The invention relates to medical devices and methods of using them. The devices are prostheses which can be percutaneously deliverable with (or on) an endovascular catheter or via other surgical or other techniques and then expanded. The prostheses are configured to have a lattice resistant to dilation and creep, which is defined by a plurality of openings. The prosthesis may also optionally have a stent disposed proximal to the lattice. In exemplary embodiments, the fluoropolymer is expanded polytetrafluoroethylene. The composite materials exhibit high elongation while substantially retaining the strength properties of the fluoropolymer membrane. In at least one embodiment, the lattice is made of a composite material that includes a least one fluoropolymer membrane including serpentine fibrils and an elastomer. A lattice including a generally tubular member formed of a composite material including a least one fluoropolymer membrane containing serpentine fibrils and an elastomer is also provided.
1. A lattice comprising:
a generally tubular member having a plurality of segments arranged to define a plurality of openings therein, the tubular member having a luminal surface and an opposite exterior surface,
wherein at least said plurality of segments of said tubular member comprises a composite material including at least one fluoropolymer membrane and an elastomer, wherein said at least one fluoropolymer membrane is configured in a retracted state such that the fluoropolymer membrane includes a microstructure comprising serpentine fibrils and is characterized by an absence of visible pleating, folding, or wrinkling of the fluoropolymer membrane, and wherein each of said serpentine fibrils has a width of 1.0 micron or less, the tubular member being transitionable from a reduced diameter in which the serpentine fibrils define a plurality of curved sections and an expanded diameter in which the serpentine fibrils define a substantially straight orientation, the tubular member being more resistant to further expansion once the expanded diameter is achieved.
2. The lattice of claim 1 , wherein each of said serpentine fibrils has a width of 0.5 micron or less.
3. The lattice of claim 1 , wherein said elastomer is present in pores of said at least one fluoropolymer membrane.
4. The lattice of claim 1 , wherein said elastomer is selected from the group consisting of perfluoromethylvinyl ether-tetrafluoroethylene copolymers, perfluoro (alkyl vinyl ether)-tetrafluoroethylene copolymers, silicones and polyurethanes.
5. The lattice of claim 1 , wherein said at least one fluoropolymer comprises expanded polytetrafluoroethylene.
6. The lattice of claim 1 , wherein said at least one fluoropolymer membrane comprises pores and said elastomer is present in substantially all of the pores.
7. The lattice of claim 1 , wherein said at least one fluoropolymer membrane comprises a microstructure of substantially only fibrils.
8. The lattice of claim 1 , wherein said at least one fluoropolymer membrane comprises a microstructure of substantially only serpentine fibrils.
9. The lattice of claim 1 , wherein said openings each have a size of less than about 2 mm.
10. A lattice comprising:
a generally tubular member having a plurality of segments arranged to define a plurality of openings therein, the tubular member having a luminal surface and an opposite exterior surface,
wherein at least said plurality of segments of said tubular member comprises a composite material including at least one fluoropolymer membrane and an elastomer, said at least one fluoropolymer membrane having undergone controlled retraction such that the fluoropolymer membrane includes a microstructure comprising fibrils and is characterized by an absence of visible pleating, folding, or wrinkling of the fluoropolymer membrane, and wherein each of said fibrils has a width of 1.0 micron or less,
wherein said fibrils are serpentine and extend longitudinally in a first direction and in a second direction different than the first direction, the tubular member being wrinkle free at a reduced diameter and at an expanded diameter.
11. The lattice of claim 10 , wherein each of said serpentine fibrils has a width of 0.5 micron or less.
12. The lattice of claim 10 , wherein said elastomer is present in pores of said at least one fluoropolymer membrane.
13. The lattice of claim 10 , wherein said elastomer is selected from the group consisting of perfluoromethylvinyl ether-tetrafluoroethylene copolymers, perfluoro (alkyl vinyl ether)-tetrafluoroethylene copolymers, silicones and polyurethanes.
14. The lattice of claim 10 , wherein said at least one fluoropolymer comprises expanded polytetrafluoroethylene.
15. The lattice of claim 10 , wherein said at least one fluoropolymer membrane comprises pores and said elastomer is present in substantially all of the pores.
16. The lattice of claim 10 , wherein said at least one fluoropolymer membrane comprises a microstructure of substantially only fibrils.
17. The lattice of claim 10 , wherein said at least one fluoropolymer membrane comprises a microstructure of substantially only serpentine fibrils.
18. The lattice of claim 10 , wherein said openings each have a size of less than about 2 mm.