mTOR inhibitor eluting medical device

1. A coated implantable medical device, consisting of:

an implantable medical device selected from the group consisting of a stent, a guide wire, a heart valve, a catheter, a vena cava filter, a vascular graft, a stent graft and combinations thereof;

a base layer on said implantable medical device consisting of one or more mTOR inhibitors, one or more biodegradable polymers and, optionally, one or more antioxidants, said one or more mTOR inhibitors dispersed in said one or more biodegradable polymers and selected from the group consisting of everolimus, pimecrolimus, tacrolimus, zotarolimus, biolimus, rapamysin, and mixtures thereof and wherein a weight ratio of said one or more mTOR inhibitors to said one or more biodegradable polymers is in a range of from 10:90 to 30:70;

a middle layer on said implantable medical device consisting of one or more mTOR inhibitors, one or more biodegradable polymers and, optionally, one or more antioxidants, said one or more mTOR inhibitors dispersed in said one or more biodegradable polymers and selected from the group consisting of everolimus, pimecrolimus, tacrolimus, zotarolimus, biolimus, rapamysin, and mixtures thereof and wherein a weight ratio of said one or more mTOR inhibitors to said one or more biodegradable polymers is in a range of from 15:85 to 40:60 and wherein in said middle layer said weight ratio of said one or more mTOR inhibitors is greater than in said base layer; and

a top layer on said medical device selected from the group consisting of one or more hydrophilic polymers, and a combination of one or more hydrophilic polymers with one or more antioxidants, the top layer being mTOR inhibitor-free, wherein a total antioxidant concentration of the one or more antioxidants in the top layer varies from 0.5 weight percent to 10 weight percent with respect to a total mTOR inhibitor concentration over said medical device;

wherein a total mTOR inhibitor concentration over said medical device is in the range of from 0.7 to 3.00 μg/mm 2 and wherein said base layer has a higher total amount of said one or more mTOR inhibitors than said middle layer, and wherein from 10 to 30% of the total amount of said one or more mTOR inhibitors is released from said medical device in the first 24 hours after use with the remainder of said mTOR inhibitor being released from said medical device over a period of time of 28 days or longer; and

wherein said one or more biodegradable polymers in said base and said middle layer are selected from the group consisting of poly(L-lactide-co-caprolactone) (PLCL), poly L-lactide (PLLA), poly dl lactide (PDLLA), poly dl lactide-co-glycolide (PLGA), poly dl lactide-co-caprolactone (PLLCL), and combinations thereof.

2. The coated implantable medical device as claimed in claim 1 , wherein each of said middle layer and said base layer further comprise an antioxidant.

3. The coated implantable medical device as claimed in claim 1 , wherein said one or more antioxidants is selected from the group consisting of tocopherol acetate, Vitamin E, butylated hydroxyl toluene (BHT) and combinations thereof.

4. The coated implantable medical device as claimed in claim 1 , wherein said one or more hydrophilic polymers is selected from the group consisting of pyrrolidone polymers.

5. The coated implantable medical device as claimed in claim 1 , wherein:

the base layer comprises everolimus and a blend of poly(L-lactide-co-caprolactone) (PLCL) and poly L-lactide (PLLA);

the middle layer comprises everolimus and a blend of poly(L-lactide-co-caprolactone) (PLCL) and poly L-lactide (PLLA); and

the one or more hydrophilic polymers includes polyvinyl pyrrolidone and the one or more antioxidants includes tocopherol acetate.

6. A method of preparing a coated implantable medical device as claimed in claim 1 , the coating process comprising:

pre-cleaning a medical device selected from the group consisting of a stent, a guide wire, a heart valve, a catheter, a vena cava filter, a vascular graft, a stent graft and combinations thereof using an organic solvent to obtain a cleaned medical device; and

coating the cleaned medical device with the base layer;

coating the base layer with the middle layer; and

coating the middle layer with the top layer to obtain a coated implantable medical device;

wherein the one or more mTOR inhibitors and the one or more biodegradable polymers in the base layer and the middle layer has a solution concentration in the range of 0.01 to 1% (w/v).

7. The method as claimed in claim 6 , wherein the one or more hydrophilic polymers and the one or more antioxidants in the top layer has a solution concentration in the range of from 0.01 to 5% (w/v).

8. The method as claimed in claim 6 , wherein the organic solvent is selected from the group consisting of dichloromethane, chloroform, hexafluoro isopropanol, and combinations thereof.

9. The coated implantable medical device as claimed in claim 6 , wherein the coating process is done on an abluminal surface, a luminal surface and side walls of the medical device.

10. The coated implantable medical device as claimed in claim 1 , wherein said device is a stent.

11. The coated implantable medical device as claimed in claim 10 , wherein said one or more mTOR inhibitors is everolimus.

12. The coated implantable medical device as claimed in claim 11 , wherein said one or more biodegradable polymers is selected from the group consisting of poly L-lactide (PLLA), poly(L-lactide-co-caprolactone (PLCL), and a mixture thereof.

13. The coated implantable medical device as claimed in claim 12 , wherein said one or more antioxidants is tocopherol acetate.

14. The coated implantable medical device as claimed in claim 13 , wherein said one or more hydrophilic polymers is polyvinyl pyrrolidone.

15. The coated implantable medical device as claimed in claim 1 , wherein the top layer does not contain any drug.

16. The coated implantable medical device as claimed in claim 1 , wherein:

30%-50% of said one or more mTOR inhibitors is released from said medical device in the first 3 days,

45%-65% of said one or more mTOR inhibitors is released from said medical device in the first 7 days, and

55%-75% of said one or more mTOR inhibitors is released from said medical device in the first 14 days.

17. The coated implantable medical device as claimed in claim 1 , wherein the at least one biodegradable polymer in the base layer and middle layer has a weight ratio in the range from 10% to 40% based on the mTOR inhibitor weight.

18. The coated implantable medical device as claimed in claim 1 , wherein said one or more biodegradable polymers in said base layer and said middle layer comprises a mixture of poly L-lactide and poly(L-lactide-co-caprolactone) each having a weight ratio in the range from 10% to 40% based on said mTOR inhibitor weight.