U.S. patent application number 17/496170 was filed with the patent office on 2022-04-14 for heat-activated crimping textile.
The applicant listed for this patent is THE SECANT GROUP, LLC. Invention is credited to Andrew METZGER, Amanda K. WEBER.
Application Number | 20220112634 17/496170 |
Document ID | / |
Family ID | |
Filed Date | 2022-04-14 |
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United States Patent
Application |
20220112634 |
Kind Code |
A1 |
WEBER; Amanda K. ; et
al. |
April 14, 2022 |
HEAT-ACTIVATED CRIMPING TEXTILE
Abstract
A heat-activated crimping textile is disclosed including a
plurality of a first yarn, a plurality of a second yarn interlaced
with the plurality of the first yarn, and a plurality of a third
yarn interlaced with the plurality of the first yarn, the plurality
of the second yarn, or both. The third yarn includes a
heat-activated shrinkage factor of greater than 30% when exposed to
a predetermined temperature. When the heat-activated crimping
textile is exposed to an elevated temperature of at least the
predetermined temperature, a plurality of crimps propagates along
the heat-activated crimping textile, forming a crimped textile.
Inventors: |
WEBER; Amanda K.; (Macungie,
PA) ; METZGER; Andrew; (Lafayette Hill, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THE SECANT GROUP, LLC |
Telford |
PA |
US |
|
|
Appl. No.: |
17/496170 |
Filed: |
October 7, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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63089294 |
Oct 8, 2020 |
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International
Class: |
D03D 15/567 20060101
D03D015/567; D03D 27/06 20060101 D03D027/06; D04B 21/16 20060101
D04B021/16; D04B 1/20 20060101 D04B001/20 |
Claims
1. A heat-activated crimping textile, comprising: a plurality of a
first yarn; a plurality of a second yarn interlaced with the
plurality of the first yarn; and a plurality of a third yarn
interlaced with the plurality of the first yarn, the plurality of
the second yarn, or both, wherein: the third yarn includes a
heat-activated shrinkage factor of greater than 30% when exposed to
a predetermined temperature; and when the heat-activated crimping
textile is exposed to an elevated temperature of at least the
predetermined temperature, a plurality of crimps propagates along
the heat-activated crimping textile, forming a crimped textile.
2. The heat-activated crimping textile of claim 1, wherein the
first yarn includes a heat-activated shrinkage factor of less than
15% when exposed to the predetermined temperature and the second
yarn includes a heat-activated shrinkage factor of less than 15%
when exposed to the predetermined temperature.
3. The heat-activated crimping textile of claim 2, wherein the
first yarn includes a heat-activated shrinkage factor of less than
10% when exposed to the predetermined temperature.
4. The heat-activated crimping textile of claim 2, wherein the
second yarn includes a heat-activated shrinkage factor of less than
10% when exposed to the predetermined temperature.
5. The heat-activated crimping textile of claim 2, wherein the
third yarn includes a heat-activated shrinkage factor between 35%
and 50% when exposed to the predetermined temperature.
6. The heat-activated crimping textile of claim 1, wherein the
first yarn includes a heat-activated shrinkage factor of greater
than 30% when exposed to a predetermined temperature and the second
yarn includes a heat-activated shrinkage factor of greater than 30%
when exposed to the predetermined temperature.
7. The heat-activated crimping textile of claim 1, wherein: the
heat-activated crimping textile is a woven fabric; the plurality of
the first yarn forms a first plurality of wefts; the plurality of
the second yarn forms a first plurality of warps interlaced with
the first plurality of wefts by interweaving; the plurality of the
third yarn forms a second plurality of warps interlaced with the
first plurality of wefts by interweaving; and the plurality of
crimps propagates along the first plurality of wefts.
8. The heat-activated crimping textile of claim 7, further
including a second plurality of wefts comprising a fourth yarn
having a heat-activated shrinkage factor of greater than 30% when
exposed to the predetermined temperature.
9. The heat-activated crimping textile of claim 7, wherein the
woven fabric includes a repeating weaving pattern in which the
second plurality of warps interlaces amongst 3-5 of the first
plurality of wefts sequentially, then floats across 4-20 of the
first plurality of wefts sequentially, and then repeats.
10. The heat-activated crimping textile of claim 9, wherein the
second plurality of warps interlaces amongst 4 of the first
plurality of wefts sequentially, then floats across 8 of the first
plurality of wefts sequentially, and then repeats.
11. The heat-activated crimping textile of claim 1, wherein: the
heat-activated crimping textile is a warp knit fabric; the
plurality of the first yarn forms a first plurality of warps; the
plurality of the second yarn forms a second plurality of warps
interlaced with the first plurality of warps by interlooping; the
plurality of the third yarn forms a third plurality of warps
interlaced with the first plurality of warps, the second plurality
of warps, or both by interlooping; and the plurality of crimps
propagates along a machine direction of the warp knit fabric.
12. The heat-activated crimping textile of claim 11, wherein the
warp knit fabric includes a repeating knit pattern in which the
third plurality of warps interloops amongst 1-4 warp ends of the
first plurality of warps and the second plurality of warps combined
sequentially, then floats across 4-20 courses sequentially of the
first plurality of warps and the second plurality of warps
combined, and then repeats.
13. The heat-activated crimping textile of claim 12, wherein the
third plurality of warps interloops amongst 1 of the warp ends of
the first plurality of warps and the second plurality of warps
combined sequentially, then floats across 11 of the courses of the
first plurality of warps and the second plurality of warps combined
sequentially, and then repeats.
14. The heat-activated crimping textile of claim 12, wherein the
third yarn floats only across a first side of the heat-activated
crimping textile.
15. The heat-activated crimping textile of claim 1, wherein the
first yarn and the second yarn are compositionally distinct from
one another.
16. The heat-activated crimping textile of claim 1, wherein the
first yarn and the second yarn are compositionally indistinct from
one another.
17. The heat-activated crimping textile of claim 1, wherein the
first yarn and the second yarn are formed from materials
independently selected from the group consisting of polyethylene
terephthalate (PET), polypropylene (PP), polyethylene (PE),
polyvinylchloride polystyrene (PS), polycarbonate (PC), nylons,
polylactic acid (PLA), poly (l-lactic acid) (PLLA),
polycaprolactone (PCL), poly lactic-co-glycolic acid (PLGA) and
combinations thereof.
18. The heat-activated crimping textile of claim 1, wherein the
third yarn is formed from a material selected from the group
consisting of polyethylene terephthalate (PET), polypropylene (PP),
polyethylene (PE), polyvinylchloride (PVC), polystyrene (PS),
polycarbonate (PC), nylons, polylactic acid (PLA), poly (l-lactic
acid) (PLLA), polycaprolactone (PCL), poly lactic-co-glycolic acid
(PLGA) and combinations thereof.
19. The heat-activated crimping textile of claim 1, wherein the
crimped textile has a pleated structure, a ruffled structure, a
channeled structure, or combinations thereof.
20. The heat-activated crimping textile of claim 1, wherein the
heat-activated crimping textile and the crimped textile formed from
the heat-activated crimping textile are substantially unsewn.
21. The heat-activated crimping textile of claim 1, wherein the
heat-activated crimping textile and the crimped textile formed from
the heat-activated crimping textile are substantially free of
needle punctures and key holes.
22. A medically implantable textile formed from the heat-activated
crimping textile of claim 1.
23. The medically implantable textile of claim 18, wherein the
medically implantable textile is a paravalvular leak skirt.
24. A heat-activated crimping textile, comprising: a first
plurality of wefts formed of a first yarn; a first plurality of
warps formed of a second yarn interwoven with the first plurality
of wefts; and a second plurality of warps formed of a third yarn
interwoven with the first plurality of wefts, wherein: the first
yarn includes a heat-activated shrinkage factor of less than 10%
when exposed to a predetermined temperature; the second yarn
includes a heat-activated shrinkage factor of less than 10% when
exposed to the predetermined temperature; the third yarn includes a
heat-activated shrinkage factor between 35% and 50% when exposed to
the predetermined temperature; the predetermined temperature is at
least 150.degree. C.; when the heat-activated crimping textile is
exposed to an elevated temperature of at least the predetermined
temperature, a plurality of crimps propagates along the first
plurality of wefts, forming a crimped textile having a pleated,
ruffled, or channeled structure; the heat-activated crimping
textile includes a repeating weaving pattern in which the third
yarn interlaces at least 2 of the first plurality of wefts
sequentially, then floats across a minimum of 3 of the first
plurality of wefts sequentially only across a first side of the
heat-activated crimping textile, and then repeats; and the
heat-activated crimping textile and the crimped textile formed from
the heat-activated crimping textile are substantially unsewn and
substantially free of needle punctures and key holes.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Patent Application No. 63/089,294, filed Oct. 8, 2020,
entitled "Heat-Activated Crimping Textile," which is hereby
incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This application is directed to heat-activated crimping
textiles. In particular, this application is directed to
heat-activated crimping textiles including a portion of the yarns
having a greater shrinkage factor than other yarns, weave
structures which promote crimping, or both.
BACKGROUND OF THE INVENTION
[0003] In recent years, transcatheter aortic valve
replacement/repair ("TAVR") surgery has grown at a 30% increase
annually over open surgical approaches. The challenges within TAVR
include patient-prosthesis mismatch, coronary obstruction, heart
rhythm abnormalities post implantation, stroke, and paravalvular
leaks post implantation. Significant paravalvular aortic
regurgitation ("AR") or paravalvular leak ("PVL") (moderate and
severe) occurs in approximately 15-20% of TAVR cases and is one of
the most important prognostic factors of mortality during both
short- and long-term follow-up. Transcatheter mitral valve
replacement ("TMVR") and Transcatheter tricuspid valve replacement
("TTVR") have moderate-to-high PVL in 3.5% of cases.
[0004] PVL skirting is currently made from warp knitted pile
fabrics which use loops to create a compressibility factor to the
textile. These fabrics do a good job of creating a soft voluminous
filler between the transcatheter heart valve device and the native
anatomy but have only their individual loop yarn strength to create
any tenacity needed to spring back from a compressed state.
[0005] Knitted pile fabrics are not dense enough to create a blood
tight vessel to contain blood flow. Rather, they depend on the
looped regions to create a torturous path between the device and
vessel that allows for clotting.
[0006] It would be desirable in the art to have an implantable
textile not having the aforementioned drawbacks.
BRIEF DESCRIPTION OF THE INVENTION
[0007] In one exemplary embodiment, a heat-activated crimping
textile includes a plurality of a first yarn, a plurality of a
second yarn interlaced with the plurality of the first yarn, and a
plurality of a third yarn interlaced with the plurality of the
first yarn, the plurality of the second yarn, or both. The third
yarn includes a heat-activated shrinkage factor of greater than 30%
when exposed to a predetermined temperature. When the
heat-activated crimping textile is exposed to an elevated
temperature of at least the predetermined temperature, a plurality
of crimps propagates along the heat-activated crimping textile,
forming a crimped textile.
[0008] In another exemplary embodiment, a heat-activated crimping
textile includes a first plurality of wefts formed of a first yarn,
a first plurality of warps formed of a second yarn interwoven with
the first plurality of wefts, and a second plurality of warps
formed of a third yarn interwoven with the first plurality of
wefts. The first yarn includes a heat-activated shrinkage factor of
less than 10% when exposed to a predetermined temperature. The
second yarn includes a heat-activated shrinkage factor of less than
10% when exposed to the predetermined temperature. The third yarn
includes a heat-activated shrinkage factor between 35% and 50% when
exposed to the predetermined temperature. The predetermined
temperature is at least 150.degree. C. When the heat-activated
crimping textile is exposed to an elevated temperature of at least
the predetermined temperature, a plurality of crimps propagates
along the first plurality of wefts, forming a crimped textile
having a pleated, ruffled, or channeled structure. The
heat-activated crimping textile includes a repeating weaving
pattern in which the third yarn interlaces at least two of the
first plurality of wefts sequentially, then floats across a minimum
of three of the first plurality of wefts sequentially only across a
first side of the heat-activated crimping textile, and then
repeats. The heat-activated crimping textile and the crimped
textile formed from the heat-activated crimping textile are
substantially unsewn and substantially free of needle punctures and
key holes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a woven loomstate diagram depicting a
heat-activated crimping textile, according to an embodiment of the
present disclosure.
[0010] FIG. 2 is a diagram of the woven textile after the
thermoforming process depicting a crimped textile formed from the
heat-activated crimping textile of FIG. 1, according to an
embodiment of the present disclosure.
[0011] FIG. 3 is a perspective view of the crimped textile of FIG.
2, according to an embodiment of the present disclosure.
[0012] FIG. 4 is a plan view of the heat-activated crimping textile
of FIG. 1, according to an embodiment of the present
disclosure.
[0013] FIG. 5 is a diagram of a woven textile having a channel or
woven effect running perpendicular to a pleat, according to an
embodiment of the present disclosure.
[0014] FIG. 6 is a plan view of a woven textile including a
combination of a single layer weave and a crimped weave repeating
in a half drop or brick layout repeat to form a checkered pattern
of pleats/ruffles, according to an embodiment of the present
disclosure.
[0015] FIG. 7 is knit pattern for a warp knit fabric, according to
an embodiment of the present disclosure.
[0016] FIG. 8 is a plan view of a warp knit fabric formed according
to the knit pattern of FIG. 7 following heat setting above the
predetermined temperature, according to an embodiment of the
present disclosure.
[0017] FIG. 9 is an elevation view of a portion of the warp knit
fabric of FIG. 8, according to an embodiment of the present
disclosure.
[0018] FIG. 10 is a knit pattern for a knitted tube fabric,
according to an embodiment of the present disclosure.
[0019] FIG. 11 is a knitted tube fabric formed according to the
knit pattern of FIG. 10, according to an embodiment of the present
disclosure.
[0020] FIG. 12 is the knitted tube fabric of FIG. 11 following heat
setting above the predetermined temperature, according to an
embodiment of the present disclosure.
[0021] Wherever possible, the same reference numbers will be used
throughout the drawings to represent the same parts. Hatching is
used to designate high shrinkage factor yarns.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Embodiments of the present invention create a textile with
customized pleats, ridges, or ruffles that are designed by a
specific weave pattern that joins to a ground layer to create
raised regions that are resilient when compressed but can expand
back to its thermoformed state when the compression is released.
Embodiments of the present disclosure, in comparison to textiles
lacking one or more of the features of the present invention, may
provide the advantage of the textile being able to be deployed to
fill space, such as between a device and native tissue/vessel wall
when used to seal heart valve devices and gives antimigratory
properties during the deployment process to inhibit paravalvular
leakage.
[0023] By creating a woven pleat or ruffle that has the strength of
not only one yarn, but a multiplex of yarns interlaced together,
the textile may provide a more robust layer with more resilience,
strength, and tunable height distinction between the multilayers
that form the textile. Embodiments of the present disclosure may
eliminate any sewing processes typically needed to create
pleats/ruffles by using a combination of high shrink/low shrink
yarns, weave designs, and thermoforming processes. When using
multi-surfaced woven solutions of embodiments of the present
disclosure, fabrics may be tuned so as to have regions that may be
dense for blood tight blocking and regions of more open porous
areas for blood capturing and clotting.
[0024] Referring to FIGS. 1-4 and 7, in one embodiment, a
heat-activated crimping textile 100 includes a plurality of a first
yarn 102, a plurality of a second yarn 104 interlaced with the
plurality of the first yarn 102, and a plurality of a third yarn
106 interlaced with the plurality of the first yarn 102, the
plurality of the second yarn 104, or both. The third yarn 106
includes a heat-activated shrinkage factor of greater than 30% when
exposed to a predetermined temperature. When the heat-activated
crimping textile 100 is exposed to an elevated temperature of at
least the predetermined temperature, a plurality of crimps 108
propagates along the heat-activated crimping textile 100, forming a
crimped textile 110.
[0025] The third yarn 106 may include any suitable heat-activated
shrinkage factor when exposed to the predetermined temperature,
including, but not limited to, a heat-activated shrinkage factor of
greater than 30%, alternatively, greater than 35%, alternatively
greater than 40%, alternatively between 35% to 50%, alternatively
40% to 45%, or any sub-range contained therein.
[0026] In one embodiment, the first yarn 102 includes a
heat-activated shrinkage factor of less than 15% when exposed to
the predetermined temperature and the second yarn 104 includes a
heat-activated shrinkage factor of less than 15% when exposed to
the predetermined temperature. The first yarn 102 may include any
suitable heat-activated shrinkage factor when exposed to the
predetermined temperature, including, but not limited to, a
heat-activated shrinkage factor of less than 15%, alternatively,
less than 10%, alternatively between 5% to 9%, alternatively 6% to
8%, alternatively 7%, or any sub-range contained therein. The
second yarn 104 may include any suitable heat-activated shrinkage
factor when exposed to the predetermined temperature, including,
but not limited to, a heat-activated shrinkage factor of less than
15%, alternatively, less than 10%, alternatively between 5% to 9%,
alternatively 6% to 8%, alternatively 7%, or any sub-range
contained therein.
[0027] In a further embodiment, to obtain a desired ruffle or
pleating effect, the shrinkage factor of the third yarn 106 exceeds
that of the greatest shrinkage factor of the first yarn 102 and the
second yarn 104 by at least 30 points (e.g., if the first yarn 102
and the second yarn 104 have a heat-activated shrinkage factor of
10%, the third yarn 106 would have a heat activated shrinkage
factor of at least 40%).
[0028] In another embodiment, the first yarn 102 includes a
heat-activated shrinkage factor of greater than 30% when exposed to
the predetermined temperature and the second yarn 104 includes a
heat-activated shrinkage factor of greater than 30% when exposed to
the predetermined temperature. The first yarn 102 may include any
suitable heat-activated shrinkage factor when exposed to the
predetermined temperature, including, but not limited to, a
heat-activated shrinkage factor of greater than 30%, alternatively,
greater than 35%, alternatively greater than 40%, alternatively
between 35% to 50%, alternatively 40% to 45%, or any sub-range
contained therein. The second yarn 104 may include any suitable
heat-activated shrinkage factor when exposed to the predetermined
temperature, including, but not limited to, a heat-activated
shrinkage factor of greater than 30%, alternatively, greater than
35%, alternatively greater than 40%, alternatively between 35% to
50%, alternatively 40% to 45%, or any sub-range contained
therein.
[0029] In yet another embodiment, the first yarn 102 includes a
heat-activated shrinkage factor of less than 15% when exposed to
the predetermined temperature and the second yarn 104 includes a
heat-activated shrinkage factor of greater than 30% when exposed to
the predetermined temperature. The first yarn 102 may include any
suitable heat-activated shrinkage factor when exposed to the
predetermined temperature, including, but not limited to, a
heat-activated shrinkage factor of less than 15%, alternatively,
less than 10%, alternatively between 5% to 9%, alternatively 6% to
8%, alternatively 7%, or any sub-range contained therein. The
second yarn 104 may include any suitable heat-activated shrinkage
factor when exposed to the predetermined temperature, including,
but not limited to, a heat-activated shrinkage factor of greater
than 30%, alternatively, greater than 35%, alternatively greater
than 40%, alternatively between 35% to 50%, alternatively 40% to
45%, or any sub-range contained therein.
[0030] In yet another embodiment, the first yarn 102 includes a
heat-activated shrinkage factor of greater than 30% when exposed to
the predetermined temperature and the second yarn 104 includes a
heat-activated shrinkage factor of less than 15% when exposed to
the predetermined temperature. The first yarn 102 may include any
suitable heat-activated shrinkage factor when exposed to the
predetermined temperature, including, but not limited to, a
heat-activated shrinkage factor of greater than 30%, alternatively,
greater than 35%, alternatively greater than 40%, alternatively
between 35% to 50%, alternatively 40% to 45%, or any sub-range
contained therein. The second yarn 104 may include any suitable
heat-activated shrinkage factor when exposed to the predetermined
temperature, including, but not limited to, a heat-activated
shrinkage factor of less than 15%, alternatively, less than 10%,
alternatively between 5% to 9%, alternatively 6% to 8%,
alternatively 7%, or any sub-range contained therein.
[0031] Any of the first yarn 102, the second yarn 104, and the
third yarn 106 may independently be flat, round, multilobal,
texturized, be core and effect yarns, or any combination thereof.
Examples of core and effect yarns include, but are not limited to,
chenille, boucle, and any other "fancy" yarn made by plying
multiple yarns or fibers together while creating a textured effect
on the outer surface of the yarn. Boucle yarn, for example, may
have an inner yarn of straight fibers while the outer surface is
wrapped with another bundle of fibers that create a looping effect
by twisting and intertwining the outer yarns to create a desired
texture effect. Core and effect yarns may also be created by
overfeeding one set of fibers and underfeeding the other set such
that the overfed set twists around the underfed set creating a
textured yarn. Monofilament fiber may also be utilized, and, in one
embodiment, incorporation of monofilament fiber increases pleat
resilience.
[0032] The first yarn 102 and the second yarn 104 may be formed
from any suitable materials, including, but not limited to,
polyethylene terephthalate (PET), polypropylene (PP), polyethylene
(PE), polyvinylchloride (PVC), polystyrene (PS), and polycarbonate
(PC), nylons as well as bioresorbable thermoplastics such as but
not limited to polylactic acid (PLA), including poly (l-lactic
acid) (PLLA), polycaprolactone (PCL), and poly lactic-co-glycolic
acid (PLGA) or combinations thereof. The first yarn 102 may be the
same material (compositionally indistinct) as the second yarn 104
or may be a different material (compositionally distinct) from the
second yarn 104. As used herein, "compositionally distinct" and
"compositionally indistinct" refers to chemical composition rather
than structural composition.
[0033] The third yarn 106 may be a high shrinkage yarn having a
heat-activated shrinkage factor of greater than 30%, but may be
otherwise formed of like materials as the first and second yarn,
including, but not limited to, polyethylene terephthalate (PET),
polypropylene (PP), polyethylene (PE), polyvinylchloride (PVC),
polystyrene (PS), and polycarbonate (PC), nylons as well as
bioresorbable thermoplastics such as but not limited to polylactic
acid (PLA), including poly (l-lactic acid) (PLLA), polycaprolactone
(PCL), and poly lactic-co-glycolic acid (PLGA) or combinations
thereof. In one embodiment, so as to be suitable for processing in
accordance with exemplary embodiments, the materials used for the
first yarn 102, the second yarn, 104, and the third yarn 106 are
able to withstand the same general exposure to heat so that melting
or other undesirable decomposition or physical changes of the first
yarn 102, the second yarn, 104, and the third yarn 106 are avoided.
The shrinkage factor of the yarn, in addition to the material from
which the yarn is formed, may also be influenced or controlled by
the polymerization process, the extrusion process, or both. As
such, two yarns formed of the same material (chemically) may have
significantly different ranges of shrinkage.
[0034] For embodiments in which some or all of the first yarn 102,
the second yarn, 104, or the third yarn 106 are formed of PET, the
predetermined temperature may be any suitable temperature,
including, but not limited to, at least 150.degree. C.,
alternatively at least 160.degree. C., alternatively at least
170.degree. C., alternatively at least 180.degree. C.,
alternatively at least 190.degree. C., alternatively at least
200.degree. C., alternatively at least 205.degree. C., or any
sub-range or combination thereof. It will be appreciated that the
predetermined temperatures for yarns the first yarn 102, the second
yarn, 104, and the third yarn 106 formed of PET may vary depending
on the material used in combination with the heat-activated
shrinkage factor for the particular yarn utilized.
[0035] In one embodiment, the third yarn 106 floats only across a
first side 120 of the heat-activated crimping textile 100. In
another embodiment, the third yarn 106 floats across both sides of
the heat-activated crimping textile 100, which may form pleats on
both sides (face and back) of the heat-activated crimping textile
100.
[0036] The crimped textile 110 may have a pleated structure, a
ruffled structure, a channeled structure, or combinations thereof.
The pleats, ruffles, or channels may have any suitable height
including, but not limited to, a height ranging from about 0.5 mm
to about 10 mm, alternatively about 0.5 mm, alternatively about 1
mm, alternatively about 2 mm, alternatively about 3 mm,
alternatively about 4 mm, alternatively about 5 mm, alternatively
about 6 mm, alternatively about 7 mm, alternatively about 8 mm,
alternatively about 9 mm, or alternatively about 10 mm. As used
herein, "about" indicates .+-.10% of the value being modified, as
well as the unmodified value, such that "about" 1 includes a range
of 0.9-1.1 and alternatively 1. In some embodiments the height is
in the range of about 0.5 mm to about 4 mm, alternatively about 0.5
mm to about 6 mm, alternatively about 1 mm to about 5 mm,
alternatively about 2 mm to about 6 mm, alternatively about 4 mm to
about 8 mm, alternatively about 6 mm to about 10 mm, or any
sub-range or combination there thereof.
[0037] The heat-activated crimping textile 100 and the crimped
textile 110 formed from the heat-activated crimping textile 100 may
be substantially unsewn, substantially free of needle puncture,
substantially free of keyholes, or combinations thereof. As used
herein, "substantially free" excludes the edges of the
heat-activated crimping textile 100 and the crimped textile 110 up
to, but not exceeding, 10% of the surface area of the
heat-activated crimping textile 100 and the crimped textile 110. In
a further embodiment, the heat-activated crimping textile 100 and
the crimped textile 110 formed from the heat-activated crimping
textile 100 are unsewn, free of needle puncture, free of keyholes,
or combinations thereof.
[0038] In one embodiment, when the heat-activated crimping textile
100 is heat set to form the crimped textile 110, the second yarn
104 forms a pleat, ruffle, channel, or combination thereof as the
third yarn 106 shrinks, pulling the heat-activated crimping textile
100 together and buckling the first yarn 102 and the second yarn
104 upward.
[0039] This pleating effect may also be achieved, for example, by
changing the position of second yarn 104 to third yarn 106 in an
every-other-end alternating pattern. In such a pattern, it would be
a second yarn 104 first end, third yarn 106 second end, second yarn
104 third end, and third yarn 106 fourth end drawing patterning. As
long as the third yarn 106 ends are floating on the first side 120
of the heat-activated crimping textile 100 and the second yarns 104
are on the face opposite to the first side 120 with first yarns
102, a ruffle may be formed during thermoforming.
[0040] In one embodiment, the crimped textile 110 formed from the
heat-activated crimping textile 100 is a medically implantable
textile. In a further embodiment, the medically implantable textile
is a paravalvular leak skirt, a textile for use with abdominal
aortic aneurysms, a textile for use with general surgery, or
combinations thereof. Textile density may be tuned depending upon
application. For example, if water/blood tightness is not as
concerning as thickness in certain applications, such as for
general surgery, a less dense, thinner, or thicker fabric may be
formed by changing the weave construction and count of first yarn
102, second yarn 104, third yarn 106, or combinations thereof. In
one embodiment, the crimped textile 110 formed from the
heat-activated crimping textile 100 is configured to clot blood and
seal during a surgery and to form a ground layer which is blood
tight.
[0041] In one embodiment, all yarn processing and weaving or
knitting or both to form the heat-activated crimping textile 100 is
conducted without treating or exposing the first yarn 102, the
second yarn 104, and the third yarn 106 to temperatures above
40.degree. C. in order to preserve the greatest shrinkability
possible during the thermoforming processes. If scouring is
performed, the scouring may be conducted at ambient
temperatures.
[0042] Before the first yarn 102, second yarn 104, or third yarn
106 is processed by any optional twisting, backwinding, or warping,
the first yarn 102, second yarn 104, or third yarn 106 may include
any suitable tensile strength and elongation factor, including, but
not limited to, a tensile strength of about 4 g/d to about 100 g/d
and elongation of about 3% to about 30%.
[0043] Heat setting the heat-activated crimping textile 100 to form
the crimped textile 110 may include any suitable heat source and
environment, including, but not limited to, an oven, exposure to
heated air, immersion in heated water, exposure to heated fluid
vapor, heated iron or fixtures, or combinations thereof.
[0044] In one embodiment, by weaving lower shrinkage yarn as a top
surface of a multilayer construction and a higher shrinkage yarn in
a ground region of the multilayer construction, the top surface may
have a constant coverage, while the higher shrinkage ground will
lose coverage as the material contracts during a thermoforming
process. By designing critical junctions between the top surface
and the ground region, the ground region may physically pull edge
regions of the top surface towards each other.
[0045] In one embodiment, a heat-activated crimping textile 100
includes at least one layer of fancy yarn such as boucle, chenille,
or other core and effect yarns that provide loft and increased
surface area for better sealing potential.
[0046] In another embodiment, a heat-activated crimping textile 100
includes a ground region with a tighter interlacement pattern, such
as, but not limited to, a tabby weave, and another layer with
longer interlacement pattern, such as, but not limited to, a satin,
a rib, or a twill, such that the longer float areas may be looser
and bulkier for maintaining a dense ground layer for better
clotting potential. In a further embodiment, a pocket structure
into the outer layer for blood capturing potential is incorporated
into the heat-activated crimping textile 100.
[0047] In another embodiment, a heat-activated crimping textile 100
incorporates yarn fibrils which circumferentially cover and extend
out of the surface of the heat-activated crimping textile 100. The
yarn fibrils may be present in the first yarn 102, the second yarn
104, the third yarn 106, the optional fourth yarn 132, or
combinations thereof.
[0048] In another embodiment, a method for forming a heat-activated
crimping textile 100 includes a texturizing technique applied to a
surface of the heat-activated crimping textile 100 (knitted or
woven), such as, but not limited to, napping, to break the outer
loops or floats resting on one side of the heat-activated crimping
textile 100.
[0049] Referring to FIGS. 1-4, in one embodiment, the
heat-activated crimping textile 100 is a woven fabric 112, the
plurality of the first yarn 102 forms a first plurality of wefts
114, the plurality of the second yarn 104 forms a first plurality
of warps 116 interlaced with the first plurality of wefts 114 by
interweaving, the plurality of the third yarn 106 forms a second
plurality of warps 118 interlaced with the first plurality of wefts
114 by interweaving, and the plurality of crimps 108 propagates
along the first plurality of wefts 114.
[0050] The woven fabric 112 may have any suitable repeating weaving
pattern, including, but not limited to, a repeating weaving pattern
in which the third yarn 106 interlaces at least 2 of the first
plurality of wefts 114 sequentially, typically 3 to 5, then floats
across a minimum of 3, typically 4 to 20 of the first plurality of
wefts 114 sequentially, and then repeats the interlacing and
floating (which may be the same or a different number as the prior
interlacement and/or float. In a further embodiment, the third yarn
106 interlaces 4 of the first plurality of wefts 114 sequentially,
then floats across 8 of the first plurality of wefts 114
sequentially, and then repeats.
[0051] When the heat-activated crimping textile 100 is exposed to
an elevated temperature of at least the predetermined temperature,
a plurality of crimps 108 propagates along the first plurality of
wefts 114, forming the crimped textile 110.
[0052] A fourth yarn 132 having a high shrinkage factor having a
heat-activated shrinkage factor of greater than 30% may optionally
be incorporated as a second plurality of wefts 138 in addition to
the second yarn 104 forming the first plurality of wefts 114. Like
the third yarn 106, the fourth yarn 132 may include any suitable
heat-activated shrinkage factor when exposed to a predetermined
temperature, including, but not limited to, a heat-activated
shrinkage factor of greater than 30%, alternatively, greater than
35%, alternatively greater than 40%, alternatively between 35% to
50%, alternatively 40% to 45%, or any sub-range contained therein.
The fourth yarn 132 may be the same as the third yarn 106 in
material and structure, distinct from the third yarn 106 in at
least one of material or structure, or distinct from the third yarn
106 in both material and structure.
[0053] The heat-activated crimping textile 100 may be woven on a
jacquard, dobby, or hand loom as a multi-surfaced flat woven or
tubular structure. In one embodiment, the jacquard, dobby, or hand
loom includes at least four harnesses for separating the standard
shrink yarn ends (heat-activated shrinkage factor of less than 15%)
from the high shrink yarn ends (heat-activated shrinkage factor of
at least 30%). Woven fabrics 112 may be made with combination warp
in which half the ends have a higher heat-activated shrinkage
factor than the other half of the ends.
[0054] During the weaving process, the third yarn 106 (or the
fourth yarn 132 if present) may be segregated into different
sections of a heat-activated crimping textile 100 either by using
multiple beams or by using a warping pattern which designates
certain areas for the first yarn 102 or second yarn 104 as opposed
to the third yarn 106 (or optionally the fourth yarn 132).
Exemplary patterns include, but are not limited to, a pattern of
two ends of the third yarn 106, then two ends of the second yarn
104, and repeating. In some embodiments, alternating warp end
patterning may be used (one second yarn 104 end, then one third
yarn 106 end), for example.
[0055] In one embodiment, a woven fabric 112 includes at least one
layer of fancy yarn such as boucle, chenille, and other core and
effect yarns that create loft and increased surface area for better
sealing potential.
[0056] In another embodiment, a woven fabric 112 includes a woven
ground with a tighter interlacement pattern, such as, but not
limited to, a tabby weave, and an outer layer with longer
interlacements pattern, such as, but not limited to, a satin, a
rib, or a twill, which provides for the longer float areas to be
looser and bulkier for maintaining a dense ground layer for better
clotting potential. A further embodiment includes the incorporation
of a pocket structure into the outer layer for blood capturing
potential.
[0057] In one embodiment, a heat-activated crimping textile 100
includes a raised area that forms bulk and volume protruding off a
surface of the heat-activated crimping textile 100 in a z-axis. The
raised area may be formed by pocketing or creating pleats, folds,
or both that rise perpendicularly off the flat plane of the pleated
fabric layer. Textured yarn may be incorporated into the folds or
pleats to further increase surface area and texture. A multilayer
shrink region which pleats may be formed with a ground layer of
high shrink yarn (having a heat-activated shrinkage factor of at
least 30%) floating behind a region with the low shrink yarn
(having a heat-activated shrinkage factor of less than 15%).
[0058] In another embodiment, the raised areas are formed by
creating a pocket weave and inserting a stuffer yarn (warp, weft,
or both) into the pocket weave to fill the space and lift up a
region of the heat-activated crimping textile 100. The ravines may
be tied down with a single cloth weave structure creating varying
thicknesses to the textile and valleys for reducing clotting,
increasing compressibility of the heat-activated crimping textile
100, improving sealing between an artificial device and vessel
wall, or combinations thereof. This embodiment may incorporate only
yarn with a common shrink factor (within 10% on an absolute basis)
or may incorporate a yarn with a higher shrink factor than the
remaining yarn (greater than 10% on an absolute basis). The raised
areas may form a grid pattern.
[0059] Referring to FIG. 5, in one embodiment, a heat-activated
crimping textile 100 includes a channel or woven effect 122 running
perpendicular to a pleat 124 which creates a checkered effect that
disrupts the length of the ruffled lumen and which may create high
and low areas of blood capturing characteristics. Including a
channel or woven tube effect 122 running perpendicular to a pleat
124 may maintain a higher degree of stretch within the
heat-activated crimping textile 100 relative to a comparative
textile lacking the channel or woven effect 122. When rotated and
cut on the bias 126 of the cloth at an about 45.degree. angle, such
a heat-activated crimping textile 100 may have better elongation
and stretch potential compared to when cut on the machine 128 or
cross-machine directions 130. Referring to FIG. 6, in another
embodiment, a heat-activated crimping textile 100 includes a
checkered effect 123 by foregoing the channel weave and using a
combination of a single layer weave and a crimped weave repeating
in a half drop or brick layout repeat to form the checkered effect
123 of pleats 124 (or ruffles).
[0060] Referring to FIGS. 1 and 4, in one embodiment first yarn 102
is woven in a first plurality of warp 116 ends and the third end
depicts the third yarn 106 woven into four wefts 114, then floating
on the back (first side 120) of the heat-activated crimping textile
100 for eight wefts 114. The hatched yarns represent the third yarn
106 which interlaces into four wefts 114 and then floats on the
back (first side 120) of the heat-activated crimping textile 100
for eight wefts 114.
[0061] Optionally, in some embodiments, the first plurality of weft
yarns 114 which are all first yarn 102 are all of the weft. In
other embodiments, fourth yarns 132 (having a heat-activated
shrinkage factor of at least 30%) may be used in a second plurality
of wefts 138 in place of some of the first yarn 102, as best seen
in FIG. 4, for example, which alternates between eight picks of
first yarns 102 and four picks of fourth yarn 132. In some
embodiments, as illustrated in FIGS. 1-4, the third yarns 106
interlace the fourth yarns 132 and float across the second yarns
104. In some embodiments employing fourth yarns 132, the third
yarns 106 interlace primarily or only the fourth yarns 132 and
float across all or substantially all of the first yarns 102. As
used herein, "primarily" indicates more than 50% and "substantially
all" indicates at more than 75%.
[0062] Referring to FIGS. 2 and 3, in a further embodiment, after a
heat-setting transformation, the third yarn 106 (back warp) pulls
the first yarn 102 and second yarn 104 regions together forming a
crimp 108 which may be, but is not limited to, a pleat, a channel,
or a ruffle, along the cross-machine direction 130 of the
heat-activated crimping textile 100.
[0063] In one embodiment, a heat-activated crimping textile 100
includes a first plurality of wefts 114 formed of a first yarn 102,
a first plurality of warps 116 formed of a second yarn 104
interwoven with the first plurality of wefts 114, and a second
plurality of warps 118 formed of a third yarn 106 interwoven with
the first plurality of wefts 114. The first yarn 102 includes a
heat-activated shrinkage factor of less than 10% when exposed to a
predetermined temperature. The second yarn 104 includes a
heat-activated shrinkage factor of less than 10% when exposed to
the predetermined temperature. The third yarn 106 includes a
heat-activated shrinkage factor between 35% and 50% when exposed to
the predetermined temperature. The predetermined temperature is at
least 150.degree. C. When the heat-activated crimping textile 100
is exposed to an elevated temperature of at least the predetermined
temperature, a plurality of crimps 108 propagate along the first
plurality of wefts 114, forming a crimped textile 110 having a
pleated, ruffled, or channeled structure. The heat-activated
crimping textile 100 includes a repeating weaving pattern in which
the third yarn 106 interlaces at least two of the first plurality
of wefts 114 sequentially, then floats across a minimum of three of
the first plurality of wefts 114 sequentially only across a first
side 120 of the heat-activated crimping textile 100, and then
repeats. The heat-activated crimping textile 100 and the crimped
textile 110 formed from the heat-activated crimping textile 100 are
substantially unsewn and substantially free of needle punctures and
key holes.
[0064] Referring to FIGS. 7-9, in one embodiment, the
heat-activated crimping textile 100 is a warp knit fabric 134, the
plurality of the first yarn 102 forms a first plurality of warps
116, the plurality of the second yarn 104 forms a second plurality
of warps 118 interlaced with the first plurality of warps 116 by
interloping, the plurality of the third yarn 106 forms a third
plurality of warps 136 interlaced with the first plurality of warps
116, the second plurality of warps 118, or both by interloping, and
the plurality of crimps 108 propagates along the machine direction
128 of the warp knit fabric 134.
[0065] In one embodiment, the warp knit fabric 134 includes a
repeating knit pattern in which the third plurality of warps 136
interloops amongst one to four warp ends of the first plurality of
warps 116 and the second plurality of warps 118 combined
sequentially, then floats across four to twenty courses
sequentially of the first plurality of warps 116 and the second
plurality of warps 118 combined, and then repeats. In a further,
embodiment, the third plurality of warps 136 interloops amongst one
of the warp ends of the first plurality of warps 116 and the second
plurality of warps 118 combined sequentially, then floats across 11
of the courses of the first plurality of warps 116 and the second
plurality of warps 118 combined sequentially, and then repeats.
[0066] By intentional placing of third yarn 106 warp ends in
combination with first yarn 102 and second yarn 104 warp ends, a
knitted ruffle post may be formed by heat setting in a similar
fashion to the woven fabric 112 heat-activated crimping textile
100. Using stitch patterns to create a more linear machine
direction 128 effect in a knit as opposed to creating long
cross-machine direction 130 laps may keep at least portions of the
third yarn 106 floating behind first yarn 102 and second yarn 104
warp ends that are interlooping on the surface of the material, in
essence creating a knitted ruffle in the course (cross-machine)
direction 130. FIG. 7 illustrates a 3-bar knit that uses a
1-0/1-2// pattern (first yarn 102) on guide bar 1 and a 1-2-/1-0//
(second yarn 104) on guide bar 2 and a long warp float (third yarn
106) on guide bar 3 in a 1-0/1-1/(/1-1/1-1//.times.6) pattern. The
third yarn 106 forms the crimped effect of this pattern by
shrinking in the first yarn 102 and second yarn 104 layer and
forming a ruffle as the crimp 108.
[0067] Referring to FIGS. 10-12, in one embodiment, the
heat-activated crimping textile 100 is a warp knit fabric 134 in
the form of a knitted tube 140. For a knitted tube 140, a top face
142 and a bottom face 144 are each knitted with a first yarn 102, a
second yarn 104, and a third yarn 106, wherein the third yarn 106
is floated along the inside surface 146 of the knitted tube. Heat
setting the knitted tube 140 forms radial pleats around the outside
surface 148 of the knitted tube 140 with the third yarn 106
remaining disposed along the inside surface 146 of the knitted tube
140. FIG. 10 illustrates a knit tube stitch pattern as follows: GB1
(1-2;1-1/1-0;1-1).times.6 and GB7 (1-1/1-2;1-1;1-0).times.6 are
first yarn 102; GB2 (1-0;1-1/1-2;1-1).times.6 and GB6
(1-1;1-0/1-1;1-2).times.6 are second yarns 104; and GB3
1-0;1-1/1-1;1-1, (1-1;1-1/1-1;1-1).times.5 and GB5 1-1;1-0/1-1;1-1,
(1-1;1-1/1-1;1-1).times.5 are the third yarn 106.
[0068] While the foregoing specification illustrates and describes
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *