Fibrous joinery interface between structures

Abstract

An implantable medical device includes a first component including a first material, a second component including a second material, and a fiber matrix including a plurality of fibers. The fiber matrix joins the first component to the second component. The fiber matrix includes a first a first portion connected to the first component, and a second portion connected to the second component. The first portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the first material. The first portion of the fiber matrix directly contacts the first material.

We claim: 
     
         1 . A joint structure between two components of an implantable medical device, the joint structure comprising:
 a first component made of a first material;   a second component made of a second material; and   a fiber matrix including a plurality of fibers, the fiber matrix joining the first component to the second component, the fiber matrix including:
 a first portion of the fiber matrix connected to the first component, wherein the first portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the first material; and 
 a second portion of the fiber matrix connected to the second component; 
 wherein the first portion of the fiber matrix directly contacts the first material. 
   
     
     
         2 . The joint structure of  claim 1 , wherein the first material is a silicone polymer, the second material is a polyurethane polymer, and the fiber matrix is a polyurethane polymer. 
     
     
         3 . The joint structure of  claim 2 , wherein at least some of the plurality of fibers in the second portion of the fiber matrix are distinctly identifiable within the second component. 
     
     
         4 . The joint structure of  claim 3 , wherein the second portion of the fiber matrix is connected to the second component by a heat bond. 
     
     
         5 . The joint structure of  claim 1 , wherein the second portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the second material, and wherein the second portion of the fiber matrix directly contacts the second material. 
     
     
         6 . The joint structure of  claim 5 , wherein the first material is a silicone polymer, the second material is a polyurethane polymer, and the fiber matrix is an aliphatic polyamide polymer. 
     
     
         7 . The joint structure of  claim 1 , wherein each fiber of the plurality of fibers has a diameter between 0.1 micrometers and 2 micrometers. 
     
     
         8 . The joint structure of  claim 1 , wherein at least some of the plurality of fibers are randomly oriented. 
     
     
         9 . The joint structure of  claim 1 , wherein at least some of the plurality of fibers include a single fiber extending a plurality of times between the first component and the second component. 
     
     
         10 . A method for joining a first component and a second component of an implantable medical device, the method comprising:
 interpenetrating a first portion of a fiber matrix within a first material, the first material being in a liquid state;   forming the first component by solidifying the first material, wherein the first portion of the fiber matrix is mechanically fixed within a portion of the first component and a second portion of the fiber matrix projects from the first component; and   connecting the second portion of the fiber matrix to the second component to join the first component to the second component.   
     
     
         11 . The method of  claim 10 , wherein interpenetrating the first portion of the fiber matrix within the first material includes electro-spinning a fiber directly into the first material. 
     
     
         12 . The method of  claim 10 , wherein interpenetrating the first portion of the fiber matrix within the first material includes:
 electro-spinning at least one fiber onto a substrate to form the fiber matrix; and   overmolding the first material onto the fiber matrix on the substrate.   
     
     
         13 . The method of  claim 10 , wherein solidifying the first material is by cross-linking portions of the first material around portions of the first portion of the fiber matrix. 
     
     
         14 . The method of  claim 10 , wherein connecting the second portion of the fiber matrix to the second component includes heat bonding the second portion of the fiber matrix to the second component. 
     
     
         15 . The method of  claim 10 , wherein connecting the second portion of the fiber matrix to the second component includes:
 interpenetrating the second portion of the fiber matrix within a liquid solution including a first portion of the second material;   solidifying the first portion of the second material evaporating a solvent from the liquid solution such that the second portion of the fiber matrix is mechanically fixed within the first portion of the second component; and   forming the second component by heat bonding a second portion of the second component to the first portion of the second component such that at least a portion of the second portion of the fiber matrix is distinctly identifiable within the second component.   
     
     
         16 . The method of  claim 15 , wherein the first material is a silicone polymer, the second material is a polyurethane polymer, and the fiber matrix is an aliphatic polyamide polymer. 
     
     
         17 . An implantable medical device comprising:
 a first tubular structure;   a second tubular structure coaxial with the first tubular structure; and   a fiber matrix joining the first tubular structure to the second tubular structure, the fiber matrix including:
 a first portion of the fiber matrix interpenetrated within, and mechanically fixed to, the first tubular structure; and 
 a second portion of the fiber matrix connected to the second tubular structure; 
 wherein the first portion of the fiber matrix directly contacts the first tubular structure. 
   
     
     
         18 . The device of  claim 17 , wherein the second tubular structure is at least partially within the first tubular structure. 
     
     
         19 . The device of  claim 17 , wherein the first tubular structure is made of a silicone polymer, the second tubular structure is made of a polyurethane polymer, and the fiber matrix is made of a polyurethane polymer. 
     
     
         20 . The device of  claim 17 , wherein the first tubular structure is a silicone polymer, the second tubular structure is a polyurethane polymer, and the fiber matrix is an aliphatic polyamide polymer; and wherein the second portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the second tubular structure, and wherein the second portion of the fiber matrix directly contacts the second tubular structure.