Multi-layer balloon design for use in combination with catheter assemblies, and methods of making the same

1. An expandable medical device having a static state and at least one expanded state, the expandable medical device in said static state comprising:

at least one first inner layer formed from a first polymer composition;

at least one intermediate layer; and

at least one second outer layer formed from a second polymer composition which is the same as or different than said first polymer composition, said at least one second outer layer having an inner surface and an outer surface and the at least one second outer layer comprising a closed lattice in said inner surface or said outer surface of said at least one second outer layer, the closed lattice is defined by channels having a thinner wall than corresponding areas of the outer surface; and

wherein said lattice is closed in said static state and said at least one intermediate layer is unexposed and said lattice is open when said expandable medical device is in said at least one expanded state, exposing said intermediate layer.

2. The expandable medical device of claim 1 wherein said at least one intermediate layer comprises at least one lubricious polymer material, at least one therapeutic agent or a combination thereof.

3. The expandable medical device of claim 1 wherein said at least one intermediate layer comprises a lubricious gel.

4. The expandable medical device of claim 3 wherein said lubricious gel is a hydrogel.

5. The expandable medical device of claim 1 wherein said at least one intermediate layer comprises at least one therapeutic agent.

6. The expandable medical device of claim 1 wherein first polymer composition comprises a polyether-block-amide copolymer.

7. The expandable medical device of claim 1 wherein said closed lattice is in said outer surface of said at least one second outer layer.

8. The expandable medical device of claim 1 in combination with a catheter assembly, the catheter assembly having a distal end, the expandable medical device disposed on the distal end of said catheter assembly.

9. The expandable medical device of claim 1 in combination with a stent, said stent disposed on said expandable medical device.

10. The expandable medical device of claim 1 , the device comprising cone, waist and body portions, the intermediate layer is on the body portion of the device.

11. An expandable medical device for the controlled, localized delivery of a therapeutic agent, said expandable medical device having at least one static state and at least one expanded state, said expandable medical device comprising:

at least one first inner layer formed from a first polymer composition;

at least one second outer layer formed from a second polymer composition which is the same as or different than said first polymer composition, said at least one second outer layer having an inner surface and an outer surface and the at least one second outer layer comprising a closed lattice in said inner surface or said outer surface of said at least one second outer layer, the closed lattice is defined by channels having a thinner wall than corresponding areas of the outer surface; and

an intermediate layer, said intermediate layer comprising at least one therapeutic agent;

wherein said lattice is closed in said static state and said intermediate layer is unexposed and said lattice is open when said expandable medical device is in said at least one expanded state, exposing said intermediate layer for delivery of said at least one therapeutic agent.

12. An expandable medical device for the delivery of an implantable medical device, said expandable medical device having a static state, at least one expanded state and at least one deflated state, said expandable medical device disposed at the distal end of a catheter assembly, said implantable medical device disposed about said expandable medical device when said expandable medical device is in said at least one deflated state, said expandable medical device comprising:

at least one first inner layer formed from a first polymer composition;

at least one second outer layer formed from a second polymer composition which is the same as or different than said first polymer composition, said at least one second outer layer having an inner surface and an outer surface and the at least one second outer layer comprising a closed lattice in said inner surface or said outer surface of said at least one second outer layer, the closed lattice is defined by channels having a thinner wall than corresponding areas of the outer surface; and

an intermediate layer, said intermediate layer comprising at least one lubricious polymer material;

wherein in said static state said lattice is closed and said intermediate layer is unexposed and said lattice is open when said expandable medical device is in said at least one expanded state, exposing said intermediate layer.

13. An expandable medical device having a static state and at least one expanded state, the expandable medical device in said static state comprising:

at least one first inner layer formed from a first polymer composition; and

at least one second outer layer formed from a second polymer composition which is the same as or different than said first polymer composition, said at least one second outer layer having an inner surface and an outer surface and the at least one second outer layer comprising a closed lattice in said inner surface or said outer surface of said at least one second outer layer, the closed lattice is defined by channels having a thinner wall than corresponding areas of the outer surface;

said lattice is open when said expandable medical device is in said at least one expanded state; and

wherein fluid is prevented from flowing through the outer surface or inner surface of the at least one second outer layer when the lattice is closed and wherein fluid can flow through said outer surface of inner surface of said outer layer at least one second when said lattice is open.