Endovascular prosthesis and a method of connecting a structural component and a woven graft material

1. An endovascular prosthesis, comprising:

at least one stent, and

a woven graft material having a length and a circumference,

wherein the at least one stent is connected to the graft material by direct attachment of the at least one stent to the graft material at thermoplastically fused regions of the graft material, and wherein the at least one stent comprises a stent segment,

wherein the thermoplastically fused regions are disposed along the entire length and about the entire circumference of the of the graft material and comprise 30% or less of the graft material,

wherein the thermoplastically fused regions are melted regions of graft material that have lost some or all of its woven attributes, wherein the remainder of the graft material retains its woven attribute,

wherein the graft material comprises a first surface, a second surface and an interior region therebetween; each stent segment comprises a length and four sides, wherein the four sides consist of: a graft material contacting face, which is substantially parallel to and in contact with the second surface; a first edge and a second edge, wherein the first and second edges are on opposite sides of the at stent segment and are substantially perpendicular to the contacting face; and an opposing face, which is located on the opposite side of the one stent segment from the contacting face, and

wherein the contacting face, the first edge and the second of each stent segment are substantially enclosed by one of the thermoplastically fused regions.

2. The endovascular prosthesis of claim 1 , wherein the graft material has an interior and an exterior the at least one stent is directly attached to the exterior of the graft material.

3. The endovascular prosthesis of claim 1 , wherein the graft material comprises a biocompatible polyester.

4. The endovascular prosthesis of claim 3 , wherein the graft material comprises polyethylene terephthalate.

5. The endovascular prosthesis of claim 1 , wherein the thermoplastically fused regions are formed by passing an electric current through each stent segment.

6. The endovascular prosthesis of claim 1 , wherein the thermoplastically fused regions are formed using laser welding.

7. The endovascular prosthesis of claim 1 , wherein each thermoplastically fused regions:

extends between the first surface and the second surface; and

is adhered to the contacting face, the first edge and the second edge along the length of the one stent segment.

8. The endovascular prosthesis of claim 1 , wherein the thermoplastically fused regions:

extend between the first surface and the second surface; and

are adhered to the contacting face, the first edge, the second edge and the opposite face of each stent segment.

9. The endovascular prosthesis of claim 1 , wherein the thermoplastically fused regions extends from the first surface to the second surface.

10. The endovascular prosthesis of claim 1 , wherein the graft material comprises a single material, a blend of materials, a laminate or a composite of two or more materials.

11. The endovascular prosthesis of claim 1 , wherein the thermoplastically fused regions comprise 10% or less of the graft material.

12. An endovascular prosthesis, comprising:

a woven graft material having a proximal end, a distal end, a length from the proximal end to the distal end, a circumference, a luminal surface and an abluminal surface;

a structural component supporting the length and circumference of the woven graft material, the structural component selected from the group consisting of a stent extending from the proximal end to the distal end and a plurality of stents along the length of the woven graft material;

wherein the stent or the plurality of stents are connected to the graft material along its entire length and circumference by direct attachment of the stent or plurality of stents to the graft material at thermoplastically fused regions along the entire length and about the entire circumference of the graft material;

wherein the thermoplastically fused regions are disposed along the entire length and circumference of the of the graft material and comprise 30% or less of the graft material,

wherein the thermoplastically fused regions are melted regions of graft material that have lost some or all of its woven attributes, and

wherein the remainder of the graft material retains its woven attribute,

wherein the graft material comprises an interior region between the abluminal and luminal surfaces, and wherein the stent or the plurality of stents comprises a stent segment having a length and four sides, wherein the four sides consist of: a contacting face, which is substantially parallel to and in contact with the abluminal surface; a first edge and a second edge, wherein the first and second edges are on opposite sides of the stent segment and are substantially perpendicular to the abluminal surface and the contacting face; and an opposing face, which is located on the opposite side of the stent segment from the contacting face, and

wherein the contacting face, the first edge and the second edge of each stent are substantially enclosed by a thermoplastically fused region of the thermoplastically fused regions.

13. The endovascular prosthesis of claim 12 , wherein the structural component comprises a series of unconnected stents disposed along the length of the graft material.

14. The endovascular prosthesis of claim 12 , wherein the structural component comprises a single stent disposed along the length of the graft material.

15. The endovascular prosthesis of claim 12 , wherein the prosthesis is free of any other attachment between the stent or plurality of stents and the graft material.