Multilayered Composite
In accordance with certain embodiments of the present disclosure, a process for forming a multilayered electrospun composite is provided. The process includes forming a dispersion of polymeric nanofibers, a fiberizing polymer, and a solvent, the dispersion having a viscosity of at least about 50,000 cPs. Nanofibers from the dispersion are electrospun onto a first ePTFE layer. A second ePTFE layer is applied onto the nanofibers to form a composite structure. The composite structure is heated.
1 . A composite structure comprising
a plurality of electrospun nanofibers on a first surface of a first expanded poly(tetrafluoroethylene) (ePTFE) layer,
wherein the nanofibers have a density such that there is a range of distances of about 0.1μ to about 50μ between points of contact of the nanofibers.
2 . The composite structure of claim 1 , wherein the electrospun nanofibers comprise poly(tetrafluoroethylene) (PTFE).
3 . The composite structure of claim 1 , wherein the nanofibers comprise nylon, polyurethane, polyester, fluorinated ethylene propylene, or combinations thereof.
4 . The composite structure of claim 1 , further comprising a second plurality of electrospun nanofibers on a second surface of the first ePTFE layer opposite to the first surface, wherein the second plurality of nanofibers have a density such that there is a range of distances of about 0.1μ to about 50μ between points of contact of the nanofibers.
5 . The composite structure of claim 1 , further comprising a second ePTFE layer.
6 . The composite structure of claim 5 , wherein the plurality of electrospun nanofibers are sandwiched between and bind together the first ePTFE layer and the second ePTFE layer.
7 . The composite structure of claim 1 , further comprising a substrate layer.
8 . The composite structure of claim 7 , wherein the plurality of electrospun nanofibers are sandwiched between and bind together the substrate layer and the first ePTFE layer.
9 . The composite structure of claim 7 , wherein the substrate layer comprises a material selected from the group consisting of a woven or nonwoven fabric of natural or man-made fibers, a plastic or ceramic membrane, and a metal, ceramic, or plastic mesh.
10 - 12 . (canceled)
13 . The composite structure of claim 23 , wherein the nanofibers comprise PTFE.
14 . The composite structure of claim 23 , wherein the nanofibers comprise nylon, polyurethane, polyester, fluorinated ethylene propylene, or combinations thereof.
15 . The composite structure of claim 23 , further comprising a third layer, the third layer comprising a plurality of electrospun nanofibers with a density such that there is a range of distances of about 0.1μ to about 50μ between points of contact of the nanofibers, wherein the third layer is joined to the first layer, second layer, or combinations thereof.
16 . The composite structure of claim 23 , further comprising a third layer, the third layer comprising ePTFE, wherein the third layer is joined to the first layer, second layer, or combinations thereof.
17 . The composite structure of claim 23 , further comprising a third layer, the third layer comprising a substrate layer.
18 . The composite structure of claim 17 , wherein the third layer comprises woven or nonwoven fabric, plastic or ceramic membrane, or metal, ceramic, or plastic mesh.
19 .- 20 . (canceled)
21 . The composite structure of claim 4 , wherein the plurality of electrospun nanofibers on the first surface and the second plurality of electrospun nanofibers on the second surface both comprise electrospun poly(tetrafluoroethylene) (PTFE).
22 . The composite structure of claim 10 , wherein the metal mesh comprises a stent.
23 . The composite structure of claim 1 , wherein the electrospun nanofibers are bonded to the first ePTFE layer.