Ultra-thin fabric, devices, and methods

Abstract

A fabric can comprise yarns comprising less than about 30 denier total and less than about 10 denier per filament; a density of greater than about 177 yarns per cm2; and a thickness of less than about 3.2 mil. The fabric can further comprises a weight of less than about 60 g/m2. The fabric can have performance characteristics equivalent to or greater than those in conventional implantable fabrics. A method of making such a fabric can include twisting together filaments into a multifilament yarn; passing adjacent yarns into a loom in parallel so as to allow the yarns to be woven together more closely; maintaining a consistent tension on the yarns during placement of the yarns on a loom beam and during weaving; and or subjecting the fabric to increased heat and pressure so as to compress the yarns more tightly.

What is claimed is: 
     
       1. A fabric, comprising:
 yarns, comprising more than 1 and less than about 30 denier total and more than 0.1 and less than about 10 denier per filament;   a density of greater than about 177 yarns per cm 2 ; and   a thickness of less than about 3.2 mil;   wherein the fabric further comprises a water permeability rating of less than about 400 cc/min/cm 2  at 120 mm Hg pressure.   
     
     
       2. The fabric of  claim 1 , wherein the fabric further comprises a weight of less than about 60 g/m 2 . 
     
     
       3. The fabric of  claim 1 , wherein the fabric further comprises an implantable medical device. 
     
     
       4. The fabric of  claim 3 , wherein the implantable medical device is passable through a size 10 French delivery catheter. 
     
     
       5. The fabric of  claim 1 , wherein the yarns comprise multifilament yarns, each yarn having 10 filaments and a total denier of about 20. 
     
     
       6. The fabric of  claim 1 , wherein the yarns comprise polyester, polypropylene, polytetrafluoroethylene, nylon, and/or polyethylene yarns. 
     
     
       7. The fabric of  claim 1 , wherein the fabric further comprises a probe burst strength of greater than about 20 lbs. 
     
     
       8. The fabric of  claim 1 , wherein the fabric further comprises a tensile strength of greater than about 25 lbs. per inch. 
     
     
       9. A method, comprising:
 fabricating a fabric comprising less than about 30 denier total and less than about 10 denier per filament, a density of greater than about 177 yarns per cm 2 , and a thickness of less than about 3.2 mil, wherein the fabric further comprises a water permeability rating of less than about 400 cc/min/cm 2 at 120 mm Hg pressure; and   slashing the yarns with a protective coating prior to fabricating the fabric.   
     
     
       10. The method of  claim 9 , the yarns comprising multifilament yarns, the method further comprising twisting the filaments together. 
     
     
       11. The method of  claim 9 , further comprising passing adjacent yarns into a loom in parallel so as to allow the yarns to be woven together more closely. 
     
     
       12. The method of  claim 9 , further comprising maintaining a consistent tension on the yarns during placement of the yarns on a loom beam during weaving. 
     
     
       13. The method of  claim 9 , further comprising subjecting the fabric to increased heat and pressure so as to compress the yarns more tightly. 
     
     
       14. A fabric comprising:
 yarns comprised of the group consisting essentially of polyester, nylon, polypropylene, polyethylene, and polytetrafluoroethylene, the yarns comprising less than about 30 denier total and less than about 10 denier filament;   a density of greater than about 177 yarns per cm 2 ; and   a thickness of less than about 3.2 mil;   wherein the fabric further comprises a water permeability rating of less that about 400 cc/min/cm 2  at 120 mm Hg pressure.   
     
     
       15. The fabric of  claim 14 , wherein the fabric further comprises a weight of less than about 60 g/m 2 . 
     
     
       16. The fabric of  claim 14 , wherein the fabric further comprises an implantable medical device. 
     
     
       17. The fabric of  claim 16 , wherein the implantable medical device is passable through a size 10 French delivery catheter. 
     
     
       18. The fabric of  claim 14 , wherein the fabric further comprises a probe burst strength of greater than about 20 lbs. 
     
     
       19. The fabric of  claim 14 , wherein the fabric further comprises a tensile strength of greater than about 25 lbs. per inch. 
     
     
       20. An implantable medical fabric, comprising:
 a fabric thickness of about 4.0 mil or less than about 4.0 mil;   a water permeability rating of less than about 400 cc/min/cm 2  at 120 mm Hg pressure; and   yarns having filaments, wherein the yarns have a total denier of less than about 30 denier and the filaments have a denier per filament of less than about 10;   wherein the yarns are selected from the group consisting of polyester, polypropylene, polytetrafluoroethylene, nylon, and polyethylene yarns; and   wherein said fabric comprises a tensile strength of greater than about 25 lbs. per inch.   
     
     
       21. The implantable medical fabric of claim 20, wherein the fabric further comprises a fabric weight of less than about 60 g/m 2 . 
     
     
       22. The implantable medical fabric of claim 20, wherein the fabric further comprises a probe burst strength of greater than about 20 lbs. 
     
     
       23. The implantable medical fabric of claim 20, wherein the fabric further comprises a density of greater than about 177 yarns per cm 2 . 
     
     
       24. The implantable medical fabric of claim 20, wherein the yarns are woven to form said fabric. 
     
     
       25. The implantable medical fabric of claim 20, wherein said fabric is a tubular fabric. 
     
     
       26. The implantable medical fabric of claim 20, wherein said fabric is a flat fabric. 
     
     
       27. A cardiovascular or endovascular device comprising the implantable medical fabric of claim 20. 
     
     
       28. The cardiovascular or endovascular device of claim 27, wherein said endovascular device is a stent-graft. 
     
     
       29. An implantable device comprising the implantable medical fabric of claim 20, wherein said device is selected from the group consisting of a heart valve, a barrier sheath in a prosthetic material, and a reinforcement material adapted for repairing a prosthetic graft. 
     
     
       30. An implantable medical fabric, comprising:
 a fabric thickness of about 4.0 mil or less than about 4.0 mil;   a water permeability rating of less than about 400 cc/min/cm 2  at 120 mm Hg pressure; and   yarns having filaments, wherein the yarns have a total denier of less than about 30 denier and the filaments have a denier per filament of less than about 10;   wherein the yarns are selected from the group consisting of polyester, polypropylene, polytetrafluoroethylene, nylon, and polyethylene yarns; and   wherein said fabric comprises a probe burst strength of greater than about 20 lbs.   
     
     
       31. The implantable medical fabric of claim 30, wherein the fabric further comprises a fabric weight of less than about 60 g/m 2 . 
     
     
       32. The implantable medical fabric of claim 30, wherein the fabric further comprises a density of greater than about 177 yarns per cm 2 . 
     
     
       33. The implantable medical fabric of claim 30, wherein the yarns are woven to form said fabric. 
     
     
       34. The implantable medical fabric of claim 30, wherein said fabric is a tubular fabric. 
     
     
       35. The implantable medical fabric of claim 30, wherein said fabric is a flat fabric. 
     
     
       36. A cardiovascular or endovascular device comprising the implantable medical fabric of claim 30. 
     
     
       37. The cardiovascular or endovascular device of claim 36, wherein said endovascular device is a stent-graft. 
     
     
       38. An implantable device comprising the implantable medical fabric of claim 30, wherein said device is selected from the group consisting of a heart valve, a barrier sheath in a prosthetic material, and a reinforcement material adapted for repairing a prosthetic graft. 
     
     
       39. An implantable medical fabric, comprising:
 a fabric thickness of about 4.0 mil or less than about 4.0 mil;   a water permeability rating of less than about 400 cc/min/cm 2  at 120 mm Hg pressure; and   yarns having filaments, wherein the yarns have a total denier of less than about 30 denier and the filaments have a denier per filament of less than about 10;   wherein said fabric comprises a tensile strength of greater than about 25 lbs. per inch; and   wherein said fabric comprises a probe burst strength of greater than about 20 lbs.   
     
     
       40. The implantable medical fabric of claim 39, wherein the fabric further comprises a fabric weight of less than about 60 g/m 2 . 
     
     
       41. The implantable medical fabric of claim 39, wherein the fabric further a density of greater than about 177 yarns per cm 2 . 
     
     
       42. The implantable medical fabric of claim 39, wherein the yarns are woven to form said fabric. 
     
     
       43. The implantable medical fabric of claim 39, wherein said fabric is a tubular fabric. 
     
     
       44. The implantable medical fabric of claim 39, wherein said fabric is a flat fabric. 
     
     
       45. A cardiovascular or endovascular device comprising the implantable medical fabric of claim 39. 
     
     
       46. The cardiovascular or endovascular device of claim 45, wherein said endovascular device is a stent-graft. 
     
     
       47. An implantable device comprising the implantable medical fabric of claim 39, wherein said device is selected from the group consisting of a heart valve, a barrier sheath in a prosthetic material, and a reinforcement material adapted for repairing a prosthetic graft.