Layered stent-graft and methods of making the same

Claim 1

A stent-graft comprising: an intraluminal implantable body configured for percutaneous intraluminal delivery into a vessel, the intraluminal implantable body comprising a porous first layer having an outer surface, the entire longitudinal length of the outer surface of the porous first layer is adapted to make contact with tissue of a vessel wall; a non-porous layer attached to the porous first layer; a self expandable. balloon expandable or combination of self expandable and balloon expandable stent, for allowing the stent-graft to expand to a suitable diameter to compress the porous first layer against a vessel wall such that the stent is mechanically supporting the vessel wall, encapsulated by the non-porous layer; and a porous second layer attached to the non-porous layer having the stent, the porous second layer having an inner surface that is adapted to make contact with bodily fluids that flow through a longitudinal bore of the stent-graft wherein the stent-graft includes (i) a compressed configuration that allows the stent-graft to be delivered percutaneouly and intraluminally into a vessel by a catheter and/or a guide wire and maneuvered along a vascular network to a delivery site and (ii) expanded configuration, substantially greater in outer diameter than the compressed configuration that allows the stent-graft to be secured inside of a vessel, and wherein the thickness of the combination of the layers is of a suitable size that does not adversely affect the flow of fluid through the vessel.

Claim 30

A method of manufacturing a intraluminal stent-graft comprising: (a) forming a porous first layer on a mandrel, the porous first layer being the inner most layer of the intraluminal stent-graft such that an inner surface of the porous first layer is configured to be exposed to bodily fluids that travel through a longitudinal bore of the intraluminal stent-graft; (b) forming a non-porous second layer on the porous first layer; (c) positioning a stent on the non-porous second layer; (d) increasing the thickness of the non-porous second layer to substantially or completely encapsulate the stent in the non-porous second layer; and (e) forming a porous third layer on the non-porous second layer, the porous third layer being the outermost layer of the intraluminal stent-graft and configured to make contact with a wall of the vessel, wherein the stent-graft is of a suitable dimension to allow for percutaneous insertion of the stent-graft within a lumen of a patient, wherein the stent-graft includes a compressed configuration that allows the entire length of the stent-graft to be delivered percutaneouly into a vessel by a catheter and/or a guide wire and a deployed, expanded configuration, substantially greater in diameter than the compressed configuration, that allows the stent-graft to be implanted within a vessel and wherein the thickness of the combination of the layers is of a suitable size that does not adversely affect the flow of fluid through the vessel.

Claim 31

A method of manufacturing a intraluminal stent-graft comprising: (a) forming a porous first layer on a mandrel, the porous first layer being the inner most layer of the intraluminal stent-graft such that an inner surface of the porous first layer is configured to be exposed to bodily fluids that travel through a longitudinal bore of the intraluminal stent-graft; (b) forming a non-porous second layer on the porous first layer; (c) positioning a stent on the non-porous second layer; (d) increasing the thickness of the non-porous second layer to substantially or completely encapsulate the stent in the non-porous second layer; and (e) forming a porous third layer on the non-porous second layer, the porous third layer being the outermost layer of the intraluminal stent-graft and configured to make contact with a wall of the vessel, wherein the stent-graft is of a suitable dimension to allow for percutaneous insertion of the stent-graft within a lumen of a patient, wherein the stent-graft includes a compressed configuration that allows the entire length of the stent-graft to be delivered percutaneouly into a vessel by a catheter and/or a guide wire and a deployed, expanded configuration, substantially greater in diameter than the compressed configuration, that allows the stent-graft to be implanted within a vessel and wherein the thickness of the combination of the layers is of a suitable size that does not adversely affect the flow of fluid through the vessel.