US20060009834A1 - Reflowed drug-polymer coated stent and method thereof - Google Patents

Abstract

The present invention provides a method of forming a drug-polymer coated stent. A polymeric coating is applied onto at least a portion of a stent framework and dried. A jet of heated gas is directed towards excess coating portions of the dried polymeric coating. The excess coating portions, which extend into apertures of the stent framework, are removed from the apertures of the stent framework by reflowing the polymeric coating with the directed jet of heated gas. A drug-polymer coated stent with a reflowed drug-polymer coating and a system for treating a vascular condition are also disclosed.

Description

FIELD OF THE INVENTION
• This invention relates generally to biomedical stents. More specifically, the invention relates to a drug-polymer coated endovascular stent with a reflowed polymeric coating, and methods of coating thereof.
BACKGROUND OF THE INVENTION
• Protective materials and bioactive drugs are used on medical devices for treating vascular conditions such as stents. With generally open cylindrical scaffolding, stents typically have apertured or lattice-like walls of a metallic or polymeric base, and can be either balloon expandable or self-expanding. A stent is typically deployed by mounting the stent on a balloon portion of a balloon catheter, positioning the stent in a body lumen, and expanding the stent by inflating the balloon. The balloon is then deflated and removed, leaving the stent in place. Stents help reduce the probability and degree of vessel blockage from restenosis.
• Various approaches for providing localized drug delivery using coated stents have been under investigation and marketed for some time. A variety of stent coatings and compositions have been proposed to provide localized therapeutic pharmacological agents and treatment of a vessel at the site being supported by the stent. Stent coatings with various families of drug polymer chemistries have been used to increase the effectiveness of stenting procedures and to control drug-elution properties. For example, polymeric coatings can be made from polyurethane, polyester, polylactic acid, polyamino acid, polyorthoester, or polyphosphate ester. Examples of drug or bioactive agents include antirestonotic and anti-inflammatory compounds.
• Medical research indicates a greater effectiveness of vascular stents when the stents are coated with pharmaceutical drugs that help prevent or treat medical conditions such as restenosis and thrombosis. These drugs may be released from a coating while in the body, delivering their patent effects at the site where they are most needed. The localized levels of the medications can be elevated, and therefore potentially more effective than orally or intravenously delivered drugs. Furthermore, drugs released from tailored stent coatings can have controlled, timed-release qualities, eluting their bioactive agents over hours, weeks or even months. Stent coatings typically have a drug or active agent, which has been dissolved or dispersed throughout the polymeric material and physically constrained within the polymer. The sustained release of drugs generally relies upon either controlled degradation of the polymer or diffusion through the polymer to control the elution of the compounds.
• Stents can be coated with a polymer or combination of a polymer and a pharmaceutical agent or drug by application techniques such as dipping, spraying, painting, and brushing. Typical methods of coating, such as spraying, dipping and brushing techniques, can be susceptible to a degree of pooling, bridging, or webbing on stent structures and struts, problems recognized by those skilled in the art of manufacturing stents.
• Several solutions have been suggested. One solution in a manual dipping process blows excessive material off an open stent framework, as disclosed in “Coating” by Taylor et al., U.S. Pat. No. 6,214,115 issued Apr. 10, 2001. The process addresses the problems of inconsistent drying and blockage of openings. Hossainy and others disclose another dipping process that addresses the issues of blockage and bridging between stent struts in “Process for Coating Stents”, U.S. Pat. No. 6,153,252 issued Nov. 28, 2000. Flow or movement of the coating fluid through the openings in the perforated medical device is used to avoid the formation of blockages or bridges. The flow system may use a perforated manifold inserted in the stent to circulate the coating fluid, or may place the stent on a mandrel or in a small tube that is moved relative to the stent during the coating process.
• Another coating method that uses airflow is disclosed in “Coating Medical Devices Using Air Suspension”, Schwarz et al., International Patent Application WO 00/62830 published Oct. 26, 2000. The proposed method suspends a medical device in air and introduces a coating material into an air stream such that the material is dispersed therein to coat at least a portion of the device.
• In addition to controlling any excessive coating material, an effective coating method needs to result in a lubricious or smooth outer surface of the coated stent, thereby reducing the probability of abrasions to body tissue as a stent is deployed. One coating method that optionally applies a solvent by dipping or spraying on an already coated stent to smooth the outer surface of the coating is described by Ding in “Method of Applying Drug-Release Coatings”, U.S. Pat. No. 5,980,972 issued Nov. 9, 1999. The method uses two solutions: one with a polymer dissolved in a first solvent and another with a drug dissolved or suspended in a second solvent. When a third solvent is used to smooth the stent coating, the solvent needs to be compatible with the polymer matrix.
• In another example, a collagen liner material forms a lubricious surface over the stent to protect the vascular wall and form a non-thrombogenic cushion for the stent in the vascular lumen, as disclosed in “Stent with Collagen”, Buirge et al., U.S. Pat. No. 5,693,085 issued Dec. 2, 1997.
• Another smooth stent surface is described in “Stent Lining”, Sahatjian et al., U.S. Pat. No. 6,364,893, issued Apr. 2, 2002. A stent is lined with a hydrogel to reduce shear forces and flow disturbances in the blood, to protect damaged cells adjacent to the stent, to reduce platelet deposition at the stent site, and to deliver a drug to reduce or prevent restenosis of stent lumens. The expandable stent is mounted on a catheter balloon, which is coated with a hydrogel. The stent is delivered in a contracted condition to a targeted site in a body where the expanding balloon lodges the stent in the body with the hydrogel coated on the inner surfaces of the stent as a lining.
• Drug polymer coatings on medical devices need to adhere well to the substrate or surface of the medical device and be mechanically pliant, because the devices often undergo significant flexion or expansion during the delivery and deployment. Excess coating material that can occur between struts of the stent needs to be removed or controlled to prevent cracking or flaking during or after the deployment of the stent. A stent deployed by self-expansion or balloon expansion is accompanied by a high level of bending at portions of the stent framework, which can cause cracking, flaking, peeling, or delaminating of many candidate drug polymers when the stent diameter is increased by threefold or more during expansion. In addition, any step within the process for coating a pre-deployed stent should not cause a drug-polymer to fall off, crystallize or melt.
• Accordingly, a desirable, efficient and improved coating method would provide a well-adhered coating with a smooth outer surface of a medical device. In addition, the method would minimize or eliminate the pooling, bridging, or webbing of excess coating material between structures such as stent struts. In addition, the stent associated with this method has a smoother coating topography with one or more well adhered drug-polymer coatings that maintain mechanical integrity during stent deployment and provide a desired elution rate for one or more drugs, overcoming the deficiencies and limitations described above.
SUMMARY OF THE INVENTION
• One aspect of the invention provides a method of forming a drug-polymer coated stent. A polymeric coating is applied onto at least a portion of a stent framework and dried. A jet of heated gas is directed towards excess coating portions of the dried polymeric coating that extend into apertures of the stent framework. The polymeric coating is reflowed with the directed jet of heated gas, removing the excess coating portions from the apertures of the stent framework.
• Another aspect of the invention provides a drug-polymer coated stent, including a stent framework and a drug-polymer coating disposed on the stent framework. The drug-polymer coating includes a reflowed portion proximate to apertures in the stent framework.
• Another aspect of the invention provides a system for treating a vascular condition, including a catheter and a drug-polymer coated stent coupled to the catheter. The drug-polymer coated stent includes a stent framework having a reflowed portion proximate to apertures in the stent framework.
• The present invention is illustrated by the accompanying drawings of various embodiments and the detailed description given below. The drawings should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding. The detailed description and drawings are merely illustrative of the invention rather than limiting, the scope of the invention being defined by the appended claims and equivalents thereof. The foregoing aspects and other attendant advantages of the present invention will become more readily appreciated by the detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
• Various embodiments of the present invention are illustrated by the accompanying figures, wherein:
• FIG. 1 is an illustration of a system for treating a vascular condition including a drug-polymer coated stent coupled to a catheter, in accordance with one embodiment of the current invention;
• FIG. 2 is a cross-sectional view of a drug-polymer coated stent, in accordance with one embodiment of the current invention;
• FIG. 3 is an illustration of a system for forming a drug-polymer coated stent, in accordance with one embodiment of the current invention; and
• FIG. 4 is a flow diagram of a method of forming a drug-polymer coated stent, in accordance with one embodiment of the current invention.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
• FIG. 1 illustrates a system for treating a vascular condition, comprising a drug-polymer coated stent coupled to a catheter, in accordance with one embodiment of the present invention at100. Vascularcondition treatment system100 includes a drug-polymer coatedstent120 coupled to adelivery catheter110.Coated stent120 includes astent framework130 and a reflowed drug-polymer coating140 disposed on at least a portion ofstent framework130. Generally tubular in shape with open ends, the latticework ofstent framework130 has a plurality ofopen apertures132 between the struts, shaped to allow expansion ofstent framework130 from an initially contracted form when deployed.
• Drug-polymer coating140 includes apolymeric coating142 positioned adjacent tostent framework130 and at least onetherapeutic agent144 encased by or interdispersed within drug-polymer coating140. In some cases, drug-polymer coating140 includes acap coating148 disposed on reflowed drug-polymer coating140. Drug-polymer coating140 can provide time-released delivery of one or more therapeutic agents to surrounding tissue aftercoated stent120 has been deployed within a vessel of the body.
• Insertion ofcoated stent120 into a vessel in the body helps treat, for example, heart disease, various cardiovascular ailments, and other vascular conditions. Catheter-deployedcoated stent120 typically is used to treat one or more blockages, occlusions, stenoses, or diseased regions in the coronary artery, femoral artery, peripheral arteries, and other arteries in the body. Treatment of vascular conditions involves the prevention or correction of various ailments and deficiencies associated with the cardiovascular system, the cerebrovascular system, urinogenital systems, biliary conduits, abdominal passageways and other biological vessels within the body.
• An exemplary drug-polymer coating140 includes or encapsulates one or more therapeutic agents. Drug-polymer coating140 may comprise one or moretherapeutic agents144 dispersed within or encased by drug-polymer coating140 oncoated stent120, which are eluted fromcoated stent120 with controlled time delivery after deployment ofcoated stent120 in the body. A therapeutic agent is capable of producing a beneficial effect against one or more conditions including coronary restenosis, cardiovascular restenosis, angiographic restenosis, arteriosclerosis, hyperplasia, and other diseases or conditions. For example, the therapeutic agent can be selected to inhibit or prevent vascular restenosis, a condition corresponding to a narrowing or constricting of the diameter of the bodily lumen where the stent is placed. Drug-polymer coating140 may comprise, for example, an antirestenotic drug such as rapamycin, a rapamycin analogue, or a rapamycin derivative to prevent or reduce the recurrence or narrowing and blockage of the bodily vessel. Drug-polymer coating140 may comprise an anti-cancer drug such as camptothecin or other topoisomerase inhibitors, an antisense agent, an antineoplastic agent, an antiproliferative agent, an antithrombogenic agent, an anticoagulant, an antiplatelet agent, an antibiotic, an anti-inflammatory agent, a steroid, a gene therapy agent, an organic drug, a pharmaceutical compound, a recombinant DNA product, a recombinant RNA product, a collagen, a collagenic derivative, a protein, a protein analog, a saccharide, a saccharide derivative, a bioactive agent, a pharmaceutical drug, a therapeutic substance, or a combination thereof.
• The elution rates of the therapeutic agents and total drug eluted into the body and the tissue bed surrounding the stent framework are based on the thickness of drug-polymer coating140; the constituency of drug-polymer coating140; the nature, distribution and concentration of the therapeutic agents; the thickness and composition of any cap coat, and other factors. Drug-polymer coating140 may include and elute multiple therapeutic agents to achieve the desired therapeutic effect. Drug-polymer coating140 can be tailored to control the elution of one or more therapeutic agents that are transported through the coating primarily by diffusion processes. In some cases, a portion of the polymeric coating is absorbed into the body, releasing therapeutic agents embedded within or encased by the coating. In other cases, drug-polymer coating140 erodes fromcoated stent120 to release the therapeutic agents, the residual polymer being expelled by the body.Cap coating148 can be selected to provide a diffusion barrier to the therapeutic agents and aid in the control of drug elution.
• Incorporation of a drug or other therapeutic agents into drug-polymer coating140 allows, for example, the rapid delivery of a pharmacologically active drug or bioactive agent within twenty-four hours following the deployment of a stent, with a slower, steady delivery of a second bioactive agent over the next three to six months. For example, the therapeutic agent may comprise an antirestenotic drug such as rapamycin, a rapamycin analogue, or a rapamycin derivative. A second therapeutic agent may comprise, for example, an anti-inflammatant such as dexamethasone. The therapeutic agent constituency in the drug-polymer coating may be, for example, between 0.1 percent and 50 percent of the drug-polymer coating by weight.
• Catheter110 of an exemplary embodiment of the present invention includes aballoon112 that expands and deploys the stent within a vessel of the body. After positioningcoated stent120 within the vessel with the assistance of a guide wire traversing through aguidewire lumen114 insidecatheter110,balloon112 is inflated by pressurizing a fluid such as a contrast fluid that fills a tube insidecatheter110 andballoon112.Coated stent120 is expanded until a desired diameter is reached, and then the contrast fluid is depressurized or pumped out, separatingballoon112 fromcoated stent120 and leavingcoated stent120 deployed in the vessel. Alternatively,catheter110 may include a sheath that retracts, allowing the expansion of a self-expanding version ofcoated stent120.
• FIG. 2 shows a cross-sectional view of a drug-polymer coated stent, in accordance with one embodiment of the present invention at200. A drug-polymer coatedstent220 includes astent framework230 with a drug-polymer coating240 disposed onstent framework230. Drug-polymer coating240 includes apolymeric coating242 positioned adjacent tostent framework230 and atherapeutic agent244 encased by or interdispersed withinpolymeric coating242.
• Drug-polymer coating240 typically encasesstent framework230, forming a relatively thin coating around the struts and latticework ofstent framework230. During processing, one or moreexcess coating portions246 may occur inapertures232 ofstent framework230 between the struts and open areas of the latticework. During coating operations such as dipping, spraying, brushing or painting, polymeric solution may pool, web, or bridge inapertures232, resulting in one or moreexcess coating portions246, particularly near places wherestent framework230 is held.Excess coating portions246 can be removed fromapertures232 ofstent framework230 by heating andreflowing polymeric coating242, resulting in a reflowed drug-polymer coating240aaround stent framework230aproximate toapertures232 instent framework230 withexcess portions246 removed fromapertures232. Reflowing drug-polymer coating240 orpolymeric coatings242 may also result in improved surface smoothness of the coating and enhanced adhesion to the metallic or polymeric base ofstent framework230 or to any underlying coatings.
• Stent framework230 comprises a metallic base or a polymeric base, such as stainless steel, nitinol, tantalum, MP35N alloy, platinum, titanium, a chromium-based alloy, a cobalt-based alloy, a suitable biocompatible alloy, a suitable biocompatible material, a biocompatible polymer, or a combination thereof. The polymeric base material may comprise any suitable polymer for biomedical stent applications, as is known in the art.
• Drug-polymer coating240 includes apolymeric coating242 with a polymer such as poly(vinyl alcohol) (PVA), poly(ethylene-vinyl acetate) (PEVA), polyurethane (PU), polycaprolactone (PCL), polyglycolide (PGA), poly(lactide-co-glycolide) (PLGA), poly(ethylene oxide) (PEO), poly(vinyl pyrrolidone) (PVP), silicone, an acrylic polymer, an acrylic and acrylonitrile copolymer, a latex polymer, a thermoplastic polymer, a thermoset polymer, a biostable polymer, a biodegradable polymer, a blended polymer, a copolymer, or a combination thereof. The polymer may be applied using a technique such as dipping or spraying with limited drying or limited crosslinking to achieve the desired level of tackiness.
• Drug-polymer coating240 comprises at least onetherapeutic agent244.Therapeutic agent244 may be mixed withpolymeric coating242 prior to the application of drug-polymer coating240, or added topolymeric coating242 after the application ofpolymeric coating242 ontostent framework230.Therapeutic agent244 may be in any suitable form such as a liquid, a gel, a powder, a particle, a granulated drug, a micronized drug, a pelletized drug, a microencapsulated drug, a nanoencapsulated drug, or a combination thereof.
• Although illustrated with one layer of drug-polymer coating240, multiple coatings of the polymer or drug-polymer may be disposed onstent framework230 to provide a thicker composite coating and a larger quantity of therapeutic agents. Multiple therapeutic agents may be arranged within drug-polymer coating240 to provide a control time-delivery of each therapeutic agent. For example, tailoring the thickness and constituency of each drug-polymer coating240, the distribution and concentration of the therapeutic agents, and inclusion of an optional cap coating helps control the elution rate of one or more therapeutic agents dispersed within or encased by drug-polymer coating240. Drug elution refers to the transfer of a therapeutic agent from drug-polymer coating240 to the surrounding area in a body. The amount of drug eluted is determined as the total amount of therapeutic agent excreted out of drug-polymer coating240, typically measured in units of weight such as micrograms, or in weight per peripheral area of the stent. The concentration of the therapeutic agent included with drug-polymer coating240 is between, for example, 0.1 percent and 50 percent by weight.
• FIG. 3 shows an illustration of a system for forming a drug-polymer coated stent, in accordance with one embodiment of the current invention at300. Drug-polymer coating system300 includes apolymeric solution350 in adipping tank352 and atransport mechanism322 such as a clamp or a tether for holding and transporting stents in and out oftank352 either manually or automatically.Multiple stent frameworks330 are readily accommodated for dipping and drying in a batch or continuous batch process. Amandrel360 withcones362 at each end ofstent framework330 may be used, for example, to holdstent framework330 during dipping and reflowing.
• In one example,polymeric solution350 includes at least onepolymer354, atherapeutic agent356, and a solvent358.Stent framework330 is dipped intopolymeric solution350 and dried, for example, by positioning the dippedstent framework330 in air and evaporating much or all of solvent358 to form a drug-polymer coating340 onstent framework330. The components ofpolymeric solution350 and the dipping treatments are selected to provide a drug-polymer coating340 onstent framework330 with the desired thickness and quantity of therapeutic agents. In one example,polymeric solution350 includes apolymer354 such as poly(vinyl alcohol), poly(ethylene-vinyl acetate), polyurethane, polycaprolactone, polyglycolide, poly(lactide-co-glycolide), poly(ethylene oxide), poly(vinyl pyrrolidone), silicone, an acrylic polymer, an acrylic and acrylonitrile copolymer, a latex polymer, a thermoplastic polymer, a thermoset polymer, a biostable polymer, a biodegradable polymer, a blended polymer, a copolymer, or a combination thereof, along with a suitable solvent358 that is compatible withpolymer354 and thetherapeutic agents356. In another example, drug-polymer coating340 is applied ontostent framework330 by spraying or brushing.Stent framework330 is generally dipped intopolymeric solution350 for a prescribed period of time, and removed for drying in air or in an oven. Additional dipping or spraying steps may be used to achieve a thicker drug-polymer coating340. Drug-polymer coating340 can be baked in an oven at an elevated temperature to further drive off buried pockets of solvent and to provide a desired level of crosslinking of the polymers.
• After applyingpolymeric coating342 onto at least a portion ofstent framework330 and drying appliedpolymeric coating342,coated stent320 may haveexcess coating portions346 extending from the struts and latticework intoapertures332 ofstent framework330. In the detailed view, drug-polymer coating340 hasexcess coating portions346 with one or more webbed regions, pooled regions, bridged regions, or combinations thereof extending intoapertures332aofstent framework330a.Coated stent320 withexcess coating portions346 may be positioned in front of a jet ofheated gas370 emitted from agas nozzle372.Apertures332 ofstent framework330 withexcess coating portions346 may be positioned adjacent to jet ofheated gas370. Driedpolymeric coating342 may be heated above a reflow temperature of driedpolymeric coating342. Driedpolymeric coating342 is reflowed with the directed jet ofheated gas370 to removeexcess coating portions346 fromapertures332 ofstent framework330.
• Theheated gas370 ejected fromgas nozzle372 may be supplied, for example, from apressurized gas tank374 and heated in aheater376. Theheated gas370 may be adjusted and controlled with agas valve378 by a microprocessor-controlledcontroller380.Controller380 may be automatic or semi-automatic, receiving commands and settings from a user or a control computer to appropriately position coatedstent320, pressurizing andheating gas370, and adjusting the ejection temperature and the ejection velocity of the ejectedgas370. In a fully automatic system, positioning and inspection capability can be added for real-time control and inspection to determineexcess coating portions346 and remove them. In one example of a manual system, the temperature of the heated gas is controlled and the gas velocity is manually controlled. A filter may be included to remove particles fromgas370.
• After the reflow ofpolymeric coating342 has been completed and thecoated stent320 has cooled,excess coating portions346 have been removed andapertures332bofstent framework330bare clear of anyexcess coating portions346, leaving drug-polymer coating340 on the struts and latticework ofstent framework330b,as shown in the detailed view ofstent framework330b.
• Multiple dipping, drying and reflow steps can be used to apply additional drug-polymer coatings340 or otherpolymeric coatings342 ontostent framework330. The reflow steps can be used to clear bridging, pooling and webbing of excess polymer and drug polymer after one or more applications of a primer coating, a drug-polymer coating, a cap coating, or a combination thereof.
• FIG. 4 shows a flow diagram of a forming a drug-polymer coated stent, in accordance with one embodiment of the present invention at400. Drug-polymer application method400 includes various steps to form and reflow a drug-polymer coating on a stent framework with an optional primer coating or an optional cap coating.
• A stent framework is provided and cleaned, as seen atblock405. The stent framework may be cleaned, for example, by inserting the stent framework into various solvents, degreasers and cleansers to remove any debris, residues, or unwanted materials from the surface of the stent framework. The stent framework is dried, and generally inspected at this point in the process. Generally, a primer coating is not required, though a primer coating may be applied to the stent framework prior to application of the polymer or drug-polymer coating. The primer coating is dried to eliminate or remove any volatile components and then cured or crosslinked as needed. Excess liquid may be blown off prior to drying the primer coating, which may be done at room temperature or at elevated temperatures under dry nitrogen or other suitable environments including a vacuum environment.
• A polymeric coating is applied onto at least a portion of the stent framework, as seen atblock410. The polymeric coating may comprise, for example, a primer coating, a drug-polymer coating, a cap coating, or a combination thereof. The polymeric coating is applied using any suitable coating technique such as dipping, spraying, painting, or brushing. Exemplary applied polymeric coatings comprise polymers such as poly(vinyl alcohol), poly(ethylene-vinyl acetate), polyurethane, polycaprolactone, polyglycolide, poly(lactide-co-glycolide), poly(ethylene oxide), poly(vinyl pyrrolidone), silicone, an acrylic polymer, an acrylic and acrylonitrile copolymer, a latex polymer, a thermoplastic polymer, a thermoset polymer, a biostable polymer, a biodegradable polymer, a blended polymer, a copolymer, and combinations thereof. In one embodiment of the present invention, one or more therapeutic agents may be added to and dispersed within the polymeric coating before its application onto the stent framework.
• The dipped, sprayed or brushed stent framework is then dried, as seen atblock415. The coated stent framework may be dried, for example, by positioning the coated stent framework in air and evaporating any solvent from the applied polymeric coating. The polymeric coating is generally dried after application by evaporating off the solvent at room temperature and under ambient conditions. A nitrogen environment or other controlled environment may also be used for drying. Alternatively, the polymeric coating can be dried by evaporating the majority of any solvent at room temperature, and then further drying the coating in a vacuum environment between, for example, a room temperature of about 25 degrees centigrade and 50 degrees centigrade or higher. Drying in a vacuum environment helps to extract any pockets of solvent buried within the polymeric coating and to provide the desired level of crosslinking in the polymer. After application and drying of the polymeric coating, excess coating portions may extend into apertures of the stent framework by webbing, pooling or bridging of the polymeric coating between struts and latticework of the stent framework.
• The apertures of the stent framework that have excess coating portions may be positioned adjacent to a jet of heated gas, as seen atblock420. The coated stent framework may be positioned manually or automatically such that a portion of the stent framework with the excess coating portions is placed in front of jet of heated gas. The heated gas may be emitted from, for example, one or more gas nozzles, one or more holes in a manifold positioned near the coated stent framework, or from a series of holes in a mandrel that is holding the coated stent framework with cups or cones at each end.
• One or more jets of heated gas are directed towards excess coating portions of the dried polymeric coating, as seen atblock425. The excess coating portions extend into apertures of the stent framework. The heated gas is directed onto the excess coating portions, softening and sometimes melting the polymeric material. For example, the directed jet of heated gas may be pressurized and ejected from a gas nozzle or from holes in a tube or manifold. In some cases, the jets of heated gas are directed or scanned along the entire coated stent framework; in other cases, the heated gas is emitted from one or more gas nozzles and directed at only the excess coating portions. The directed jet of heated gas may comprise, for example, a gas such as nitrogen, argon, or air. A filter may be used to remove large particles from the jets of heated gas.
• The temperature and velocity of the heated gas may be adjusted, for example, to effectively remove excess coating portions from the apertures and to reflow the polymeric coating onto the stent framework. The temperature of the directed jet of heated gas may have an ejection temperature, for example, between 25 degrees centigrade and 500 degrees centigrade, although a typical ejection temperature is between 100 degrees centigrade and 150 degrees centigrade. The type of polymer and drug used in the formulation may impose limits on the temperature of the heated gas. The velocity of the directed jet of heated gas may have an ejection velocity, for example, of greater than two meters per second.
• The dried polymeric coating may be heated close to or above a reflow temperature of the dried polymeric coating, as seen atblock430. For example, a polymeric coating with a glass transition temperature of 150 degrees centigrade may be heated to a reflow temperature of 140 degrees where the polymeric coating is soft and can reflow. In another example, the excess coating portions are locally heated to a reflow temperature above the glass transition temperature, so that the excess polymeric coating liquefies and is blown away or reflows onto the coated stent framework where it cools and hardens. In another example, the coated stent framework is pre-heated prior to directing heated gas into the apertures and reflowing the excess coating portions.
• The polymeric coating is reflowed to remove excess coating portions, as seen atblock435. The polymeric coating may be reflowed by heating the polymeric coating with directed jets of heated gas for a sufficient period of time so that excess coating portions from the apertures of the stent framework are removed. Excess coating portions may be caused, for example, by webbing, pooling or bridging between struts and open spaces in the latticework of the stent framework. Excess coating portions may occur near the ends of the stent framework where the stent framework is held with cones or cups to a mandrel, or at frayed regions where the holding apparatus has been removed. The reflowed polymeric coating may be blown off the stent framework, although the polymeric coating is usually heated to melt and fuse the excess coating portions proximate to the apertures in the stent framework. When heated, the polymeric coating generally reflows and reshapes around the struts and latticework of the stent framework. Reflowing the polymeric coatings and drug-polymer coatings, in addition to alleviating bridging, pooling and webbing, may also improve surface smoothness of the coatings and enhance adhesion to the stent framework or any underlying coatings. After the removal of the heated gas, the polymeric coating and the stent framework is cooled.
• The coated stent framework with the reflowed polymeric coating may be re-positioned, as seen back atblock420, to remove excess coating portions from any remaining untreated apertures, until all excess coating portions have been removed from the apertures.
• The polymeric coating may be reflowed and excess coating portions removed at the end of each application and drying step, such as after an application of a primer coating, after an application of each drug-polymer coating, and after an application of a cap coating. Additional coatings may be applied to the coated stent framework, as seen back atblock410. Subsequent coatings may be applied, for example, by repeated dipping into the same polymeric solution in a dipping tank. Other coatings may be applied, for example, by dipping the coated stent framework into a separate tank with another polymeric solution comprising a different polymer or a different therapeutic agent. The thickness, constituency and concentrations of the various layers can be applied and controlled to achieve the desired coating structure.
• For example, a cap coating may be applied onto the polymer-coated stent framework. The cap coating is applied by using, for example, any suitable application technique such as dipping, spraying, brushing or painting. The cap coating provides a level of scratch and abrasion resistance during the handling of the coated stent, and can serve as a diffusion barrier that provides additional control over the elution of therapeutic agents from the drug-polymer coating after deployment of the stent within the body. The cap coating may be formed from polymers such as polycaprolactone, polyglycolide, poly(lactide-co-glycolide), a silicone-urethane copolymer, a polyurethane, or poly(ethylene-vinyl acetate). Multiple cap coats may be applied to achieve a thicker cap coating.
• The reflow process allows for a higher concentration of solids in the polymeric solution during dipping or spraying, requiring less solvent and providing for a thicker coating on the stent framework without bridging, pooling or webbing.
• The reflowed polymeric coating may be baked after removing the excess coating portions from the apertures of the stent framework, as seen atblock440. The reflowed polymeric coating may be baked in an oven under an inert environment such as nitrogen or vacuum, removing any remaining solvent and providing for further crosslinking of the polymeric coating. For example, the coated stent framework with the reflowed polymeric coating may be dried in a vacuum oven at 45 degrees centigrade for twenty minutes or more.
• Other variations such as the application and reflowing of a drug-polymer coating prior to application of a cap coating are possible and within the spirit and scope of the present invention.
• The coated stent may be crosslinked and sterilized as needed, as seen atblock445. Crosslinking may be done by providing additional drying cycles in air, or by heating the coated stent above a curing temperature in an oven with a controlled ambient such as vacuum, nitrogen, or air. Sterilization may employ, for example, gamma-ray irradiation, e-beam radiation, ethylene oxide gas, or hydrogen peroxide gas plasma sterilization techniques. The coated stent may be packaged, shipped, and stored in a suitable package until it is used.
• A delivery catheter may be coupled to the coated stent, as seen atblock450. The delivery catheter may include an inflatable balloon that is positioned between the coated stent and the catheter and used for deploying the coated stent in the body. Alternatively, the delivery catheter may include a sheath that retracts to deploy a self-expanding version of the coated stent.
• In one exemplary method, fully processed coated stents are reduced in diameter and placed into the distal end of the catheter to form an interference fit, which secures the stent onto the catheter. The catheter with the stent may be placed in a catheter package and sterilized prior to shipping and storing. Before clinical use, the stent is sterilized by any appropriate or medically conventional means.
• When ready for deployment, the drug-polymer coated stent is inserted into a vessel of the body. The drug-polymer coated stent is inserted typically in a controlled environment such as a catheter lab or hospital. The delivery catheter, which helps position the drug-polymer coated stent in a vessel of the body, is typically inserted through a small incision of the leg and into the femoral artery, and directed through the vascular system to a desired place in the vessel. Guide wires threaded through an inner lumen of the delivery catheter assist in positioning and orienting the drug-polymer coated stent. The position of the drug-polymer coated stent may be monitored, for example, with a fluoroscopic imaging system or an x-ray viewing system in conjunction with radiopaque markers on the coated stent, radiopaque markers on the delivery catheter, or contrast fluid injected into an inner lumen of the delivery catheter and into an inflatable catheter balloon that is coupled to the drug-polymer coated stent. The stent is deployed, for example, by expanding the stent with a balloon or by extracting a sheath that allows a self-expandable stent to enlarge after positioning the stent at a desired location within the body.
• Once the coated stent is deployed, the therapeutic agents in the drug-polymer coating are eluted. The elution rates of the therapeutic agents into the body and the tissue bed surrounding the stent framework are based on the polymers, thickness of the drug-polymer coating and any cap coating, and the distribution and concentration of the therapeutic agents contained therein, among other factors.
• While the embodiments of the invention disclosed herein are presently considered to be preferred, various changes and modifications can be made without departing from the spirit and scope of the invention. The scope of the invention is indicated in the appended claims, and all changes that come within the meaning and range of equivalents are intended to be embraced therein.

Claims (9)

1-12. (canceled)

13. A drug-polymer coated stent, comprising:

a stent framework; and

a drug-polymer coating disposed on the stent framework, the drug-polymer coating including a reflowed portion proximate to apertures in the stent framework.

14. The stent ofclaim 13 wherein the stent framework comprises one of a metallic base or a polymeric base including a material selected from the group consisting of stainless steel, nitinol, tantalum, MP35N alloy, platinum, titanium, a chromium-based alloy, a cobalt-based alloy, a suitable biocompatible alloy, a suitable biocompatible material, a biocompatible polymer, and a combination thereof.

15. The stent ofclaim 13 wherein the drug-polymer coating comprises a polymer selected from the group consisting of poly(vinyl alcohol), poly(ethylene-vinyl acetate), polyurethane, polycaprolactone, polyglycolide, poly(lactide-co-glycolide), poly(ethylene oxide), poly(vinyl pyrrolidone), silicone, an acrylic polymer, an acrylic and acrylonitrile copolymer, a latex polymer, a thermoplastic polymer, a thermoset polymer, a biostable polymer, a biodegradable polymer, a blended polymer, a copolymer, and a combination thereof.

16. The stent ofclaim 13 wherein the drug-polymer coating comprises at least one therapeutic agent selected from the group consisting of rapamycin, a rapamycin derivative, a rapamycin analogue, an antirestenotic drug, an anti-cancer agent, an antisense agent, an antineoplastic agent, an antiproliferative agent, an antithrombogenic agent, an anticoagulant, an antiplatelet agent, an antibiotic, an anti-inflammatory agent, a steroid, a gene therapy agent, a therapeutic substance, an organic drug, a pharmaceutical compound, a recombinant DNA product, a recombinant RNA product, a collagen, a collagenic derivative, a protein, a protein analog, a saccharide, a saccharide derivative, a bioactive agent, a pharmaceutical drug, and a combination thereof.

17. The stent ofclaim 13 further comprising:

a cap coating disposed on the reflowed drug-polymer coating.

18. A system for treating a vascular condition, comprising:

a catheter; and

a drug-polymer coated stent coupled to the catheter, the drug-polymer coated stent including a stent framework having a reflowed portion proximate to apertures in the stent framework.

19. The system ofclaim 18 wherein the catheter includes a balloon to expand the stent.

20. The system ofclaim 18 wherein the catheter includes a sheath that retracts to allow expansion of the stent.

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