SERIALLY EXPANDING AN ARTIFICIAL HEART VALVE WITHIN A PEDIATRIC PATIENT

Abstract

Some embodiments are directed to methods for serially expanding an artificial heart valve within a pediatric patient. For example, the artificial heart valve can be implanted into the pediatric patient during a first procedure, and then expanded during a second procedure to accommodate for the pediatric patient’s growth. Some embodiments include introducing an expander into the implanted valve when the frame is expanded to a first working diameter, and then actuating the expander to expand the frame to a second working diameter greater than the first working diameter, to accommodate for the pediatric patient’s growth.

Claims

1-21. (canceled)

22. A catheter insertable and re-expandable artificial growth heart valve for implantation, comprising: an expandable stent frame having a compressed, delivery configuration, in which the valve is deliverable to a patient via a catheter, and an expanded, deployed configuration, in which the valve is implantable within the patient, the valve having a first working condition when the expandable stent frame is in the deployed configuration and expanded to a first diameter and a second working condition when the expandable stent frame is in the deployed configuration and re-expanded after initial implantation and initial expansion to a second diameter that is greater than the first diameter to accommodate growth of the patient; and a plurality of leaflets disposed within and coupled to the expandable stent frame, each leaflet from the plurality of leaflets extending from the expandable stent frame and terminating at a free edge, the plurality of leaflets being configured to provide competent valvular function when the valve is expanded to the first diameter and when the valve is re-expanded to the second diameter.

23. The artificial growth heart valve of claim 22, wherein each free edge has a length that is greater than the first diameter.

24. The artificial growth heart valve of claim 22, wherein the expandable stent frame has a diameter between about 2 mm and 6 mm when in the compressed, delivery configuration, and a diameter between about 5 mm and about 30 mm when in the expanded, deployed configuration.

25. The artificial growth heart valve of claim 22, wherein: the expandable stent frame has a first open end, a second open end, and a longitudinal axis extending therebetween, the longitudinal axis defining a flow path through the valve, the frame being formed by a plurality of struts each extending continuously from the first open end to the second open end, the plurality of struts defining a plurality of cells therebetween.

26. The artificial growth heart valve of claim 25, wherein at least a portion of the plurality of cells are covered.

27. The artificial growth heart valve of claim 25, wherein at least a portion of the plurality of cells are coated with a polymer.

28. The artificial growth heart valve of claim 25, wherein the expandable stent frame further defines a plurality of vertical posts, at least two of the vertical posts having different widths.

29. The artificial growth heart valve of claim 22, wherein: each leaflet from the plurality of leaflets has a center spaced apart from the leaflet free edge, each free edge of each leaflet having a thickness greater than a thickness of each center of each leaflet from the plurality of leaflets.

30. The artificial growth heart valve of claim 22, wherein the expandable stent frame has a first open end, a second open end, and a longitudinal axis defined therebetween, the longitudinal axis defining a flow path through the valve, the free edge of each leaflet varying along the longitudinal axis of the frame when the frame is in the deployed configuration.

31. The artificial growth heart valve of claim 22, wherein the plurality of leaflets is formed of a polymer.

32. The artificial growth heart valve of claim 22, wherein the expandable stent frame is configured to be expanded to the first diameter and re-expanded to the second diameter via a catheter insertable expander.

33. The artificial growth heart valve of claim 32, wherein the expander is a balloon catheter.

34. An artificial expandable heart valve, comprising: an expandable stent frame having a compressed, delivery configuration, in which the valve is deliverable to a patient via a catheter, and an expanded, deployed configuration, in which the valve is implantable within the patient; and a plurality of leaflets disposed within and coupled to the frame, each leaflet from the plurality of leaflets extending from the frame and terminating at a free edge, the frame being formed by a plurality of struts defining a plurality of cells therebetween, each leaflet from the plurality of leaflets being coupled to the frame along a leaflet attachment line, each leaflet attachment line traversing the cells while remaining within about 3 mm of a strut from the plurality of struts.

35. The artificial expandable heart valve of claim 34, wherein: each leaflet attachment line includes a curved portion and a linear portion, the curved portion terminating at the linear portion and the linear portion terminating at the free edge of the leaflet, each linear portion extending parallel to a longitudinal axis of the valve.

36. The artificial expandable heart valve of claim 35, wherein the expandable stent includes a plurality of vertical posts, each linear portion of each leaflet attachment line traversing a vertical post from the plurality of vertical posts.

37. The artificial expandable heart valve of claim 36, wherein a first vertical post from the plurality of vertical posts is disposed at a junction between two leaflets from the plurality of leaflets.

38. The artificial expandable heart valve of claim 37, wherein the first vertical post defines a window covered by a polymer, the two leaflets being cohesively coupled to the polymer.

39. The artificial expandable heart valve of claim 35, wherein the expandable stent frame is dip-coated in a polymer.

40. A method of manufacturing an implantable heart valve, comprising: dipping an expandable stent in a polymer, the expandable stent defining a plurality of vertical posts; dipping a mandrel in a polymer to form polymer leaflets, the mandrel having a cylindrical profile and defining a plurality of recesses configured to define the polymer leaflets, each of the recesses terminating at a commissure line; placing the dipped expandable stent about the dipped mandrel and aligning the dipped expandable stent such that the polymer leaflets bond to the plurality of vertical posts of the expandable stent; and after the placing, separating the mandrel from the dipped stent, leaving the manufactured heart valve for implantation.

41. The method of claim 40, wherein each of the plurality of vertical posts define one or more windows, the dipping the expandable stent including filling the one or more windows with polymer, and the placing the dipped expandable stent including bonding the polymer leaflets to the polymer disposed within the one or more windows.

42. The method of claim 40, wherein the mandrel defines a reinforcing zone to allow for additional thickness in certain regions of the leaflets.

43. The method of claim 42, wherein the reinforcing zone is defined along a perimeter of the plurality of recesses.

44. The method of claim 42, wherein the mandrel defines a gap portion between each plurality of recesses such that the polymer leaflets formed on the mandrel during the dipping the mandrel are separated by the gap portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] For a fuller understanding of the nature and desired objects of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawing figures wherein like reference characters denote corresponding parts throughout the several views and wherein:

[0044] FIGS. 1A and 1B provide perspective (in which fluid flows from the bottom of the stent toward the top of the stent) and top (in which fluid flows out of the page when the valve is open and flows down into the page to close the valve) views of a valve according to an embodiment of the invention;

[0045] FIG. 2 depicts a stent according to an embodiment of the invention;

[0046] FIGS. 3A-3F depict various stent geometries according to embodiments of the invention;

[0047] FIG. 4 depicts various vertical post geometries according to embodiments of the invention;

[0048] FIGS. 5A-5D depict the positioning of a leaflet joint adjacent to a window of a vertical post according to an embodiment of the invention;

[0049] FIG. 6 depicts a stent prior to expansion, dip coating, and leaflet installation according to an embodiment of the invention;

[0050] FIG. 7 depicts a stent including one or more anchor points according to an embodiment of the invention;

[0051] FIG. 8 depicts the engagement of a stent with a holder for dipping and rotation according to an embodiment of the invention;

[0052] FIGS. 9A-9E depict a mandrel according to an embodiment of the invention;

[0053] FIG. 9F depicts the positioning of a hyperbolic commissure line relative to defined asymptotes according to embodiments of the invention;

[0054] FIG. 10A depicts a comparison of elliptical vs. parabolic geometries leaflet valley lines according to embodiments of the invention;

[0055] FIGS. 10B and 10C depict a comparison of elliptical vs. parabolic leaflet stent attachment lines according to embodiments of the invention;

[0056] FIGS. 11A-11D depict mandrels for forming coaptation regions of varying height according to embodiments of the invention;

[0057] FIGS. 12A-12D depict mandrels for forming coaptation regions of varying radial length according to embodiments of the invention;

[0058] FIGS. 12E-12H depict mandrels for forming commissure lines having variable depths along the z-axis according to embodiments of the invention;

[0059] FIGS. 12I-12K depict mandrels for forming coaptation regions having curved profiles in an x-y plane, resulting in increased coaptation length, according to embodiments of the invention;

[0060] FIGS. 12L-12N depict mandrels for forming commissure lines having curved profiles in an x-y plane, resulting in increased coaptation length, according to embodiments of the invention;

[0061] FIG. 13A depicts a mandrel according to an embodiment of the invention;

[0062] FIGS. 13B and 13C depict the positioning of reinforcing zones on a mandrel according to an embodiment of the invention;

[0063] FIGS. 14A-14C depict various top profiles according to an embodiment of the invention;

[0064] FIGS. 15A and 15B depict the fabrication of valves according to embodiments of the invention;

[0065] FIG. 16 depict the fabrication of valves according to an embodiment of the invention;

[0066] FIGS. 17A and 17B depict the compression of a valve after assembly in order to bring leaflets into contact with each other according to embodiments of the invention;

[0067] FIG. 17C is a high-speed photograph of a closed valve under pressure according to embodiments of the invention;

[0068] FIG. 18 depicts a method of implanting a valve according to embodiments of the invention; and

[0069] FIG. 19 depicts a method of expanding an implanted valve according to embodiments of the invention.

DEFINITIONS

[0070] The instant invention is most clearly understood with reference to the following definitions.

[0071] As used herein, the singular form “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

[0072] Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from context, all numerical values provided herein are modified by the term about.

[0073] As used in the specification and claims, the terms “comprises,” “comprising,” “containing,” “having,” and the like can have the meaning ascribed to them in U.S. patent law and can mean “includes,” “including,” and the like.

[0074] Unless specifically stated or obvious from context, the term “or,” as used herein, is understood to be inclusive.

[0075] Ranges provided herein are understood to be shorthand for all of the values within the range. For example, a range of 1 to 50 is understood to include any number, combination of numbers, or sub-range from the group consisting 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 (as well as fractions thereof unless the context clearly dictates otherwise).

DETAILED DESCRIPTION OF THE INVENTION

[0076] Aspects of the invention provide a novel platform that allows development of polymeric valves of any size and shape. Aspects of the invention can be applied to valves designed for surgical implantation (e.g., through a sternotomy or thoracotomy) or valves designed for percutaneous, transcatheter implantation. Additionally, embodiments of the invention allow for possible percutaneous replacement of a dysfunctional valve, whether in adults or in small children. In addition, if implanted in a child, embodiments of the invention allow the valve to be serially expanded to accompany the child’s growth.

Cardiac Applications

[0077] Multiple types of congenital heart defects require heart valve replacement surgery in infancy or childhood. In adults, the most commonly replaced valves are aortic and mitral, whereas in children, the pulmonary valve is the most commonly replaced valve. Heart valves are currently replaced using tissue valves (homograft or xenograft) or mechanical metal valves, each having their shortcomings. Homograft valves are in short supply, particularly in sizes suitable for use in children, and biologic tissue-based valves (whether bovine, porcine, or homograft) tend to induce an immunologic reaction which leads to failure of these valves. Mechanical valves generally require anticoagulation, and are almost never used in the pulmonary position due to an increased risk of thrombosis.

[0078] Furthermore, none of the surgically implanted valves can adapt to growing patients. The rapid growth of pediatric patients leads them to outgrow their implanted valves within a few years and induces a cycle of frequent surgical valve replacements during childhood. Aspects of the invention provide valves having improved biocompatibility, durability, and hemodynamic performance and would reduce the frequency of recurrent open heart surgeries for valve replacement.

Venous Applications

[0079] Additionally, aspects of the invention can be used for venous valve replacement in patients having venous disease such as chronic venous insufficiency (leading to leg swelling). Because the polymer leaflets can be made extremely thin, the valves can even open under extremely low venous pressure gradients.

Artificial, Flexible Valves

[0080] Referring now to FIGS. 1A and 1B, one aspect of the invention provides an artificial, flexible valve 100. The valve includes an expandable, cylindrical stent 102 defining a wall 104. Valve 100 further includes a plurality of leaflets 106a–106c. Wall 104 can be formed by dip coating stent 102 in a polymer as further described herein. Leaflets 106 can be coupled to wall 104 along seams 108 (also referred to herein as “attachment line,” “leaflet-stent attachment line,” and “attachment seam”) using a variety of approaches (e.g., glue) as discussed further herein. Stent 102 can include one or more vertical posts 110, 112, which can be relatively narrow posts 110 (also referred to herein as a “first set of posts”) or relatively wide posts 112 (also referred to herein as a “second set of posts”). Preferably leaflet joints between adjacent leaflets 106 arc positioned on or close to a vertical post 110, 112 of the stent 102.

[0081] The valve 100 will now be described in the context of its components and methods of fabrication.

Stents

[0082] Referring now to FIG. 2, stent 102 can be a metallic stent having plurality of wires, strips, and the like 202 defining a plurality of cells 204, 206 of various sizes, and extending between a first open end FE and a second open end SE, and defining a longitudinal axis LA therebetween. Stent 102 can be fabricated from a variety of malleable materials such as stainless steel, 316L stainless steel, cobalt-chromium alloys, nickel-titanium alloys (colloquially known as “nitinol”), and the like. Stent 102 can also be formed from various non-metallic materials such as plastics such as polyethylene, polyurethane, polytetrafluoroethylene (PTFE), silicone, poly(propylene) (PP), polyethylene terephthalate (PET), and the like.

[0083] Stent 102 can be completely enveloped (e.g., about its external surface ES, as shown in FIG. 2) by a polymer dip coating. Stent 102 and/or wall 104 can also be fabricated from a biocompatible material.

[0084] The stent 102 can be manufactured by laser cutting or wire forming. To increase bonding strength between metal and polymer, roughness of stent surface can be controlled. Some or all open cells 204, 206 of the stent can be covered as the bare 102 stent is dipped into the polymer solution.

[0085] FIG. 6 depicts a stent 102 prior to expansion, dip coating, and leaflet installation. Stents 102 typically have a diameter of between about 2 mm and 6 mm prior to expansion and can be expanded to between about 5 mm and about 30 mm for implantation into a subject.

[0086] The components of stent 102 can have a variety of dimensions that can be selected to achieve a desired flexibility, rigidity, resilience, and the like. For example, the thickness and width of components of the stent 102 can be between about 0.1 mm and about 2 mm.

[0087] As discussed above, stent 102 can include one or more vertical posts 110a–110c to enhance bonding with leaflets 106.

[0088] Stent 102 can include a plurality of vertical posts 110 that can serve a variety of functions. Some vertical posts 110 can include additional structure and are referred to herein as wide posts 112. Wide posts 112 are preferably located at leaflet joints where two leaflets 106 meet. For example, in a valve 100 having three leaflets 106, wide posts 112 can be positioned at 120° intervals within cylindrical stent 102.

[0089] Wide posts 112 provide mechanical support to leaflets and prevent or substantially limit inward deformation of wall 104 due to tensile forces applied to leaflets 106 transferred to wall 104. Without being bound by theory, it is believed that the wide posts 112 provide increased strength and resiliency due to formation of polymer wall 104 through windows 208 and around wide posts 112, thus providing cohesive holding of the polymer to itself around the stent 102 instead of relying solely on adhesive bonding of the polymer wall 104 to the stent 102.

[0090] Wide posts 112 advantageously allow for relaxed tolerances in positioning leaflets 106 relative to wide posts 112. For example, window 208 can have a width of between about 0.5 mm and about 3 nun (e.g., about 1 mm) and a height of between about 1 mm and about 10 mm (e.g., about 5 mm).

[0091] A variety of additional wide post geometries are depicts in FIGS. 3A-3F. In FIG. 3A, the wide posts have a solid architecture without any windows. In FIG. 3B, the wide posts have a substantially rectangular architecture defining a single, long window as in FIGS. 1A, 1B, and 2. In FIG. 3C, the wide posts define a plurality of coaxial substantially rectangular windows. In FIG. 3D, the wide posts define a plurality of coaxial, substantially parallel windows. In FIG. 3E, the wide posts define a plurality of coaxial, substantially rectangular windows in a 2×3 arrangement. In FIG. 3F, the wide posts include a plurality of circular windows. These wide post architectures are further depicted in FIG. 4. Although substantially circular and rectangular window geometries are depicted, any geometry can be utilized including windows having a profile approximating a triangle, a square, an n-gon (e.g., a hexagon, an octagon, and the like), and the like.

[0092] Referring now to FIGS. 5A-5D, the positioning of a leaflet joint 502 (formed, e.g., on mandrel 900 as discussed herein) adjacent to window 208 of wide post 112 is depicted. (The polymer dip-coated wall 104 is completely transparent for case and clarity in viewing, but can be transparent, translucent, or opaque.) FIGS. 5B-5D further depict how a geometry of the stent 102 can be selected to substantially approximate the leaflet-stent attachment seam 108 discussed herein in order to provide added mechanical support and resiliency.

[0093] Referring now to FIG. 7, stent 102 can include one or more anchor points 702. Anchor points 702 advantageously facilitate holding, dipping, and rotation of the stent 102 during the dip coating process without interfering with the dip coating of the remainder of the stent architecture. Accordingly, the entire stent 102 can be dip coated in a single dipping, although multiple dippings can be utilized to control coating density, thickness, and the like. Anchor points 702 can also receive one or more radio-opaque materials such as platinum to aid in placement and visualization of the valve.

[0094] In one embodiments depicted in FIG. 8, stent 102 can be engaged with a holder 802 (e.g., by posts 804) for dipping and rotation. Once the polymer (again depicted as, but not necessarily, transparent) is wet on the stent 102, the stent can be positioned horizontally and rotated axially.

Leaflets

[0095] Leaflets 106 can be formed using a variety of techniques including dip coating, 3D-printing (also known as additive manufacturing), molding, and the like.

[0096] Referring now to FIG. 9A, leaflets 106 can be fabricated by dip coating a mandrel 900 with a polymer. The mandrel 900 can be made with a solid such as a metal (e.g., stainless steel, titanium, aluminum, and the like), a plastic (e.g., polyethylene, polypropylene, polyvinyl chloride, polytetrafluoroethylene, polyoxymethylene, and the like), and the like. Since the coated polymer leaflets 106 will be removed from the mandrel 900 after the polymer dries, roughness of mandrel surface can be controlled using known machining and other manufacturing techniques. The mandrel 900 can be made from a cylinder. Preferably, the diameter of the mandrel 900 is a slightly (e.g., between about 0.05 and about 0.4 mm) smaller than inner diameter of stent 102 after expansion.

[0097] The mandrel 900 for the leaflets 106 can have novel features, including edges representing the leaflet attachment points that are mathematically defined and leaflet tips that are extended in order to increase the coaptation length of the leaflets (including a curved portion CP and a linear portion LP, as shown in FIG. 9A). The mandrel 900 can be dimensioned to produce leaflets 106 having different regional thickness and supplementary materials such as directional fibers or reinforcing particles inserted between layers or mixed into the polymer solution in order to increase durability. For example, polymer interaction with particles on the nanoscale or microscale can greatly improve the physical properties or tear resistance of the polymer leaflets 106.

[0098] Mandrel 900 can be designed to have a complementary geometry to the desired leaflet shape and permits easier viewing of leaflet geometry. Although mandrel 900 is utilized to describe the geometry of the leaflet 106, it should be recognized that the upstream surface of the resulting leaflets will have this geometry when formed by dip coating and that the complementary geometry of the leaflet(s) 106 can be produced using techniques other than dip coating. Mandrel 900 is preferably cylindrical and can have an outer profile substantially approximating an inner profile of stent 102. Mandrel 900 can define a plurality of pockets 902 that each define a leaflet 106 as it hangs from wall 104 via attachment line 108. Each leaflet 106 terminates in a commissure line 904 often, but not necessarily lying in a plane at the point where the elliptical or parabolic curve ends and where the leaflet often contacts the other leaflets. A substantially vertical coaptation region 906 can extend beyond the commissure line 904 to an extended commissure line 912 for improved sealing as will be discussed herein.

[0099] Referring now to FIGS. 9B and 9C, mandrel can be cast, machined, printed, or otherwise fabricated so that pockets 902 have a desired geometry. In one embodiment of the invention, the commissure line 904 (and optionally the coaptation region 906 and extended commissure line 912) has a substantially hyperbolic profile when viewed in the x-y plane. Additionally or alternatively, leaflet-stent attachment line 108 and/or a leaflet valley line 908 (formed by taking a cross-section in a z plane) can have substantially elliptical profiles. Although other quadratic profiles (e.g., parabolic) could be used, elliptical profiles better promote a secure pocket shape and the closure of the leaflet-stent attachment line 108 to the contour of the cylindrical mandrel 900. A comparison of elliptical vs. parabolic leaflet valley lines is provided in FIG. 10A. A comparison of elliptical vs. parabolic leaflet-stent attachment lines is provided in FIGS. 10B and 10C.

[0100] Referring now to FIG. 9D, mandrel 900 can define a gap 910 between adjacent leaflets. Advantageously, leaflets 106 with a hyperbolic profile can produce smaller gaps than leaflets with parabolic profiles. For example, gaps 910 can be less than 1 mm or between about 0.1 mm and about 1 mm (e.g., between about 0.1 mm and about 0.2 mm, between about 0.2 mm and about 0.3 mm, between about 0.3 mm and about 0.4 mm, between about 0.4 mm and about 0.5 mm, between about 0.5 mm and about 0.6 mm, between about 0.6 mm and about 0.7 mm, between about 0.7 mm and about 0.8 mm, about 0.8 mm and about 0.9 mm, about 0.9 mm and about 1 mm, and the like).

[0101] As seen in FIG. 9E, the length of hyperbolic commissure line 904 is about twice the radius of the stent or mandrel. The positioning of a hyperbolic commissure line 904 relative to defined asymptotes is depicted in FIG. 9F.

[0102] Referring now to FIG. 11A, coaptation region can have minimal height in the z-axis so as to consist only of the commissure line 904. Alternatively, coaptation region 906 can have a vertical extension in the z-axis to an extended commissure line 912 as depicted in FIGS. 11B-11D. The height of the coaptation region 906 can be selected to reduce the amount of regurgitation, while still allowing the valve to open. For example the coaptation region 906 can have a height between about 1 mm and about 10 mm (e.g., about 3 mm). Although FIGS. 11B-11D depict extensions of coaptation region 904 that extend solely in the z-axis, the same effect can be achieved using a smooth leaflet-stent attachment line that extends in the z-axis so that the adjacent leaflet-stent attachment lines (and/or the regions of leaflets hanging therebetween) approach and/or contact each other to form an extended coaptation region.

[0103] The zone of coaptation is affected by the pressure placed upon the closed valve 100. The higher the pressure, the more downward tension is placed on the leaflets 106, possibly leading to a failure of coaptation with consequent regurgitation. Proper coaptation also allows the leaflets 106 to support each other, so there is less stress placed on any individual leaflet 106. Another benefit of enhancing height of the coaptation zone is that this allows the valve 100 to be re-dilated to a larger diameter late after implantation (such as to accommodate growth of a pediatric patient), while still maintaining competence of the valve 100.

[0104] Options for enhancing the height of the coaptation zone include creating excess length of the leaflet free edges, so that the free edge length is greater than twice the radius of the stent or mandrel depicted in FIG. 9E. Lengthening of the leaflet free edges can be accomplished by curved edges in the x-y plane, or in the z-axis, or in all 3 axes.

[0105] Referring now to FIGS. 12A-12D, coaptation regions 906 can have varying heights in the z-axis between the commissure line 904 and extended commissure line 912. For example, the height of coaptation region 906 can increase toward the outside of the mandrel as depicted in FIG. 12B. In another embodiment, the height of the coaptation region 906 can dip to form a trough between the outside and the center of the mandrel 900 as depicted in FIG. 12C.

[0106] Referring now to FIGS. 12E-12H, the same profiles can be applied to commissure line 904 without any coaptation region 906.

[0107] Referring now to FIGS. 12I-12K, the commissure lines 904, coaptation regions 906 and/or extended commissure lines 912 can have curved profiles in an x-y plane (as opposed to a substantially hyperbolic profile) in order to increase the length of the commissure line 904, coaptation region 906, and/or extended commissure line 912. For example, the mandrel 900 can be thicker between the perimeter and the center as depicted in FIG. 12I to produce one or more scallops. In FIGS. 12J and 12K, the mandrel 900 can have either a single curve or multiple curves.

[0108] Referring now to FIGS. 12L-12N, the same profiles can be applied to commissure line 904 without any coaptation region 906.

[0109] In order to increase tear-resistance of the leaflets 106 and enhance bonding strength between leaflets 106 and stent 102, the thickness of the leaflets 106 can be controlled regionally. Because the most common failure points are at the outer edges of the leaflets 106 (such as commissure line 904 or extended commissure line 912 and leaflet-stent attachment line 108), increased thickness at outer areas of the leaflets 106 can improve the strength and durability. Also, if local areas are expected to have concentrated stress, the areas can be locally reinforced (e.g., made thicker than other areas). The thickness can be smoothly increased. The width of thickened area along leaflet-stent attachment line 108 can be large enough to cover the glued area for bonding the leaflets 106 and the covered stent 102. In some embodiments, the thickness of thickened areas of the leaflets is between about 0.1 mm and about 1 mm.

[0110] Multiple dippings can be performed to produce leaflets with a desired thickness. In some embodiments, the thickness of the leaflets is between about 0.01 mm and about 0.2 mm.

[0111] Different reinforcing materials such as strips, fibers and particles can be placed between the layers, or directly mixed into the polymer solution. The inserted material(s) can prevent tearing and reduce propagation of the tear if it occurs. The materials can have directional properties and can be layered onto, or embedded into, the leaflets in an optimal direction to prevent or limit tears.

[0112] Referring now to FIG. 13A, a photograph of a mandrel 900 is provided. Referring now to FIG. 13B, a reinforcing zone 1302 can be formed on the mandrel 900 prior either by removing mandrel material to allow for additional thickness in certain (e.g., outer) regions of leaflets 106 or by introducing one or more reinforcing fibers prior to, during, or after dip coating. Suitable reinforcing materials include fibers (e.g., polymers, nanotubules, aramids, para-aramids, and the like), wires, and the like. Transitions between reinforced and non-reinforced areas can be smooth in order to minimize any turbulence in the implanted valve 100.

[0113] After dipping the mandrel 900 into the polymer solution, the coated polymer dries in order to form the leaflet(s) 106. Because the formed leaflets 106 are connected, they need to be separated from each other. These can be cut by a sharp cutter (e.g., a knife, a scalpel, a razor blade, a utility knife, and the like), a heated iron, a laser, a rotary tool, and the like. A guide on the top surface of the mandrel for cutting provides a clear, easy, and safe cutting path. The guide can be grooved/concave or convex. Also, the commissure edges of the mandrel can be sharp like a blade to facilitate leaflet separation and to improve on the quality of the cut edges.

[0114] Referring now to FIGS. 14A-14C, the gap portion 910 of the mandrel can have various top profiles to facilitate sealing of the leaflets and/or separation of the leaflets prior to removal from mandrel 900. For example, the gap portion 910 can have a grooved profile as depicted in FIG. 14A, a concave profile as depicted in FIG. 14B, or an angled profile as depicted in FIG. 14C. Additionally or alternatively, a heating element (e.g., an Ohmic or resistive heating element such as a wire) can be included in the mandrel and can be actuated to melt the polymer to separate the leaflets and/or relax the polymer to facilitate removal of the leaflets from the mandrel 900.

[0115] The stent-mounted valve 100 can be implanted with smaller diameter than its manufactured diameter for reducing leakage and improving durability.

Methods of Fabricating Valves

[0116] Referring now to FIGS. 15A, 15B, and 16, a method for fabricating a valve is depicted. A bare stent 102 and a bare mandrel 900 are provided.

[0117] In some embodiments, the stent 102 can be first coated with a polymer such as PEEK or other metal surface modifier prior to further dip coating of the stent 102 in another polymer in order to improve adhesion of the leaflet polymer 106 to the metal stent 102.

[0118] The bare mandrel 900 can optionally be coated with a release agent to promote separation of the polymer leaflets from the mandrel 900.

[0119] Both the bare stent 102 and the mandrel 900 are dip coated separately in a polymer, which may be the same or different for the bare stent 102 and the mandrel 900.

[0120] The leaflets 106 formed on the mandrel 900 can be removed prior to introduction to the coated stent. Alternatively, the coated mandrel 900 can be introduced into the coated stent, the leaflets 106 can be bonded to the coated stent, and the mandrel 900 can be then be removed to leave the assembled valve 100.

[0121] Leaflets 106 can be bonded to the dip-coated stent using a variety of techniques including gluing, chemical fusing (i.e., dissolving the polymers) thermal fusing, sonic welding, stitching, mechanical fastening, and the like. For example, the same polymer solution used to coat either bare stent 102 and/or mandrel 900 can be applied to bond the leaflets 106 to the dip-coated stent.

[0122] Although separate fabrication of the polymer-coated stent and the leaflets 106 are currently preferred as a means of avoiding or minimizing air bubbles, the entire valve could be formed in a single dip coating (or series of dip coatings) through use of production-grade manufacturing techniques and other optimizations.

[0123] Although dipcoating was successfully used to fabricate prototypes of the valves described herein, any other manufacturing technique capable of producing flexible leaflets can be utilized. Exemplary techniques include injection molding and additive manufacturing or 3D printing.

[0124] Referring now to FIGS. 17A and 17B, stent 102 and leaflets 106 can be fabricated based on a diameter that is slightly larger than the placement location as depicted in FIG. 17A. When deployed to a location having a smaller diameter than the manufactured diameter, the leaflets 106 will be held in tight contact with each other as seen in FIG. 17B to form a tight seal. (In order to form a press fit with the vessel wall, the deployed diameter will be greater than the vessel diameter, but less than the manufactured diameter.)

[0125] As can be seen in FIGS. 17A and 17B, the coaptation regions of leaflets 106 have a substantially hyperbolic profile both at the manufactured diameter and the deployed diameter.

[0126] Referring now to FIG. 17C, a high-speed photograph of a closed valve under pressure during in vitro testing in a hemodynamic pulse duplicator is provided.

Polymers

[0127] The leaflets 106 can be formed from the same or different polymer with which the stent 102 is coated to form wall 104. For example, the leaflets 106 can be formed from polymers such as polyethylene, polyurethane, silicone, and the like. Wall 104 can be formed from polyethylene, polyurethane, silicone, and the like.

[0128] Supplementary materials such as directional fibers can mixed into the polymer solution or applied to the leaflets between coatings in order to increase durability

[0129] The selected polymer can be dissolved by a solvent such as tetrahydrofuran or dimethylacetamide. The thickness of the coated polymer can be controlled as a function of the density of the polymer solution and total number of dippings. When the polymer becomes dry after dipping, the coated stent and mandrel can be placed horizontally and axially rotated in order to produce a constant thickness and prevent the polymer from dripping.

Implantation of Valves

[0130] Referring now to FIG. 18, a method 1800 of implanting an artificial valve is provided. The valve to be implanted can be a valve 100 as described herein.

[0131] In step S1802, the valve is placed over an expander and within a sheath. Various surgical expanders and access devices exist in the cardiac surgery field. For example, a balloon catheter could be introduced into a patient’s femoral artery and guided to the location of the implanted valve (e.g., within the patient’s heart or systemic veins).

[0132] In step S1804, the sheath (containing the valve and the expander) is introduced into a vessel of the subject.

[0133] In step S1806, the valve and the expander are advanced from the sheath and positioned in the desired location.

[0134] In step S1808, the desired positioning can be verified using various imaging techniques such as fiber optics, ultrasound, X-ray, and the like.

[0135] In step S1810, the expander is actuated within the valve to expand the valve to form a press fit against the vessel in which the valve is implanted. For example, a balloon catheter can be expanded by introducing gas or a liquid into the balloon.

[0136] In step S1812, the desired positioning and expansion can be verified using various imaging techniques such as fiber optics, ultrasound, X-ray, and the like.

[0137] In step S1814, the expander and sheath can be retracted according to standard surgical techniques.

Expansion of Implanted Valves

[0138] Referring now to FIG. 19, a method 1900 of expanding an implanted valve is provided. The implanted valve can be a valve 100 as described herein.

[0139] In step S1902, an expander is introduced into the implanted valve.

[0140] In step S1904, the expander is actuated within the implanted valve to increase the diameter of the implanted valve.

[0141] In step S1906, the desired expansion can be verified using various imaging techniques.

[0142] In step S1908, the expander can be retracted according to standard surgical techniques.

Surgically-Implanted Valves

[0143] Although embodiments of the invention are described and depicted in the context of percutaneous, transcatheter valves having expandable, cylindrical stents, embodiments of the invention described herein can be applied to surgically-implanted valves that generally include anchors having fixed-diameter anchors supporting a plurality of leaflets (e.g., the CARPENTIER-EDWARDS™ series of valves available from Edwards Lifesciences Corporation of Irvine, California). In such embodiments, the anchor replaces the expandable, cylindrical stents described herein.

EQUIVALENTS

[0144] Although preferred embodiments of the invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.

INCORPORATION BY REFERENCE

[0145] The entire contents of all patents, published patent applications, and other references cited herein are hereby expressly incorporated herein in their entireties by reference.