U.S. patent application number 10/626083 was filed with the patent office on 2004-05-20 for expandable stents and method for making same.
Invention is credited to Frantzen, John J., Hartigan, William M., Lau, Lilip.
Application Number | 20040098080 10/626083 |
Document ID | / |
Family ID | 25129650 |
Filed Date | 2004-05-20 |
United States Patent
Application |
20040098080 |
Kind Code |
A1 |
Lau, Lilip ; et al. |
May 20, 2004 |
Expandable stents and method for making same
Abstract
The invention is directed to an expandable stent for
implantation in a body lumen, such as an artery, and a method for
making it from a single length of tubing. The stent consists of a
plurality of radially expandable cylindrical elements generally
aligned on a common axis and interconnected by one or more
interconnective elements. The individual radially expandable
cylindrical elements consist of ribbon-like material disposed in an
undulating pattern. Portions of the expanded stent project
outwardly into engagement with the vessel wall to more securely
attach the stent.
Inventors: |
Lau, Lilip; (Sunnyvale,
CA) ; Hartigan, William M.; (Fremont, CA) ;
Frantzen, John J.; (Copperopolis, CA) |
Correspondence
Address: |
FULWIDER PATTON LEE & UTECHT, LLP
HOWARD HUGHES CENTER
6060 CENTER DRIVE
TENTH FLOOR
LOS ANGELES
CA
90045
US
|
Family ID: |
25129650 |
Appl. No.: |
10/626083 |
Filed: |
July 24, 2003 |
Related U.S. Patent Documents
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Application
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Filing Date |
Patent Number |
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10626083 |
Jul 24, 2003 |
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09779078 |
Feb 8, 2001 |
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6596022 |
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09779078 |
Feb 8, 2001 |
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09561098 |
Apr 28, 2000 |
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6309412 |
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09561098 |
Apr 28, 2000 |
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09135222 |
Aug 17, 1998 |
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6056776 |
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09135222 |
Aug 17, 1998 |
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09055582 |
Apr 6, 1998 |
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6066168 |
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09055582 |
Apr 6, 1998 |
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08783097 |
Jan 14, 1997 |
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5735893 |
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08783097 |
Jan 14, 1997 |
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08556516 |
Nov 13, 1995 |
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5603721 |
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08556516 |
Nov 13, 1995 |
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08281790 |
Jul 28, 1994 |
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5514154 |
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08281790 |
Jul 28, 1994 |
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08164986 |
Dec 9, 1993 |
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08164986 |
Dec 9, 1993 |
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07783558 |
Oct 28, 1991 |
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Current U.S.
Class: |
623/1.11 ;
623/1.15 |
Current CPC
Class: |
Y10S 623/903 20130101;
A61F 2002/9155 20130101; A61F 2/915 20130101; Y10T 29/49995
20150115; A61F 2/958 20130101; A61F 2002/91558 20130101; A61F
2210/0019 20130101; A61F 2/848 20130101; A61F 2/86 20130101; A61F
2002/91533 20130101; C23F 1/02 20130101; A61F 2/88 20130101; C23F
1/04 20130101; A61F 2/89 20130101; A61M 2025/1081 20130101; Y10S
623/901 20130101; A61F 2002/91575 20130101; Y10S 623/921 20130101;
A61F 2/91 20130101 |
Class at
Publication: |
623/001.11 ;
623/001.15 |
International
Class: |
A61F 002/06 |
Claims
What is claimed is:
1. A longitudinally flexible stent for implanting in a body lumen,
comprising: a plurality of cylindrical elements which are
independently expandable in the radial direction and which are
interconnected so as to be generally aligned on a common
longitudinal axis; a plurality of connecting elements for
interconnecting said cylindrical elements, said connecting elements
configured to interconnect only said cylindrical elements that are
adjacent to each other; and an outer wall surface on said
cylindrical elements, said outer wall surface having a plurality of
outwardly projecting edges which form as said stent is expanded
radially outwardly from a first diameter to a second, enlarged
diameter.
2. The stent of claim 1, wherein said outer wall surface is
substantially smooth when said stent in said first diameter
configuration and said outwardly projecting edges form only as said
stent is expanded radially outwardly from said first diameter to
said second, enlarged diameter.
3. The stent of claim 1, wherein said plurality of outwardly
projecting edges extend a distance from said outer wall surface
sufficient enough to embed in the vascular wall of the body lumen
in order to more firmly attach said stent to the vascular wall.
4. The stent of claim 1, wherein said plurality of cylindrical
elements include a plurality of peaks and valleys having a
serpentine pattern.
5. The stent of claim 4, wherein said plurality of peaks and
valleys include a plurality of U-shaped members, a plurality of
Y-shaped members, and a plurality of W-shaped members, some of said
U-shaped, Y-shaped, and W-shaped members being interconnected.
6. The stent of claim 5, wherein at least some of said plurality of
said U-shaped members tip radially outwardly to form said outwardly
projecting edges upon radial expansion of said stent.
7. The stent of claim 5, wherein at least some of said plurality of
U-shaped, W-shaped, and Y-shaped members tip radially outwardly to
form said outwardly projecting edges upon radial expansion of said
stent.
8. The stent of claim 1, wherein said cylindrical elements are
capable of retaining their expanded condition upon the expansion
thereof.
9. The stent of claim 1, wherein said stent is formed of a
biocompatible material selected from the group of materials
consisting of stainless steel, tantalum, NiTi alloys, and
thermoplastic polymers.
10. The stent of claim 1, wherein said stent is formed from a
single piece of tubing.
11. The stent of claim 1, wherein said stent is coated with a
biocompatible coating.
12. A longitudinally flexible stent, comprising: a plurality of
cylindrical elements which are independently expandable in the
radial direction and which are interconnected so as to be
concentrically aligned on a common longitudinal axis; and a
plurality of generally parallel connecting elements for
interconnecting said cylindrical elements, said connecting elements
configured to interconnect only said cylindrical elements that are
adjacent to each other, so that said stent, when expanded radially
outwardly, retains its overall length without appreciable
shortening.
13. The stent of claim 12, wherein said cylindrical elements are
capable of retaining their expanded condition upon the expansion
thereof.
14. The stent of claim 12, wherein said radially expandable
cylindrical elements in an expanded condition have a length less
than the diameter thereof.
15. The stent of claim 14, wherein said stent is formed of a
biocompatible material selected from the group consisting of
stainless steel, tantalum, super-elastic NiTi alloys, and
thermoplastic polymers.
16. The stent of claim 12, wherein said connecting elements between
adjacent cylindrical elements are in axial alignment.
17. The stent of claim 12, wherein said connecting elements between
adjacent cylindrical elements are circumferentially displaced with
respect to said longitudinal axis.
18. The stent of claim 17, wherein the circumferential displacement
of said connecting elements between adjacent cylindrical elements
is uniform.
19. The stent of claim 12, wherein there are up to four of said
connecting elements disposed between adjacent radially expandable
cylindrical elements.
20. The stent of claim 12, wherein said radially expandable
cylindrical elements and said connecting elements are made of the
same material.
21. The stent of claim 12, wherein said stent is formed from a
single piece of tubing.
22. The stent of claim 12, wherein the stent is coated with a
biocompatible coating.
23. A kit of parts, comprising: an elongated stent delivery
catheter having a proximal end and a distal end, and an expandable
member on the distal end; and a longitudinally flexible stent which
is adapted to be slidably mounted onto the expandable member of
said catheter and which comprises a plurality of cylindrical
elements which are independently expandable in the radial direction
and which are interconnected so as to be concentrically aligned on
a common longitudinal axis, wherein each said element is formed of
a single elongated structural member forming a serpentine pattern
having undulations with peaks and valleys, said elements being
interconnected by a plurality of generally parallel interconnecting
members between adjacent elements, each said interconnecting member
configured to interconnect only said cylindrical elements that are
adjacent to each other.
24. A method of transluminally implanting a longitudinally flexible
stent in a body lumen, said stent having a plurality of cylindrical
elements which are independently expandable in the radial direction
and which are interconnected so as to be concentrically aligned on
a common longitudinal axis, wherein each said cylindrical element
is interconnected a plurality of generally parallel connecting
members between adjacent elements, the method comprising the steps
of: placing the stent on an expandable portion of a catheter which
is adapted to radially expand the stent; delivering the stent to a
desired location within the body lumen; expanding said cylindrical
elements with the expandable portion of the catheter; contracting
the expandable portion of the catheter; and withdrawing the
catheter, leaving the expanded stent implanted in the body lumen.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
U.S. patent application Ser. No. 08/164,986 filed Dec. 9, 1993,
which is a continuation application of U.S. Ser. No. 07/783,558
filed Oct. 28, 1991, now abandoned.
BACKGROUND OF THE INVENTION
[0002] This invention relates to expandable endoprosthesis devices,
generally called stents, which are adapted to be implanted into a
patient's body lumen, such as blood vessel, to maintain the patency
thereof. These devices are very useful in the treatment of
atherosclerotic stenosis in blood vessels.
[0003] Stents are generally tubular-shaped devices which function
to hold open a segment of a blood vessel or other anatomical lumen.
They are particularly suitable for use to support and hold back a
dissected arterial lining which can occlude the fluid passageway
therethrough.
[0004] Further details of prior art stents can be found in U.S.
Pat. No. 3,868,956 (Alfidi et al.); U.S. Pat. No. 4,512,338 (Balko
et al.); U.S. Pat. No. 4,553,545 (Maass et al.); U.S. Pat. No.
4,733,665 (Palmaz); U.S. Pat. No. 4,762,128 (Rosenbluth); U.S. Pat.
No. 4,800,882 (Gianturco); U.S. Pat. No. 4,856,516 (Hillstead); and
U.S. Pat. No. 4,886,062 (Wiktor), which are hereby incorporated
herein in their entirety by reference thereto.
[0005] Various means have been described to deliver and implant
stents. One method frequently described for delivering a stent to a
desired intraluminal location includes mounting the expandable
stent on an expandable member, such as a balloon, provided on the
distal end of an intravascular catheter, advancing the catheter to
the desired location within the patient's body lumen, inflating the
balloon on the catheter to expand the stent into a permanent
expanded condition and then deflating the balloon and removing the
catheter. One of the difficulties encountered using prior stents
involved maintaining the radial rigidity needed to hold open a body
lumen while at the same time maintaining the longitudinal
flexibility of the stent to facilitate its delivery.
[0006] What has been needed and heretofore unavailable is a stent
which has a high degree of flexibility so that it can be advanced
through tortuous passageways and can be readily expanded and yet
have the mechanical strength to hold open the body lumen into which
it expanded. The present invention satisfies this need.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to an expandable stent
which is relatively flexible along its longitudinal axis to
facilitate delivery through tortuous body lumens, but which is
stiff and stable enough radially in an expanded condition to
maintain the patency of a body lumen such as an artery when
implanted therein.
[0008] The stent of the invention generally includes a plurality of
radially expandable cylindrical elements which are relatively
independent in their ability to expand and to flex relative to one
another. The individual radially expandable cylindrical elements of
the stent are dimensioned so as to be longitudinally shorter than
their own diameters. Interconnecting elements or struts extending
between adjacent cylindrical elements provide increased stability
and a preferable position to prevent warping of the stent upon the
expansion thereof. The resulting stent structure is a series of
radially expandable cylindrical elements which are spaced
longitudinally close enough so that small dissections in the wall
of a body lumen may be pressed back into position against the
lumenal wall, but not so close as to compromise the longitudinal
flexibilities of the stent. The individual cylindrical elements may
rotate slightly relative to adjacent cylindrical elements without
significant deformation, cumulatively giving a stent which is
flexible along its length and about its longitudinal axis but is
still very stiff in the radial direction in order to resist
collapse.
[0009] The stent embodying features of the invention can be readily
delivered to the desired lumenal location by mounting it on an
expandable member of a delivery catheter, for example a balloon,
and passing the catheter-stent assembly through the body lumen to
the implantation site. A variety of means for securing the stent to
the expandable member on the catheter for delivery to the desired
location are available. It is presently preferred to compress the
stent onto the balloon. Other means to secure the stent to the
balloon include providing ridges or collars on the inflatable
member to restrain lateral movement, or using bioresorbable
temporary adhesives.
[0010] The presently preferred structure for the expandable
cylindrical elements which form the stents of the present invention
generally circumferential undulating pattern, e.g. serpentine. The
transverse cross-section of the undulating component of the
cylindrical element is relatively small and preferably has an apect
ratio of about two to one to about 0.5 to one. A one to one apect
ratio has been found particularly suitable. The open reticulated
structure of the stent allows for the perfusion of blood over a
large portion of the arterial wall which can improve the healing
and repair of a damaged arterial lining.
[0011] The radial expansion of the expandable cylinder deforms the
undulating pattern thereof similar to changes in a waveform which
result from decreasing the waveform's amplitude and the frequency.
Preferably, the undulating patterns of the individual cylindrical
structures are in phase with each other in order to prevent the
contraction of the stent along its length when it is expanded. The
cylindrical structures of the stent are plastically deformed when
expanded (except with NiTi alloys) so that the stent will remain in
the expanded condition and therefore they must be sufficiently
rigid when expanded to prevent the collapse thereof in use. During
expansion of the stent, portions of the undulating pattern will tip
outwardly resulting in projecting members on the outer surface of
the expanded stent. These projecting members tip radially outwardly
from the outer surface of the stent and embed in the vessel wall
and help secure the expanded stent so that it does not move once it
is implanted.
[0012] With superelastic NiTi alloys, the expansion occurs when the
stress of compression is removed so as to allow the phase
transformation from austenite back to martensite and as a result
the expansion of the stent.
[0013] The elongated elements which interconnect adjacent
cylindrical elements should have a transverse cross-section similar
to the transverse dimensions of the undulating components of the
expandable cylindrical elements. The interconnecting elements may
be formed in a unitary structure with the expandable cylindrical
elements from the same intermediate product, such as a tubular
element, or they may be formed independently and connected by
suitable means, such as by welding or by mechanically securing the
ends of the interconnecting elements to the ends of the expandable
cylindrical elements. Preferably, all of the interconnecting
elements of a stent are joined at either the peaks or the valleys
of the undulating structure of the cylindrical elements which for
the stent. In this manner there is no shortening of the stent upon
expansion.
[0014] The number and location of elements interconnecting adjacent
cylindrical elements can be varied in order to develop the desired
longitudinal flexibility in the stent structure both in the
unexpanded as well as the expanded condition. These properties are
important to minimize alteration of the natural physiology of the
body lumen into which the stent is implanted and to maintain the
compliance of the body lumen which is internally supported by the
stent. Generally, the greater the longitudinal flexibility of the
stent, the easier and the more safely it can be delivered to the
implantation site.
[0015] In a presently preferred embodiment of the invention the
stent is conveniently and easily formed by coating stainless steel
tubing with a material resistant to chemical etching, removing
portions of the coating to expose portions of underlying tubing
which are to be removed to develop the desired stent structure. The
exposed portions of the tubing are removed by chemically etching
from the tubing exterior leaving the coated portion of the tubing
material in the desired pattern of the stent structure. The etching
process develops smooth openings in the tubing wall without burrs
or other artifacts which are characteristic of mechanical or laser
machining processes in the small sized products contemplated.
Moreover, a computer controlled laser patterning process to remove
the chemical resistive coating makes photolithography technology
adaptable to the manufacture of these small products. The forming
of a mask in the extremely small sizes needed to make the small
stents of the invention would be a most difficult task. A plurality
of stents can be formed from one length of tubing by repeating the
stent pattern and providing small webs or tabs to interconnect the
stents. After the etching process, the stents can be separated by
severing the small webs or tabs which connect them.
[0016] Other features and advantages of the present invention will
become more apparent from the following detailed description of the
invention. When taken in conjunction with the accompanying
exemplary drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an elevational view, partially in section, of a
stent embodying features of the invention which is mounted on a
delivery catheter and disposed within a damaged artery.
[0018] FIG. 2 is an elevational view, partially in section, similar
to that shown in FIG. 1 wherein the stent is expanded within a
damaged artery, pressing the damaged lining against the arterial
wall.
[0019] FIG. 3 is an elevational view, partially in section showing
the expanded stent within the artery after withdrawal of the
delivery catheter.
[0020] FIG. 4 is a perspective view of a stent embodying features
of the invention in an unexpanded state, with one end of the stent
being shown in an exploded view illustrate the details thereof.
[0021] FIG. 5 is a plan view of a flattened section of a stent of
the invention which illustrates the undulating pattern of the stent
shown in FIG. 4.
[0022] FIG. 6 is a schematic representation of equipment for
selectively removing coating applied to tubing in the manufacturing
of the stents of the present invention.
[0023] FIGS. 7 through 10 are perspective views schematically
illustrating various configurations of interconnective element
placement between the radially expandable cylindrical elements of
the stent.
[0024] FIG. 11 is a plan view of a flattened section of a stent
illustrating an alternate undulating pattern in the expandable
cylindrical elements of the stent which are out of phase.
[0025] FIG. 12 is an enlarged partial view of the stent of FIG. 5
with the various members slightly expanded.
[0026] FIG. 13 is a perspective view of the stent of FIG. 4 after
it is fully expanded depicting some members projecting radially
outwardly.
[0027] FIG. 14 is an enlarged, partial perspective view of one
U-shaped member with its tip projecting outwardly after
expansion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] FIG. 1 illustrates a stent 10 incorporating features of the
invention which is mounted onto a delivery catheter 11. The stent
generally comprises a plurality of radially expandable cylindrical
elements 12 disposed generally coaxially and interconnected by
elements 13 disposed between adjacent cylindrical elements. The
delivery catheter 11 has an expandable portion or balloon 14 for
expanding of the stent 10 within an artery 15. The artery 15, as
shown in FIG. 1 has a dissected lining 16 which has occluded a
portion of the arterial passageway.
[0029] The delivery catheter 11 onto which the stent 10 is mounted,
is essentially the same as a conventional balloon dilatation
catheter for angioplasty procedures. The balloon 14 may be formed
of suitable materials such as polyethylene, polyethylene
terephthalate, polyvinyl chloride, nylon and ionomers such as
Surlyn.RTM. manufactured by the Polymer Products Division of the Du
Pont Company. Other polymers may also be used. In order for the
stent 10 to remain in place on the balloon 14 during delivery to
the site of the damage within the artery 15, the stent 10 is
compressed onto the balloon. A retractable protective delivery
sleeve 20 as described in co-pending applications Ser. No.
07/647,464 filed on Apr. 25, 1990 and entitled STENT DELIVERY
SYSTEM may be provided to further ensure that the stent stays in
place on the expandable portion of the delivery catheter 11 and
prevent abrasion of the body lumen by the open surface of the stent
20 during delivery to the desired arterial location. Other means
for securing the stent 10 onto the balloon 14 may also be used,
such as providing collars or ridges on the ends of the working
portion, i.e. the cylindrical portion, of the balloon.
[0030] Each radially expandable cylindrical element 12 of the stent
10 may be independently expanded. Therefore, the balloon 14 may be
provided with an inflated shape other than cylindrical, e.g.
tapered, to facilitate implantation of the stent 10 in a variety of
body lumen shapes.
[0031] In a preferred embodiment, the delivery of the stent 10 is
accomplished in the following manner. The stent 10 is first mounted
onto the inflatable balloon 14 on the distal extremity of the
delivery catheter 11. The balloon 14 is slightly inflated to secure
the stent 10 onto the exterior of the balloon. The catheter-stent
assembly is introduced within the patient's vasculature in a
conventional Seldinger technique through a guiding catheter (not
shown). A guidewire 18 is disposed across the damaged arterial
section with the detached or dissected lining 16 and then the
catheter-stent assembly is advanced over a guidewire 18 within the
artery 15 until the stent 10 is directly under the detached lining
16. The balloon 14 of the catheter is expanded, expanding the stent
10 against the artery 15, which is illustrated in FIG. 2. While not
shown in the drawing, the artery 15 is preferably expanded slightly
by the expansion of the stent 10 to seat or otherwise fix the stent
10 to prevent movement. In some circumstances during the treatment
of stenotic portions of an artery, the artery may have to be
expanded considerably in order to facilitate passage of blood or
other fluid therethrough.
[0032] The stent 10 serves to hold open the artery 15 after the
catheter 11 is withdrawn, as illustrated by FIG. 3. Due to the
formation of the stent 10 from elongated tubular member, the
undulating component of the cylindrical elements of the stent 10 is
relatively flat in transverse cross-section, so that when the stent
is expanded, the cylindrical elements are pressed into the wall of
the artery 15 and as a result do not interfere with the blood flow
through the artery 15. The cylindrical elements 12 of stent 10
which are pressed into the wall of the artery 15 will eventually be
covered with endothelial cell growth which further minimizes blood
flow interference. The undulating portion of the cylindrical
sections 12 provide good tacking characteristics to prevent stent
movement within the artery. Furthermore, the closely spaced
cylindrical elements 12 at regular intervals provide uniform
support for the wall of the artery 15, and consequently are well
adapted to tack up and hold in place small flaps or dissections in
the wall of the artery 15 as illustrated in FIGS. 2 and 3.
[0033] FIG. 4 is an enlarged perspective view of the stent 10 shown
in FIG. 1 with one end of the stent shown in an exploded view to
illustrate in greater detail the placement of interconnecting
elements 13 between adjacent radially expandable cylindrical
elements 12. Each pair of the interconnecting elements 13 on one
side of a cylindrical element 12 are preferably placed to achieve
maximum flexibility for a stent. In the embodiment shown in FIG. 4
the stent 10 has three interconnecting elements 13 between adjacent
radially expandable cylindrical elements 12 which are 120 degrees
apart. Each pair of interconnecting elements 13 on one side of a
cylindrical element 12 are offset radially 60 degrees from the pair
on the other side of the cylindrical element. The alternation of
the interconnecting elements results in a stent which is
longitudinally flexible in essentially all directions. Various
configurations for the placement of interconnecting elements are
possible, and several examples are illustrated schematically in
FIGS. 7-10. However, as previously mentioned, all of the
interconnecting elements of an individual stent should be secured
to either the peaks or valleys of the undulating structural
elements in order to prevent shortening of the stent during the
expansion thereof.
[0034] FIG. 10 illustrates a stent of the present invention wherein
three interconnecting elements 12 are disposed between radially
expandable cylindrical elements 11. The interconnecting elements 12
are distributed radially around the circumference of the stent at a
120-degree spacing. Disposing four or more interconnecting elements
13 between adjacent cylindrical elements 12 will generally give
rise to the same considerations discussed above for two and three
interconnecting elements.
[0035] The properties of the stent 10 may also be varied by
alteration of the undulating pattern of the cylindrical elements
13. FIG. 11 illustrates an alternative stent structure in which the
cylindrical elements are in serpentine patterns but out of phase
with adjacent cylindrical elements. The particular pattern and how
many undulations per unit of length around the circumference of the
cylindrical element 13, or the amplitude of the undulations, are
chosen to fill particular mechanical requirements for the stent
such as radial stiffness.
[0036] The number of undulations may also be varied to accommodate
placement of interconnecting elements 13, e.g. at the peaks of the
undulations or along the sides of the undulations as shown in FIGS.
5 and 11.
[0037] In keeping with the invention, and with reference to FIGS. 4
and 12-14, cylindrical elements 12 are in the form of a serpentine
pattern 30. As previously mentioned, each cylindrical element 12 is
connected by interconnecting elements 13. Serpentine pattern 30 is
made up of a plurality of U-shaped members 31, W-shaped members 32,
and Y-shaped members 33, each having a different radius so that
expansion forces are more evenly distributed over the various
members.
[0038] As depicted in FIGS. 13 and 14, after cylindrical elements
12 have been radially expanded, outwardly projecting edges 34 are
formed. That is, during radial expansion U-shaped members 31 will
tip outwardly thereby forming outwardly projecting edges. These
outwardly projecting edges provide for a roughened outer wall
surface of stent 10 and assist in implanting the stent in the
vascular wall by embedding into the vascular wall. In other words,
outwardly projecting edges embed into the vascular wall, for
example artery 15, as depicted in FIG. 3. Depending upon the
dimensions of stent 10 and the thickness of the various members
making up the serpentine pattern 30, any of the U-shaped members
31, W-shaped members 32, and Y-shaped members 33 can tip radially
outwardly to form a projecting edge 34. It is most likely and
preferred that U-shaped members 31 tip outwardly since they do not
join with any connecting member 13 to prevent them from expanding
outwardly.
[0039] The stent 10 of the present invention can be made in many
ways. However, the preferred method of making the stent is to coat
a thin-walled tubular member, such as stainless steel tubing, with
a material which is resistive to chemical etchants, remove portions
of the coating to expose underlying tubing which is to be removed
but to leave coated portions of the tubing in the desired pattern
for the stent so that subsequent etching will remove the exposed
portions of the metallic tubing, but will leave relatively
untouched the portions of the metallic tubing which are to form the
stent. The coated portion of the metallic tube is in the desired
shape for the stent. An etching process avoids the necessity of
removing burrs or slag inherent in conventional or laser machining
process. It is preferred to remove the etchant-resistive material
by means of a machine-controlled laser as illustrated schematically
in FIG. 6.
[0040] A coating is applied to a length of tubing which, when
cured, is resistive to chemical etchants. "Blue Photoresist" made
by the Shipley Company in San Jose, Calif., is an example of
suitable commercially available photolithographic coatings. The
coating is preferably applied by electrophoretic deposition.
[0041] To ensure that the surface finish is reasonably uniform, one
of the electrodes used for the electrochemical polishing is a
doughnut-shaped electrode which is placed about the central portion
of the tubular member.
[0042] The tubing may be made of suitable biocompatible material
such as stainless steel, titanium, tantalum, superelastic NiTi
alloys and even high strength thermoplastic polymers. The stent
diameter is very small, so the tubing from which it is made must
necessarily also have a small diameter. Typically the stent has an
outer diameter on the order of about 0.06 inch in the unexpanded
condition, the same outer diameter of the tubing from which it is
made, and can be expanded to an outer diameter of 0.1 inch or more.
The wall thickness of the tubing is about 0.003 inch. In the
instance when the stent was plastic, it would have to be heated
within the arterial site where the stent is expanded to facilitate
the expansion of the stent. Once expanded, it would then be cooled
to retain its expanded state. The stent may be conveniently heated
by heating the fluid within the balloon or the balloon directly by
a suitable system such as disclosed in a co-pending application
Ser. No. 07/521,337, filed Jan. 26, 1990 entitled DILATATION
CATHETER ASSEMBLY WITH HEATED BALLOON which is incorporated herein
in its entirety by reference. The stent may also be made of
materials such as superelastic NiTi alloys such as described in
co-pending application Ser. No. 07/629,381, filed Dec. 18, 1990,
entitled SUPERELASTIC GUIDING MEMBER which is incorporated herein
in its entirety by reference. In this case the stent would be
formed full size but deformed (e.g. compressed) into a smaller
diameter onto the balloon of the delivery catheter to facilitate
transfer to a desired intraluminal site. The stress induced by the
deformation transforms the stent from a martensite phase to an
austenite phase and upon release of the force, when the stent
reaches the desired intraluminal location, allows the stent to
expand due to the transformation back to the martensite phase.
[0043] Referring to FIG. 6, the coated tubing 21 is put in a
rotatable collet fixture 22 of a machine controlled apparatus 23
for positioning the tubing 21 relative to a laser 24. According to
machine-encoded instructions, the tubing 21 is rotated and moved
longitudinally relative to the laser 24 which is also machine
controlled. The laser selectively removes the etchant-resistive
coating on the tubing by ablation and a pattern is formed such that
the surface of the tube that is to be removed by a subsequent
chemical etching process is exposed. The surface of the tube is
therefore left coated in the discrete pattern of the finished
stent.
[0044] A presently preferred system for removing the coating on the
tubing includes the use an 80-watt CO.sub.2 laser, such as a
Coherent Model 44, in pulse mode (0.3 mS pulse length); 48 mA key
current and 48 W key power with 0.75 W average power, at 100 Hz;
Anorad FR=20; 12.5 Torr; with no assist gas. Low pressure air is
directed through the fine focus head to ensure that no vapor
contacts the lens. The assist gas jet assembly on the laser unit
may be removed to allow a closer proximity of the fine focus head
and the collet fixture. Optimum focus is set at the surface of the
tubing. Cured photo-resist coating readily absorbs the energy of
the CO.sub.2 wavelength, so that it can be readily removed by the
laser. A coated 4-inch length of 0.06 inch stainless steel tubing
is preferred and four stents can be patterned on the length of
tubing. Three tabs or webs between stents provide good handling
characteristics for the tubing after the etching process.
[0045] The process of patterning the resistive coating on the stent
is automated except for loading and unloading the length of tubing.
Referring again to FIG. 6 it may be done, for example, using a
CNC-opposing collet fixture 22 for axial rotation of the length of
tubing, in conjunction with a CNC X/Y table 25 to move the length
of tubing axially relative to a machine-controlled laser as
described. The entire space between collets can be patterned using
the CO.sub.2 laser set-up of the foregoing example. The program for
control of the apparatus is dependent on the particular
configuration used and the pattern to be ablated in the coating,
but is otherwise conventional.
[0046] This process makes possible the application of present
photolithography technology in manufacturing the stents. While
there is presently no practical way to mask and expose a tubular
photo-resist coated part of the small size required for making
intravascular stents, the foregoing steps eliminate the need for
conventional masking techniques.
[0047] After the coating is thus selectively ablated, the tubing is
removed from the collet fixture 22. Next, wax such at ThermoCote
N-4 is heated to preferably just above its melting point, and
inserted into the tubing under vacuum or pressure. After the wax
has solidified upon cooling, it is reheated below its melting point
to allow softening, and a smaller diameter stainless steel shaft is
inserted into the softened wax to provide support. The tubing is
then etched chemically in a conventional manner. After cutting the
tabs connecting the stents any surface roughness or debris from the
tabs is removed. The stents are preferably electrochemically
polished in an acidic aqueous solution such as a solution of
ELECTRO-GLO #300, sold by the ELECTRO-GLO CO., Inc. in Chicago,
Ill., which is a mixture of sulfuric acid, carboxylic acids,
phosphates, corrosion inhibitors and a biodegradable surface active
agent. The bath temperature is maintained at about 110-135 degrees
F. and the current density is about 0.4 to about 1.5 amps per
in..sup.2 Cathode to anode area should be at least about two to
one. The stents may be further treated if desired, for example by
applying a biocompatible coating.
[0048] While the invention has been illustrated and described
herein in terms of its use as an intravascular stent, it will be
apparent to those skilled in the art that the stent can be used in
other instances such as to expand prostatic urethras in cases of
prostate hyperplasia. Other modifications and improvements may be
made without departing from the scope of the invention.
[0049] Other modifications and improvements can be made to the
invention without departing from the scope thereof.
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