenosis.
Stents may be placed in a wide array of blood vessels, both
arteries and veins. Representative examples of sites include the
iliac, renal, and coronary arteries.
[0054] Briefly, an angiogram is first performed to determine the
appropriate positioning for stent therapy. Angiography is typically
accomplished by injecting a radiopaque contrast agent through a
catheter inserted into an artery or vein as an x-ray is taken. A
guidewire is then advanced through the lesion or proposed site of
treatment. Over the guidewire is passed a delivery catheter which
allows a stent in its collapsed configuration to be inserted into
the passageway. The delivery catheter is inserted either
percutaneously or by surgery into the femoral artery, brachial
artery, femoral vein, or brachial vein, and advanced into the
appropriate blood vessel by steering the catheter through the
vascular system under fluoroscopic guidance. A stent having the
above-described coating may then be expanded at the desired area of
treatment. A post insertion angiogram may also be utilized to
confirm appropriate positioning.
[0055] While, particular embodiments of the present invention have
been shown and described, it will be obvious to those skilled in
the art that changes and modifications can be made without
departing from this invention in its broader aspects and,
therefore, the appended claims are to encompass within their scope
all such changes and modifications as fall within the true spirit
and scope of this invention.
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