WO2005122961A2 - Radiopaque coating for biomedical devices - Google Patents
Radiopaque coating for biomedical devices Download PDFInfo
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- WO2005122961A2 WO2005122961A2 PCT/US2005/020667 US2005020667W WO2005122961A2 WO 2005122961 A2 WO2005122961 A2 WO 2005122961A2 US 2005020667 W US2005020667 W US 2005020667W WO 2005122961 A2 WO2005122961 A2 WO 2005122961A2
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- WIPO (PCT)
- Prior art keywords
- coating
- medical device
- stents
- flux
- voltage
- Prior art date
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Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
- A61L31/08—Materials for coatings
- A61L31/082—Inorganic materials
- A61L31/088—Other specific inorganic materials not covered by A61L31/084 or A61L31/086
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
- A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
- A61L31/146—Porous materials, e.g. foams or sponges
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
- A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
- A61L31/18—Materials at least partially X-ray or laser opaque
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/82—Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/86—Stents in a form characterised by the wire-like elements; Stents in the form characterised by a net-like or mesh-like structure
Definitions
- a stent is a small mesh "scaffold" that can be positioned in an artery to hold it open, thereby maintaining adequate blood flow.
- a stent is introduced into the patient's system through the brachial or femoral arteries and moved into position using a catheter and guide wire. This minimally invasive procedure replaces surgery and is now used widely because of the significant advantages it offers for patient care and cost.
- stents and guide wires are made of an alloy of nickel and titanium, known as nitinol, which has the unusual properties of super elasticity and shape memory. Both of these properties result from the fact that nitinol exists in a martensitic phase below a first transition temperature, known as M f , and an austenitic phase above a second transition temperature, known as A f . Both M f and Af can be manipulated through the ratio of nickel to titanium in the alloy as well as thermal processing of the material.
- nitinol In the martensitic phase nitinol is very ductile and easily deformed, while in the austenitic phase it has a high elastic modulus. Applied stresses produce some martensitic mate ⁇ al at temperatures above A f and when the stresses are removed tne mate ⁇ ai returns to its original shape. This results in a very springy behavior for nitinol, referred to as superelasticity or pseudoelasticity. Furthermore, if the temperature is lowered below M f and the nitinol is defonned, when the temperature is raised above A f it will recover its original shape. This is described as shape memory.
- Stents having superelasticity and shape memory can be compressed to small diameters, moved into position, and deployed so that they recover their full size.
- an alloy composition having an A f below normal body temperature the stent will remain expanded with significant force once in place.
- the nitinol must typically withstand strain deformations of as much as 8%.
- Stents and similar intraluminal devices can also be made of materials like stainless steel and other metal alloys. Although they do not exhibit shape memory or superelasticity, stents made from these materials also must undergo significant strain deformations in use.
- Figure 1 illustrates one of many stent designs that are used to facilitate this compression and expansion.
- This design uses ring shaped "struts" 12, each one having corrugations that allow it to be collapsed to a small diameter.
- Bridges 14, a.k.a. nodes, that also must flex in use connect the struts.
- Many other types of expandable geometries, such as helical spirals, braided and woven designs and coils, are known in the field and are used for various purposes.
- stents made from nitinol and many other alloys are made from nitinol and many other alloys. Consequently, stents of typical dimensions are difficult or impossible to see with X-rays when they are being manipulated or are in place. Such devices are called radio transparent.
- radiopacity as it is called, would result in the ability to precisely position the stent initially and in being able to identify changes in shape once it is in place that may reflect important medical conditions.
- Many methods are described in the prior art for rendering stents or portions of stents radiopaque.
- radiopaque material US 6,635,082; US 6,641,607
- radiopaque markers attached to the stent US 6,293,966; US 6,312,456; US 6,334,871; US 6,361,557; US 6,402,777; US 6,497,671; US 6,503,271; US 6,554,854
- stents comprised of multiple layers of materials with different radiopacities (US 6,638,301; US 6,620,192)
- stents that incorporate radiopaque structural elements US 6,464,723; US 6,471,721; US 6,540,774; US 6,585,757; US 6,652,579
- coatings of radiopaque particles in binders US 6,355,058
- methods for spray coating radiopaque material on stents US 6,616,765).
- Physical vapor deposition techniques such as sputtering, thermal evaporation and cathodic arc deposition, can produce dense and confo ⁇ nal coatings of radiopaque materials like gold, platinum, tantalum, tungsten and others. Physical vapor deposition is widely used and reliable. However, coatings produced by these methods do not typically adhere well to substrates that undergo strains of up to 8% as required in this application. This problem is recognized in US 6,174,329, which describes the need for protective coatings over radiopaque coatings to prevent the radiopaque coatings from flaking off when the stent is being used.
- Radiopaque coatings deposited by physical vapor deposition is the temperature sensitivity of nitinol and other stent materials.
- shape memory biomedical devices are made with values of A f close to but somewhat below normal body temperature. If nitinol is raised to too high a temperature for too long its A f value will rise and sustained temperatures above 300- 400 C will adversely affect typical A f values used in stents. Likewise, if stainless steel is raised to too high a temperature, it can lose its temper.
- the time-temperature history of a stent during the coating operation is critical.
- This process is known as controlling the temperature directly or direct control. Because of its shape and structure, controlling the temperature of a stent directly during coating would be a challenging task. Moreover, the portion of the stent in contact with the heat sink would receive no coating and the resulting radiographic image could be difficult to interpret.
- thermo-coatings thick enough to provide good x-ray contrast, biomedical compatibility and corrosion resistance. Further, the coating needs to withstand the extreme strains in use without cracking or flaking and be sufficiently ductile so that the thermo-
- the present invention is directed towards a medical device having a radiopaque outer coating that is able to withstand the strains produced in the use of the device without delamination.
- a medical device in accordance with the present invention can include a body at least partially comprising a nickel and titanium alloy or some other suitable material and a Ta coating on at least a portion of the body; wherein the Ta coating is sufficiently thick so that the device is radiopaque and the Ta coating is able to withstand the
- the Ta coating can consist of either the bcc crystalline phase or the tetragonal crystalline phase.
- the coating thickness is preferably between approximately 3 and 10 microns.
- the device can be a stent or a guidewire, for example.
- the coating preferably is porous. The coating is applied via one of a generally oblique coating flux or a low energy coating
- a process for depositing a Ta layer on a medical device consisting of the steps of: maintaining a background pressure of inert gas in a sputter coating system containing a Ta sputter target; applying a voltage to the Ta target to cause sputtering; and
- the device preferably is not directly heated or cooled and the equilibrium temperature of the device during deposition is controlled indirectly by the process.
- the equilibrium temperature preferably is between 150° and 450° C.
- a voltage, ac or dc, can be
- An initial high voltage preferably between 100 and 500 volts
- a second, lower voltage preferably between 50 and 200 volts
- the inert gas is from the group
- the voltage on the target(s) produces a deposition rate of 1 to 4 microns per hour.
- the target preferably is a cylinder or a plate.
- a medical device comprises a body having an outer layer and a radiopaque coating on 155 at least a portion of the outer layer; wherein the coating is applied using a physical vapor deposition technique.
- Figure 4 illustrates a cross section of a conformal coating of Ta on a strut 12 of a stent
- Figure 5 is a graph showing the reflectance of a Ta coating made according to the present invention with respect to wavelength
- Figure 6 is a graph showing the x-ray diffraction pattern of a Ta coating made 170 according to the present invention
- Figure 7 is a side cross-sectional view of the target surrounding stents in position C of Figure 3 with a plate above the stents
- Figure 8 is a top view of a Ta target surrounding stents
- Figure 9 is a side cross-sectional view of the target surrounding stents of Fig.
- Figure 10 is a side elevation view of stents positioned beside a planar target at a high angle of incidence;
- Figure 11 shows a scanning electron micrograph of the surface of a Ta coating applied to a polished stainless steel surface;
- Figure 12 shows an atomic force microscopy image of a Ta coating made according to another preferred embodiment of the present invention and applied to a polished nitinol substrate;
- Figure 13 shows an X-ray diffraction pattern of a coating made according to another preferred embodiment of the present invention.
- the present invention is directed towards a medical device having a radiopaque outer coating that is able to withstand the strains produced in the use of the device without delamination.
- Tantalum has a high atomic number and is also biomedically inert and co ⁇ osion resistant, making it an attractive material for radiopaque coatings in this application, although other materials may be used, such as, but not limited to, platinum, gold or tungsten . It is known that 3 to 10 microns of Ta is sufficiently thick to produce good X-ray contrast. However, because Ta has a melting point of almost 3000 C, any
- radiopaque Ta coatings deposited under the co ⁇ ect conditions are able to withstand the strains inherent in stent use without unacceptable flaking. Still more remarkable is the fact that we can deposit these adherent coatings at high 205 rates with no direct control of the stent temperature without substantially affecting Af. Since normal body temperature is 37 C, the A f value after coating should be less than this temperature to avoid hanning the thermomechanical properties of the nitinol. The lower A f is after coating the more desirable the process.
- the equilibrium temperature will be determined by factors such as the heat of condensation of the coating material, the energy of the atoms impinging on the substrate, the coating rate, the radiative cooling to the surrounding chamber and the thermal mass of the substrate. It is surprising that this energy balance permits high-rate coating of a temperature sensitive low mass object
- This patent relates to coatings that render biomedical devices including intraluminal biomedical devices radiopaque and that withstand the extremely high strains inherent in the use of such devices without unacceptable delamination. Specifically, it relates to coatings of Ta having these properties and methods for applying them that do not adversely affect the thermomechanical properties of stents.
- Position A- The stents were held on a 10 cm diameter fixture 24 that rotated about a 240 vertical axis, which was approximately 7 cm from the cathode centerline. The vertical position of the stents was in the center of the upper cathode. Finally, each stent was periodically rotated about its own vertical axis by a small “kicker", in a manner well known in the art.
- Position C- The stents 22 were on a 10 cm diameter fixture or plate 24 that rotated 250 about a vertical axis, which was approximately 7 cm from the cathode centerline. The vertical position of the stents was in the center of the chamber, midway between the upper and lower cathodes. Finally, each stent was periodically rotated about its own vertical axis with a "kicker.”
- the stents were cleaned with a warm aqueous cleaner in an ultrasonic bath. Crest 270 Cleaner (Crest Ultrasonics, Inc.) diluted to 0.5 pounds per gallon of water was used at a temperature of 55 C. This ultrasonic detergent cleaning was done for 10 minutes. The stents were then rinsed for 2 minutes in ultrasonically agitated tap water and 2 minutes in ultrasonically agitated de-ionized water. The stents were
- the Ta sputtering targets were preconditioned at the power and pressure to be used in that particular coating run for 10 minutes. During this step a shutter isolated the stents from the targets. This preheating allowed the stents to further degas and approach the actual temperature of the coating step. After opening the shutter, the coating time was 270 adjusted so that a coating thickness of approximately 10 microns resulted. At a power of 4 kW the time was 2 hours and 15 minutes and at a power of 2 kW the time was 4 hours and 30 minutes. These are very acceptable coating rates for a manufacturing process. The stents were not heated or cooled directly in any way during deposition. Their time-temperature history was determined entirely by the coating process.
- Figure 4 illustrates the cross section of a conformal coating of Ta 40 on a strut 12, shown approximately to scale for a 10-micron thick coating. Stents coated in this manner were evaluated in several ways. First, they were pressed into adhesive tape to see if there was any flaking or removal when the tape was peeled away. Next, the
- 280 stents were flexed to their maximum extent and examined for flaking. In all cases this flexing was done at least three times and in some cases it was done as many as ten times. Finally, the A f values for the stents were measured by determining the temperature at which they recovered their original shape using a water bath.
- Table 1 summarizes the results.
- the level of flaking and A f temperatures at positions A and B were very similar in the experiments and were averaged to produce the values shown.
- the level of flaking was ranked using the following procedure:
- Level 5 Approximately 10% or more of the coated area flaked. 290 Level 4: Between approximately 5% and 10% of the coated area flaked. Level 3: Between approximately 1% and 5% of the coated area flaked. Level 2: Between approximately 0.1% and 1% of the coated area flaked. Level 1: An occasional flake was observed, but less than approximately 0.1 % of the coated area flaked. 295 Level 0: No flakes were observed.
- a bias of -150 V produces much better adhesion overall than a bias of- 50 V. This is consistent with many reports in the literature that higher substrate bias produces better adhesion in many applications. However, it also produces greater heating at a given power, as determined by the A f values.
- the observed black appearance may be the result of an extremely porous coating. It is also known in the art that such morphology is also associated with very low coating stress, since the coating has less than full density. However, even if this explanation 335 is correct, the excellent adhesion is very surprising. Typically the coating conditions that lead to such porous coatings result in very poor adhesion and we were able to aggressively flex the coating with no indication of flaking.
- Another possible consequence of the high emissivity of the coating is the fact that the 340 radiative cooling of the stent during coating is more effective than that of a low emissivity, shiny surface, thereby helping to maintain a low coating temperature.
- FIG. 6 is an X-ray diffraction pattern of a coating made under the conditions of Run No. 5 described above, showing that the coating is
- alpha tantalum 350 alpha tantalum. It is known in the art that sputtering Ta in Kr or Xe with substrate bias can result in the alpha phase being deposited. See, for example, Surface and Coatings Technology ⁇ A6- ⁇ A1 (2001) pages 344-350. However, there is nothing in the prior art or in our experience to suggest that alpha Ta coatings of 10 microns thickness can withstand the very high strains inherent in the use of stents without
- alpha Ta can be deposited in such an open, porous structure.
- An open, porous structure may have other advantages as well.
- the microvoids in the coating would permit the incorporation of drugs or other materials 360 that diffuse out over time.
- drug-eluting coatings on stents are presently made using polymeric materials.
- a porous inorganic coating would allow drug- eluting stents to be made without polymeric overcoats.
- the stents at position C as shown in Figure 3 all had adhesion equal to or 365 better than the stents at positions A and B, regardless of conditions.
- Table 2 illustrates the surprising results. (NA indicates coating runs for which no data was taken at those positions.)
- the stents at position C always had very little or no flaking, even under coating conditions where stents in positions A or B had significant flaking. As can be seen from Table 2, this is true over a wide range of coating conditions.
- the 370 A f values of the stents in position C were comparable to those in the other positions, and in the case of the AC coatings they were sometimes significantly lower.
- Stents in the C position that were sputter coated in Kr at a pressure of 3.4 mTorr, an AC power of 2 kW with -150 V bias had a metallic appearance and an A f between 38 and 42 C.
- Those coated in the C position using Kr at a pressure of 3.4 375 mTorr, a DC power of 2 kW and -50 V bias were black in appearance with an A f of only 24 C.
- An A f of 24 C is virtually unchanged from the A f values before coating.
- Stents in position C receive a generally more oblique and lower energy coating flux than stents in positions A or B.
- an oblique coating flux we mean that the majority of the depositing atoms arrive in directions that are not generally perpendicular to the surface being coated.
- Some of the atoms arriving at the surfaces of the stents in 90 position C from the upper and lower targets will have done so without losing significant energy or directionality because of collisions with the background sputter gas.
- Those atoms, most of which will come from portions of the targets close to the stents as seen in Figures 2 and 3, will create an oblique coating flux.
- Other atoms will undergo several collisions with the background gas and lose energy and directionality95 before arriving at the substrate surfaces. Those atoms, which will generally come from portions of the targets at greater distances, will form a low energy coating flux.
- sputtered atoms leave the target surface with average kinetic energies of several electron volts (eV). As described by Westwood, after several collisions with the background gas the sputtered atoms lose most of their kinetic energy. By low energy, we are referring to sputtered atoms that have average energies of approximately 1 eV or less.
- the plate above the stents shown in Figure 7 the more direct coating flux is shielded at all points on the stents and the coating material either arrives at relatively oblique incidence or after scattering from the background gas and losing energy and directionality.
- the plate above the stents restores the symmetry of the situation and the coatings on the stents become uniformly black overall.
- An alternative, although less desirable, approach to oblique incidence coatings or large target to substrate distances in order to reduce the energy of the arriving atoms through collisions is to raise the pressure of the sputtering gas.
- Sputtering takes place under conditions of continuous gas flow. That is, the 485 sputtering gas is brought into the chamber at a constant rate and is removed from the chamber at the same rate, resulting in a fixed pressure and continuous purging of the gas in the chamber. This flow is needed to remove unwanted gases, such as water vapor, that evolve from the system during coating. These unwanted gases can become incorporated in the growing coating and affect its properties. 490
- the high vacuum pumps used in sputtering, such as diffusion pumps, turbomolecular pumps and cryogenic pumps, are limited with respect to the pressure that they can tolerate at their openings.
- a cylindrical magnetron cathode with an inside diameter of 19 cm and length of 10 cm was used to coat a stent with Ta at a sputtering pressure of 30 mTorr in Ar.
- a sputtering pressure of 30 mTorr in Ar.
- the Ar flow during this coating was 0.63 Torr-liters per second, corresponding to a throttled pumping speed 505 of 21 liters per second.
- the stent was placed in the center of the cathode, approximately 9 cm from the target surface.
- the sputtering power to the cathode was 200 W.
- inventive method could be used with geometries other than cylindrical magnetrons.
- Figure 12 is an atomic force microscope image of the resulting coating showing that the microstructure is changed by the initial conditions. While the features in Figures 11 and 12 are similar
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Abstract
Description
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Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2570194A CA2570194C (en) | 2004-06-14 | 2005-06-13 | Radiopaque coating for biomedical devices |
JP2007516591A JP5060946B2 (en) | 2004-06-14 | 2005-06-13 | Radiopaque coatings for biomedical devices |
EP05758081A EP1755490A4 (en) | 2004-06-14 | 2005-06-13 | Radiopaque coating for biomedical devices |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US57957704P | 2004-06-14 | 2004-06-14 | |
US60/579,577 | 2004-06-14 | ||
US11/040,433 US20050165472A1 (en) | 2004-01-22 | 2005-01-21 | Radiopaque coating for biomedical devices |
US11/040,433 | 2005-01-21 | ||
US11/087,909 | 2005-03-23 | ||
US11/087,909 US8002822B2 (en) | 2004-01-22 | 2005-03-23 | Radiopaque coating for biomedical devices |
Publications (2)
Publication Number | Publication Date |
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WO2005122961A2 true WO2005122961A2 (en) | 2005-12-29 |
WO2005122961A3 WO2005122961A3 (en) | 2006-10-26 |
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PCT/US2005/020667 WO2005122961A2 (en) | 2004-06-14 | 2005-06-13 | Radiopaque coating for biomedical devices |
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US (1) | US8002822B2 (en) |
EP (1) | EP1755490A4 (en) |
JP (1) | JP5060946B2 (en) |
CA (1) | CA2570194C (en) |
WO (1) | WO2005122961A2 (en) |
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Also Published As
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WO2005122961A3 (en) | 2006-10-26 |
EP1755490A4 (en) | 2011-08-17 |
CA2570194A1 (en) | 2005-12-29 |
US20050187466A1 (en) | 2005-08-25 |
EP1755490A2 (en) | 2007-02-28 |
JP2008502425A (en) | 2008-01-31 |
CA2570194C (en) | 2013-09-10 |
JP5060946B2 (en) | 2012-10-31 |
US8002822B2 (en) | 2011-08-23 |
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