The present invention generally relates to implantable stent medical devices, methods for manufacturing the same, and more particularly, to novel stent structures.
Medical stents are used for supporting, maintaining, or repairing a lumen, passageway or opening in a living body. Stent design is unique to location and objective of the treatment as the stent must be flexible enough in a collapsed state to navigate body lumen to arrive at a treatment site, structurally robust enough in an implanted state to provide the required structural support to repair the treatment site, and flexibly expandable to have high conformity in treatment sites having tapered, bent, or other non-linear or non-tubular shapes. Flexibility, structural integrity, and conformability are often competing design goals that will vary depending on the location of the treatment site, goal of the treatment, and geometry of the treatment site.
Wire, or braided stents, are typically braided from flexible wires to form a tube of wires that wrap helically around a center axis of the stent, with roughly half of the wires wrapping clockwise, and the other half wrapping counterclockwise such that wires extending in opposite direction wrap over and under each other diagonally in an alternating fashion. Wire stents can be very flexible, can achieve high conformity within a body lumen containing a bend, and can resist kinking; however, the wire stents typically lack structural integrity to apply outward force radially against a lumen wall that is required in some treatments.
A general strategy for stent design when structural integrity is desired involves laser cutting patterns from a length of elastic tubing, typically made of a memory shape metal such as Nitinol or a Nitinol alloy. In general, material is removed from the tubing to form a cell pattern. Generally speaking, enough material must remain so that the overall structural integrity of the laser cut stent is sufficient to apply the required outward force against a lumen wall once implanted. Material is strategically removed to increase the flexibility of the stent for delivery to a treatment site and conformity to lumen walls in treatment sites including a bend or other non-uniform wall structure. In many stent designs, patterns are cut to form rings that are substantially circumferential connected longitudinally by bridge struts. In such designs, bridge struts are added to achieve greater structural integrity and taken away to achieve greater flexibility.
Attempts have been made to design a stent having greater flexibility and kink resistance compared to stents cut from elastic tubing and greater structural integrity compared to wire stents. One such strategy involves cutting elastic tubing to for a single helical structure that wraps circumferentially around the body of the stent such that adjacent windings of the helix are longitudinally interconnected with bridge struts (e.g. U.S. Pat. No. 5,925,061). Another strategy involves cutting a sheet of material to form a lattice strand that can be wrapped as a single helix about a mandrel and adjacent windings are subsequently interconnected (e.g. U.S. Pat. No. 5,370,683). Although such designs typically can achieve greater flexibility compared to a laser cut tubular stent utilizing circumferential rings, it is at the cost of structural integrity; and although such designs can achieve greater structural integrity compared to wire stents, they cannot achieve the conformability and kink resistance of most wire stents.
There therefore exists a need for alternative stent designs for achieving flexibility, structural integrity, and conformability to meet the needs of a variety of treatment goals at a variety of treatment sites having a variety of anatomical geometries.
Disclosed herein are various exemplary stents of the present invention that can address the above needs. The stents generally can include a tubular structure having circumferentially positioned undulating wires that extend over a majority of a length of the stent such that the undulations oscillate circumferentially, and the undulations of the wires collectively define a circumference of the stent. The undulations can wrap over and under adjacent undulations to form an interwoven structure. Additionally, or alternatively, adjacent wires can be joined.
An example stent can include a stent length measured from a first open end to a second open end, two or more wires each having a three-dimensional oscillating portion that extends over most of the stent length and is movable independent of the oscillating portion of every other of the one or more wires. The oscillating portion for each wire can have an oscillating portion length measured parallel to a z-axis, a curvature extending circumferentially through an arc of less than 360° about the z-axis at a constant radius from the z-axis, and a waveform that oscillates over the length of the oscillating portion through the arc. The oscillating portion of each of the one or more wires can be movable independent of every other of the one or more wires.
Another example stent having a circumference and a length can include two or more wires, each wire having a three-dimensional waveform that oscillates circumferentially within an arc about a z-axis parallel to the stent length, such that each waveform extends parallel to the z-axis through a majority of the stent length, maintaining a substantially constant radial distance from the z-axis. The wires of the stent can be positioned circumferentially adjacent each other about the circumference of the stent to define the circumference of the stent. Each wire can be movable along a majority of the length of the stent independently of every other wire in the stent.
Another example stent having a tubular structure with a circumference and a length can include a plurality of wires positioned around the circumference of the stent. Each wire can be independently formed, can undulate circumferentially to form a wave pattern that extends over a majority of the length of the stent, can pass under an over an adjacent wire in a repeated fashion while maintaining an adjacent position to the adjacent wire over the majority of the length of the stent, and can intertwine circumferentially with other wires to form the tubular stent.
Another example stent having tubular structure can include circumferentially positioned undulating wires that extend over a majority of a length of the stent. The wires can each have undulations that oscillate circumferentially. The undulations of each wire can recess circumferentially within undulations of an adjacent wire such that the circumferential positioning of the undulating wires can define a circumference of the stent, and the circumferential positioning of the undulating wires can solely define the circumference of the stent absent any additional structures to define the circumference of the stent.
In any of the example stents, each wire of the stent can be independently formed from every other wire of the stent. Each wire of the stent can be joined at one or more locations to a circumferentially adjacent wire. The stent can include a first joint affixing a first wire to a second wire near the first open end. The first joint can be the only affixed joint between the first wire and the second wire. Additionally, or alternatively, to affixing adjacent wires, the first wire can cross under and cross over the second wire within one period of oscillation of the waveform of the first wire.
In any of the example stents, the stent can include a first end structure positioned adjacent the first open end, extending between the first open end and the oscillating portion of the stent, and the stent can include a second end structure positioned adjacent the second open end, extending between the second open end and the oscillating portion. One or both of the first and second end structures can have an atraumatic shape.
In any of the example stents, a wire of the stent can have a width that varies along the length of the stent.
In any of the example stents, one or more of the wires can include a memory shape material. At least one wire can have a pre-determined three-dimensional shape curved along an arc, the three-dimensional shape having a wave pattern that undulates within the arc.
An example method for manufacturing a stent including any of the example stents described herein can include the steps of providing an elastic tubing, cutting the tubing to form a plurality of substantially similar wave patterns, separating each of the plurality of wave patterns from the tubing, positioning each wave pattern to extend across a majority of the length of the stent, and forming a majority of a tubular stent body from the plurality of wave patterns. Each wave pattern can have an amplitude extending circumferentially through an arc within a circumference of the tubing from which it is cut, an axis extending along at least a portion of a length of the tubing over which the wave pattern repeats, and a curved inner surface being the cut portion of the luminal surface of the tubing.
Another example method for manufacturing a stent including any of the example stents described herein can include the steps of providing an elastic tubing having a circumference and a length, cutting individual wires from the tubing such that each wire has a wave pattern oscillating peak-to-peak across a portion of the circumference, and weaving the wires to form a tube shape.
Any of the example methods can include any combination of the steps of cutting individual wires from the provided tubing such that each wire has a wave pattern that oscillates peak-to-peak across a portion of the circumference, separating the cut wires from the tubing such that the wires are disconnected from each other, joining a first wire to a second wire at one or more locations, joining a first wire to a second wire near an end of the stent body, and/or intertwining each wire with a clockwise adjacent wire and a counterclockwise adjacent wire.
The above and further aspects of this invention are further discussed with reference to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating principles of the invention. The figures depict one or more implementations of the inventive devices, by way of example only, not by way of limitation.
Various exemplary stents are described herein that can address the above needs. In general, a stent can have a generally tubular structure with circumferentially positioned undulating wires extending over a majority of a length of the stent. Undulations of each wire can oscillate circumferentially, and the undulations of a wire can recess within undulations of adjacent wires, such that the recession of each wire into each other defines a circumference of the stent. Adjacent wires can be joined at few locations, such as at the ends, or not at all, such that individual wires are movable independent from every other wire. Additionally, or alternatively, the undulations can wrap over and under adjacent undulations to form an interwoven structure.
Generally, example stents described herein can be cut from a metal tube and can be prepared by cutting the tube into separate wires that retain a helical curvature from the tube wall from which they are cut. Wires can be cut from the tube to be substantially independent from one another, and these wires can be braided, woven, or otherwise intertwined to form a tubular shape. In some applications it may be desirable to utilize between eight and sixteen laser cut wires to form a stent with desired flexibility, structural integrity, and conformability. Wires in some example stents can move independently of each other to some extent; for example, the wires of an example stent can be movable like how wires in known braided or woven structures are generally movable independent of each other. Additionally, or alternatively, wires in some example stents can be welded or otherwise joined to each other at one or more locations along a length of each of the wires. Joined wires can form an interlocking structure and can increase structural integrity of the stent.
Because wires of some example stents can be made substantially movable to each other, some example stents can have improved flexibility and kink resistance compared to known laser cut tube designs and can achieve flexibility and kink resistance like known wire braid stent designs. Because the wires of some example stents can be cut from a metal tube, the wires of an example stent can provide greater radial force compared to wires of known wire braid stent designs, the wires of the stent can be designed to have an atraumatic end structure (which is typically not achievable by using cut wires in known wire braid stent designs), and the stent can have wires that vary in thickness and shape along the length of the stent (which is generally not possible in known wire braid stent designs that utilize constant diameter wires). A potential application of some example stents can be supporting embolic coils within an aneurysm at a treatment site that requires navigation of torturous anatomy to reach.
A wire 200 is illustrated in
Referring to
Referring to
The tubing can have a lumen with an inner luminal surface. The wire 200 can be cut from the tubing to have an inner surface that is cut from the luminal surface of the tubing. The wire 200 can be cut from the tubing such that a majority of the oscillating portion 210 is movable independent of oscillating portions 210 of other wires. The wire 200, once cut, can be separated from the tubing to form an independently formed wire 200.
The wires 200a, 200b, 200c, 200d can be cut from tubing, and each wire can be positioned to define a circumference of a stent. Wires can be positioned such that each oscillating portion 210 extends across a length of the stent. Inner curved surface of each oscillating portion 210 of each wire 200a, 200b, 200c, 200d can be aligned to collectively form the circumference of the stent. Wires 200a, 200b, 200c, 200d can be joined and/or woven to form a tube shape.
As will be appreciated and understood, each joint can be formed by any conventional means such as welding, brazing, soldering, gluing, tying, etc. Alternatively, or additionally, a stent can be cut from a single piece of tubing such that the joints 230a, 230b, 230c, 230d are uncut portions of the tubing. In one example, a wire 200a, 200b, 200c, 200d joined to a neighboring wire by an uncut tubing portion would not be completely separated from the neighbor during manufacturing. However, the uncut portion can be placed at a joint location 230a, 230b, 230c, 230d like those shown in
The descriptions contained herein are examples of embodiments of the invention and are not intended in any way to limit the scope of the invention. As described herein, the invention contemplates many variations and modifications of the stent, including alternative shapes for oscillating portions of wires, alternate shapes for atraumatic end segments of wires, alternative means of joining or connecting wires, alternative patterns for interlacing wires to form the stent, forming stents with any number of wires, or utilizing any of numerous materials or manufacturing means for the stent, for example. These modifications would be apparent to those having ordinary skill in the art to which this invention relates and are intended to be within the scope of the claims which follow.
This application claims the benefit of U.S. Provisional Application No. 62/734,128 titled “STENT WITH SHAPED WIRES” filed on Sep. 20, 2018 which prior application is hereby incorporated by reference in its entirety herein into this application as if set forth in full.
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