Method for manufacturing manipulated coated tube

Abstract

A method for manufacturing a manipulated coated tube includes providing a tube having an outer surface. Further, the method includes coating the outer surface of the tube with an outer coating to obtain a coated tube. The method further includes passing the coated tube through at least one set of rollers for straining the coated tube to obtain the manipulated coated tube.

Description

[0001] METHOD FOR MANUFACTURING MANIPULATED COATED TUBE

[0002] Technical Field

[0003] The present disclosure relates to a method for manufacturing a manipulated coated tube and the manipulated coated tube.

[0004] Background

[0005] Medical devices and articles, such as stethoscopes, include a tubing which may utilize a wide range of polymeric materials. Among the materials used are polyvinyl chloride (PVC) often referred to as “vinyl”. PVC by itself is a rigid material, and thus plasticizers may be added to the material to make it softer and more flexible.

[0006] The tubing of the medical devices and articles is also coated with a barrier coating that may provide a cleanable surface and reduced microbial touch transfer. In some cases, the barrier coating is a hard coating and the tubing coated with the barrier coating may have an uneven glossy surface finish.

[0007] In such cases, manipulation of the tubing coated with the barrier coating may be required to achieve an even and matte surface finish.

[0008] Summary

[0009] In a first aspect, the present disclosure provides a method for manufacturing a manipulated coated tube. The method includes providing a tube having an outer surface. Further, the method includes coating the outer surface of the tube with an outer coating to obtain a coated tube. The method further includes passing the coated tube through at least one set of rollers for straining the coated tube to obtain the manipulated coated tube.

[0010] In a second aspect, the present disclosure provides a manipulated coated tube. The manipulated coated tube includes a polyvinyl chloride (PVC) tube having an outer surface. The manipulated coated tube further includes a parylene coating disposed on the outer surface of the PVC tube. The parylene coating includes microcracks.

[0011] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.

[0012] Brief Description of the Drawings

[0013] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0014] FIG. 1 shows a schematic top view of a medical article including a manipulated coated tube, according to an embodiment of the present disclosure;

[0015] FIG. 2 shows a schematic perspective view of a coated tube including a sectional view of a segment of the coated tube, according to an embodiment of the present disclosure;

[0016] FIG. 3A shows a schematic view of a single set of rollers, according to an embodiment of the present disclosure;

[0017] FIG. 3B shows a schematic view of a plurality of sets of rollers, according to an embodiment of the present disclosure;

[0018] FIG. 4 shows a flowchart of a method for manufacturing the manipulated coated tube, according to an embodiment of the present disclosure; and

[0019] FIG. 5 shows an image depicting a comparison between a surface finish of the coated tube and a surface finish the manipulated coated tube, according to an embodiment of the present disclosure.

[0020] Detailed Description

[0021] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0022] In the following disclosure, the following definitions are adopted.

[0023] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

[0024] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / - 20 % for quantifiable properties).

[0025] The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 10% for quantifiable properties) but again without requiring absolute precision or a perfect match. The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0026] As used herein, the terms “first” and “second” are used as identifiers. Therefore, such terms should not be construed as limiting of this disclosure. The terms “first” and “second” when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

[0027] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0028] The term “anti-microbial” is used herein according to the commonly used meaning, that is an agent that kills or stops the growth of microorganisms.

[0029] The term “tube” and “tubing” as used herein refers to a three-dimensional tubular article that is cylindrically symmetric. Tubes and tubing are defined by an inner diameter, an outer diameter, (the thickness of the tubing is the difference between the outer diameter and the inner diameter) and a length. While the thickness of the tubing can vary slightly through the length of the tube as the result of the method of preparation, etc., no intentional asymmetries are present in the tubing. Typically, the length is substantially greater than the diameter of the tube.

[0030] As used herein the term “PVC” is used as a shorthand definition of polyvinyl chloride. The term “phthalate-free PVC” as used herein refers to a PVC material that does not contain phthalate plasticizer.

[0031] As used herein the term “parylene” is a trade name for a variety of chemical vapor- deposited poly(p-xylylene) polymers. The term is used herein as a generic name for members of a unique polymer series.

[0032] Medical devices and articles, such as stethoscopes, include a tubing which may utilize a wide range of polymeric materials. Among the materials used are polyvinyl chloride (PVC) often referred to as “vinyl”. PVC by itself is a rigid material, and thus plasticizers may be added to the material to make it softer and more flexible.

[0033] The tubing of the medical devices and articles is also coated with a barrier coating that may provide a cleanable surface and reduced microbial touch transfer. In some cases, the barrier coating is a hard coating and the tubing coated with the barrier coating may have an uneven glossy surface finish.

[0034] In such cases, manipulation of the tubing coated with the barrier coating may be required to achieve an even and matte surface finish. Current methods for manipulating the coated tubing include stretching and twisting, which may present challenges in terms of scalability and ergonomics. These processes may be labor- intensive and may be difficult to standardize, which may lead to inconsistent results.

[0035] Therefore, industry demands a method for manipulating the coated tubing which may provide a more efficient and ergonomic solution for achieving a coated tubing coated with the even and matte surface finish.

[0036] The present disclosure relates to a method for manufacturing a manipulated coated tube. The method includes providing a tube having an outer surface. Further, the method includes coating the outer surface of the tube with an outer coating to obtain a coated tube. The method further includes passing the coated tube through at least one set of rollers for straining the coated tube to obtain the manipulated coated tube.

[0037] Straining the coated tube via the at least one set of rollers may induce microcracking in the outer coating, which is typically a thin, hard coating. Further, the at least one set of rollers may ensure consistent and uniform straining, which may be difficult to achieve with current processes. This consistency may improve a quality and a reliability of the manipulated coated tube. Therefore, the manipulated coated tube may have an even and matte surface finish.

[0038] Referring now to figures, FIG. 1 shows a schematic top view of a medical article 10, according to an embodiment of the present disclosure. In some embodiments, the medical article 10 is a stethoscope. The medical article 10 may be interchangeably referred to as “the stethoscope 10” herein. The stethoscope 10 enables healthcare professionals to listen to subtle sounds of a heart, lungs, and other organs, providing insights of a patient’s health that might go unnoticed. The stethoscope 10 may also be considered as vital tool for the healthcare professionals.

[0039] The stethoscope 10 is used in medical environments, and exposed to a wide range of environments, such as microbe-rich environments. This exposure may permit the stethoscope 10 to form a conduit for the spreading of microbes.

[0040] Therefore, the stethoscope 10 may utilize a wide range of polymeric materials. Among the materials used is a polyvinyl chloride (PVC) which may offer non-porous surface that is easier to clean and disinfect.

[0041] In the illustrated example of FIG. 1, the stethoscope 10 includes a manipulated coated tube 40 attached to dual sound transmitting tubes 12, terminating in ear tips 14. The dual sound transmitting tubes 12 of the stethoscope 10 may be desirably coated which would contact a skin surface when worn around a neck of a user (not shown). The elements of the stethoscope 10 can vary from those shown, but the fundamental elements are present.

[0042] FIG. 2 shows a schematic perspective view of a coated tube 30 including a sectional view of a segment of the coated tube 30, according to an embodiment of the present disclosure. The illustrated embodiment of FIG. 2, the coated tube 30 includes a tube 20 is having an outer surface 25. Further, the coated tube 30 includes an outer coating 35. Specifically, the outer surface 25 of the tube 20 is coated with the outer coating 35. In some embodiments, the outer coating 35 has a thickness of from about 1 to about 10 micrometers. However, the outer coating 35 may have any thickness based on desired application attributes.

[0043] In some embodiments, the tube 20 is a polyvinyl chloride (PVC) tube. In such embodiments, the tube 20 may be interchangeably referred as “the PVC tube 20” herein.

[0044] In some embodiments, the outer coating 35 is a vapor-deposited coating. In some embodiments, the outer coating 35 is a parylene coating. In such embodiments, the outer coating 35 may be interchangeably referred as “the parylene coating 35” herein.

[0045] PVC materials are typically used in the tube 20 of the stethoscope 10. The tube 20 may require a variety of features such as flexibility, resistance to degradation from exposure to heat and chemicals, durability, an aesthetically pleasant look, and a pleasant feel.

[0046] The parylene coating 35 may act as a protective film which may help the tube 20 to maintain flexibility, reduce tacky feel, ease cleaning, and provide a matte finish when manipulated after application of the parylene coating 35.

[0047] FIG. 3A shows a schematic view of at least one set of rollers 80, according to an embodiment of the present disclosure.

[0048] In the illustrated embodiment of FIG. 3 A, the at least one set of rollers 80 includes a single set of rollers 80. The single set of rollers 80 includes a first set of rollers 50. Specifically, the first set of rollers 50 includes a roller 100 and a roller 120.

[0049] The coated tube 30 passes through the at least one set of rollers 80 for straining the coated tube 30 to obtain the manipulated coated tube 40. As shown in FIG. 3A, the coated tube 30 passes through the rollers 100, 120 for straining the coated tube 30 to obtain the manipulated coated tube 40.

[0050] Referring to FIGS. 2 and 3A, the manipulated coated tube 40 includes the PVC tube 20 having the outer surface 25. The manipulated coated tube 40 further includes the parylene coating 35 disposed on the outer surface 25 of the PVC tube 20. The parylene coating 35 includes microcracks 45 (shown in FIG. 5).

[0051] Further, as shown in FIG. 3A, the roller 100 has a rotational axis R1 and the roller 120 has a rotational axis R2. In the illustrated embodiment of FIG. 3A, the rollers 100, 120 have a same rotational speed S. In some other embodiments, the rollers 100, 120 may have different rotational speeds. Further, the roller 100 has a roller diameter 102 and the roller 120 has a roller diameter 112. In the illustrated embodiment of FIG. 3 A, the roller diameter 112 is equal to the roller diameter 102. However, in some other embodiments, the roller diameters 102, 112 may be different.

[0052] FIG. 3B shows a schematic view of the at least one set of rollers 80 including a plurality of sets of rollers, according to an embodiment of the present disclosure.

[0053] Specifically, in the illustrated embodiment of FIG. 3B, the at least one set of rollers 80 includes the first set of rollers 50 and a second set of rollers 60.

[0054] Specifically, the second set of rollers 60 includes a roller 200 and a roller 220. In some embodiments, the rollers 200, 220) of the second set of rollers 60 are substantially similar to the rollers 100, 120 of the first set of rollers 50.

[0055] In the illustrated example of FIG. 3B, the coated tube 30 passes through the first set of rollers 50 in a direction D towards the second set of rollers 60.

[0056] Further, as shown in FIG. 3B, the roller 200 has a rotational axis Rl’ and the roller 220 has a rotational axis R2’. In the illustrated embodiment of FIG. 3B, the rollers 200, 220 have a same rotational speed S’. In some other embodiments, the rollers 200, 220 may have different rotational speeds.

[0057] In some embodiments, a rotational axis of at least one roller of the at least one set of rollers 80 is horizontally offset from a rotational axis of other rollers of the at least one set of rollers 80. For example, in some embodiments, the rotational axis Rl, R2, Rl ’, R2’ of at least one of the rollers 100, 120, 200, 210 of the at least one set of rollers 80 is horizontally offset from the rotational axis Rl, R2, Rl ’, R2’ of the other rollers 100, 120, 200, 210 of the at least one set of rollers 80.

[0058] In some embodiments, at least one roller (e.g., at least one of the rollers 200, 210) of the second set of rollers 60 has the rotational speed S’ greater than the rotational speed S of at least one roller (e.g., at least one of the rollers 100, 120) of the first set of rollers 50.

[0059] The first and second sets of rollers 50, 60 having different rotational speeds S, S’ may allow differential straining of the coated tube 30. Further, the different rotational speeds S, S’ may further induce varying degrees of stretching and the microcracks 45 on the outer coating 35, which may be controlled to achieve a desired surface characteristics of the manipulated coated tube 40.

[0060] Further, the roller 200 has a roller diameter 102’ and the roller 220 has a roller diameter 112’. In the illustrated embodiment of FIG. 3B, the roller diameter 112’ is equal to the roller diameter 102’. However, in some other embodiments, the roller diameters 102’, 112’ may be different.

[0061] In some embodiments, at least one roller of the at least one set of rollers 80 has a roller diameter different from a roller diameter of other rollers of the at least one set of rollers 80. For example, at least one of the rollers 100, 120, 200, 220 may have the roller diameter 102, 112, 102’, 112’ different from the roller diameter 102, 112, 102’, 112’ of the other rollers 100, 120, 200, 220 of the at least one set of rollers 80.

[0062] In some embodiments, at least one roller of the at least one set of rollers 80 includes a metal roller or a rubber roller. For example, in some embodiments, at least one of the rollers 100, 120, 200, 210 includes the metal roller or the rubber roller.

[0063] Furthermore, in some embodiments, the at least one roller of the at least one set of rollers 80 has a textured outer surface. For example, in some embodiments, at least one of the rollers 100, 120, 200, 210 has the textured outer surface.

[0064] In some embodiments, the at least one set of rollers 80 has a gap 90 between rollers of the at least one set of rollers 80. For example, in some embodiments, the rollers 100, 120, 200, 210 has the gap 90 between the rollers 100, 120, 200, 210. The gap 90 may provide desired application attributes to the manipulated coated tube 40.

[0065] FIG. 4 shows a flowchart of a method 400 for manufacturing the manipulated coated tube 40, according to an embodiment of the present disclosure. The method 400 is described with further reference to FIGS. 2, 3A, and 3B.

[0066] At step 402, the method 400 includes providing the tube 20 having the outer surface 25. As discussed above, in some embodiments, the tube 20 is the PVC tube.

[0067] At step 404, the method 400 includes coating the outer surface 25 of the tube 20 with the outer coating 35 to obtain the coated tube 30. As discussed above, in some embodiments, the outer coating 35 is the parylene coating.

[0068] At step 406, the method 400 includes passing the coated tube 30 through the at least one set of rollers 80 for straining the coated tube 30 to obtain the manipulated coated tube 40.

[0069] In some embodiments, at least one roller of the at least one set of rollers 80 includes the metal roller or the rubber roller. Further, in some embodiments, at least one roller of the at least one set of rollers 80 has the textured outer surface.

[0070] In some embodiments, the at least one set of rollers 80 includes the first set of rollers 50 and the second set of rollers 60. The at least one roller of the second set of rollers 60 has the rotational speed S’ greater than the rotational speed S of the at least one roller of the first set of rollers 50.

[0071] In some embodiments, at least one roller 100, 120, 200, 210 of the at least one set of rollers 80 has the roller diameter 102, 112, 102’, 112’ different from the roller diameter 102, 112, 102’, 112’ of other rollers 100, 120, 200, 210 of the at least one set of rollers 80.

[0072] In some embodiments, the rotational axis Rl, R2, Rl’, R2’ of at least one roller 100, 120, 200, 210 of the at least one set of rollers 80 is horizontally offset from the rotational axis Rl, R2, Rl’, R2’ of other rollers 100, 120, 200, 210 of the at least one set of rollers 80. In some embodiments, the method 400 further includes adjusting the gap 90 between rollers of the at least one set of rollers 80 to control straining of the coated tube 30.

[0073] The type of rollers 100, 120, 200, 210, the textured outer surface of the rollers 100, 120, 200, 210, the rotational speeds S, S’ of the rollers 100, 120, 200, 210, the roller diameter 102, 112, 102’, 112’ of the rollers 100, 120, 200, 210, the gap 90 between the rollers 100, 120, 200, 210, and / or the horizontal offset of the rotational axis Rl, R2, Rl’, R2’ of the rollers 100, 120, 200, 210 may allow a precise control over the straining of the coated tube 30.

[0074] FIG. 5 shows an image depicting a comparison between a surface finish of the coated tube 30 and a surface finish of the manipulated coated tube 40, according to an embodiment of the present disclosure.

[0075] As is apparent from FIG. 5, the coated tube 30 has an inferior surface finish compared to a matte finish of the manipulated coated tube 40. Specifically, the manipulated coated tube 40 has a consistent matte finish which may be desirable in many applications.

[0076] Therefore, when the coated tube 30 is passed through the at least one set of rollers 80 and strained to obtain the manipulated coated tube 40, the surface finish of the coated tube 30 is improved.

[0077] Referring to FIGS. 1 to 5, therefore, straining the coated tube 30 via the at least one set of rollers 80 may induce microcracking in the outer coating 35, which is typically a thin, hard coating. Further, the at least one set of rollers 80 may ensure consistent and uniform straining, which may be difficult to achieve with current processes. This consistency may improve a quality and a reliability of the manipulated coated tube 40. Thus, the manipulated coated tube 40 may have an even and matte surface finish.

[0078] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0079] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Claims

CLAIMS1. A method for manufacturing a manipulated coated tube, the method comprising: providing a tube having an outer surface; coating the outer surface of the tube with an outer coating to obtain a coated tube; and passing the coated tube through at least one set of rollers for straining the coated tube to obtain the manipulated coated tube.

2. The method of claim 1, wherein the outer coating is a parylene coating.

3. The method of claim 1, wherein the tube is a polyvinyl chloride (PVC) tube.

4. The method of claim 1, wherein at least one roller of the at least one set of rollers comprises a metal roller or a rubber roller.

5. The method of claim 1, wherein at least one roller of the at least one set of rollers has a textured outer surface.

6. The method of claim 1, wherein the at least one set of rollers comprises a first set of rollers and a second set of rollers, and wherein at least one roller of the second set of rollers has a rotational speed greater than a rotational speed of at least one roller of the first set of rollers.

7. The method of claim 1, wherein at least one roller of the at least one set of rollers has a roller diameter different from a roller diameter of other rollers of the at least one set of rollers.

8. The method of claim 1, wherein a rotational axis of at least one roller of the at least one set of rollers is horizontally offset from a rotational axis of other rollers of the at least one set of rollers.

9. The method of claim 1, further comprising adjusting a gap between rollers of the at least one set of rollers to control straining of the coated tube.

10. A manipulated coated tube comprising: a PVC tube having an outer surface; and a parylene coating disposed on the outer surface of the PVC tube, wherein the parylene coating comprises microcracks.

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