Shaped woven tubular soft-tissue prostheses and method of manufacturing the same
View Patent ↗Continuously flat-woven implantable tubular prostheses have seamless woven sections which gradually change the number of warp yarns to smoothly transition, i.e., taper, from one diameter to another. Multi-diameter endoluminal grafts having a variety of shapes and configurations are made using a seamless weaving process without unacceptable voids or gaps in the tubular wall.
1. A flat-woven tubular implantable prosthesis comprising:
a tubular wall having opposed open ends defining a fluid passageway therebetween;
said tubular wall comprising a plurality of interwoven monofilament warp yarns and monofilament fill yarns, wherein said monofilament warp and monofilament fill yarns are woven in a sufficiently dense pattern to provide a substantially fluid-tight wall portion; wherein said tubular wall has a wall thickness less than about 0.16 mm; and further wherein said dense pattern is free of voids greater than a diameter of about three of said warp yarns.
2. The prosthesis of claim 1 , wherein said monofilament warp yarns include yarns of thermoplastic materials selected from the group consisting of polyester, polypropylene, polyethylene, polyurethane, polytetrafluoroethylene and combinations thereof; and said monofilament fill yarns include yarns of thermoplastic selected from the group consisting of polyester, polypropylene, polyethylene, polyurethane, polytetrafluoroethylene and combinations thereof.
3. The prosthesis of claim 1 , wherein said tubular wall has a wall thickness from about 0.07 mm to about 0.14 mm.
4. The prosthesis of claim 1 , wherein said monofilament warp yarns and said monofilament fill yarns are interwoven into a weaving pattern, wherein said weaving pattern is selected from the group consisting of a simple weave, a basket weave, a twill weave and a velour weave.
5. The prosthesis of claim 1 , wherein said interwoven monofilament yarns are within a distance of about 1 micron from each other.
6. The prosthesis of claim 1 , further including a second tubular wall of interwoven monofilament warp yarns and monofilament fill yarns, said second tubular wall being seamlessly and contiguously transitioned from said tubular wall.
7. The prosthesis of claim 6 , wherein said second tubular wall includes a plurality of tubular walls.
8. The prosthesis of claim 6 , wherein said second tubular wall includes two tubular walls to provide a bifurcated prosthesis.
9. The prosthesis of claim 1 , further including a stent.
10. The prosthesis of claim 1 , wherein said interwoven monofilament yarns are within a distance of about 1 micron from each other.
11. The prosthesis of claim 1 , wherein said monofilament warp and said monofilament fill yarns have a denier from about 40 to about 300.
12. The prosthesis of claim 1 , wherein said monofilament warp and said monofilament fill yarns have a denier from about 20 to about 1,000.
13. A flat-woven tubular implantable prosthesis comprising:
a tubular wall having opposed open ends defining a fluid passageway therebetween;
said tubular wall comprising a plurality of interwoven warp yarns and monofilament fill yarns, wherein said monofilament warp and said monofilament fill yarns are closely interwoven to each other within a distance of about 1 micron; wherein said monofilament wrap and said monofilament fill yarn have a denier from about 20 to about 1,000; and further within said tubular wall has a wall thickness less than about 0.16 mm.
14. The prosthesis of claim 13 , wherein said warp yarns include yarns of thermoplastic materials selected from the group consisting of polyester, polypropylene, polyethylene, polyurethane, polytetrafluoroethylene and combinations thereof; and said fill yarns include yarns of thermoplastic selected from the group consisting of polyester, polypropylene, polyethylene, polyurethane, polytetrafluoroethylene and combinations thereof.
15. The prosthesis of claim 13 , wherein said tubular wall has a wall thickness from about 0.07 mm to about 0.14 mm.
16. The prosthesis of claim 13 , wherein said warp and said fill yarns are interwoven into a weaving pattern, wherein said weaving pattern is selected from the group consisting of a simple weave, a basket weave, a twill weave and a velour weave.
17. The prosthesis of claim 13 , further including a second tubular wall of interwoven warp and fill yarns, said second tubular wall being seamlessly and contiguously transitioned from said tubular wall.
18. The prosthesis of claim 17 , wherein said second tubular wall includes a plurality of tubular walls.
19. The prosthesis of claim 17 , wherein said second tubular wall includes two tubular walls to provide a bifurcated prosthesis.
20. The prosthesis of claim 13 , further including a stent.
21. The prosthesis of claim 13 , wherein said monofilament warp and said monofilament fill yarns have a denier from about 40 to about 300.