Method for roll coating multiple stents

Abstract

An improved method and apparatus for high-volume production of coated stents with highly uniform stent coatings using a roll coating technique is provided. In a first embodiment, uncoated stents are placed onto rotating stent holders with automated stent handling equipment. The holders are mounted on an endless conveyer belt which advances the stents toward a stent coater. As the stents advance through the coater, the holders rotate, thereby rolling the stents about their longitudinal axes as coating material is sprayed toward them, ensuring the stents are uniformly coated on their exterior and interior surfaces. After the conveyer turns to carry the coated stents back toward the loading area, the rotating stents pass again through the coating spray, downstream of the initial coating location, thereby increasing the efficient utilization of the coating material. The conveyer then advances the coated stents to an unloading area for removal before the holders return to the stent loading area to receive new stents.

1 - 21 . (canceled)  
     
     
         22 . A method for coating stents, comprising the steps of: 
 placing a plurality of stents on a plurality of stent holders, wherein the stent holders are attached to a conveyer;    turning the stent holders while the conveyer moves the stents; and    applying a coating to the turning stents as the stents pass through a coater.    
     
     
         23 . The method of coating stents of  claim 22 , wherein the step of turning the stent holders while the conveyer moves the stents includes revolving the stent holders around a point.  
     
     
         24 . The method of coating stents of  claim 22 , wherein the step of turning the stent holders while the conveyer moves the stents includes pivoting the stent holders.  
     
     
         25 . The method of coating stents of  claim 22 , wherein the stent holders are removably attached to a conveyer.  
     
     
         26 . The method of coating stents of  claim 22 , wherein the conveyer is an endless belt, and the endless belt is moving as the plurality of stents is placed on the plurality of stent holders.  
     
     
         27 . The method of coating stents of  claim 26 , wherein the coater includes a coating sprayer, and the conveyer moves the plurality of stents through a coating spray released from the coating sprayer.  
     
     
         28 . The method of coating stents of  claim 26 , wherein the coater includes a coating bath, and the conveyer moves the plurality of stents through the coating bath.  
     
     
         29 . The method of coating stents of  claim 27 , wherein the step of applying a coating further comprises: 
 passing the stents through the coating spray at a first distance from the sprayer, then passing the stents through the coating spray at a second distance from the sprayer.    
     
     
         30 . The method of coating stents of  claim 26 , wherein the step of placing a plurality of stents on a plurality of stent holders is performed with an automated stent loader.  
     
     
         31 . The method of coating stents of  claim 26 , wherein the stent holders are revolving bases adapted to receive individual stent handling devices on which at least one stent is pre-mounted, and wherein the step of placing the stents on the stent holders further comprises: 
 placing stents pre-mounted on stent handling devices onto the stent holders by engaging the stent handling devices with the revolving bases.    
     
     
         32 . The method of coating stents of  claim 27 , wherein the coating sprayer sprays the stent coating toward the stents from a plurality of directions.  
     
     
         33 . The method of coating stents of  claim 22 , further comprising the step of: 
 drying the coated stents prior to removal of the coated stents from the stent holders.    
     
     
         34 . A system for coating medical devices comprising: 
 a plurality of holders for holding a plurality of medical devices to be coated;    a conveyer;    a means for advancing the conveyer;    a means for turning the plurality of holders; and    a coater;    wherein the plurality of holders is attached to a conveyer, and wherein the means for turning the holder turns the plurality of holders and medical devices while the conveyer moves the medical devices through the coater, so that a coating is applied to the turning medical devices as the medical devices pass through the coater.    
     
     
         35 . The system of  claim 34 , wherein at least one of the plurality of holders is adapted to receive each of the plurality of medical devices.  
     
     
         36 . The system of  claim 34 , wherein the means for turning the plurality of holders is a backing plate.  
     
     
         37 . The system of  claim 36 , wherein the plurality of holders is adapted to cooperate with the backing plate, so that the plurality of holders turns upon contact with the backing plate as the conveyer is advanced.  
     
     
         38 . The system of  claim 34 , wherein the means for turning the plurality of holders is a gear mechanism.  
     
     
         39 . The system of  claim 34 , further comprising a dryer.  
     
     
         40 . The system of  claim 34 , wherein the medical devices are stents.  
     
     
         41 . A system for coating stents comprising: 
 a plurality of stent holders for holding a plurality of stents to be coated;    a conveyer;    a means for advancing the conveyer;    a means for rotating the plurality of stent holders; and    a coater;    wherein the conveyer is an endless belt; and    wherein the plurality of stent holders is attached to the conveyer, and wherein the means for rotating the holder rotates the plurality of holders and stents while the conveyer moves the stents through the coater, so that a coating is applied to the rotating stents as the stents pass through the coater.