Antimicrobial Catheter Coating with Copper Layer

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Solution Overview

Problem

Central venous catheters (CVCs) are prone to catheter-related sepsis due to bacterial colonization, and frequent replacement poses risks and inefficiencies, necessitating the development of antimicrobial catheters to prevent bacterial migration into the blood.

Innovation Solution

An antimicrobial catheter assembly featuring a composite coating with a copper-based layer between a corrosion-preventing and adhesion-promoting layer applied to internal and external surfaces, providing a non-eluting antimicrobial barrier to inhibit microbial colonization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If frequent catheter replacement is performed to prevent CRS, then bacterial colonization risk is reduced, but patient risk and inefficiency increase

Engineering Contradiction:

Improveprevention of catheter-related sepsisVSAvoidpatient risk from repeated catheterization

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The catheter is pre-coated with copper-based antimicrobial layers during manufacturing, providing proactive protection against bacterial colonization before clinical use begins. This preliminary antimicrobial barrier prevents bacterial adhesion and proliferation, eliminating the need for frequent replacements and associated patient risks

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The copper-based coating provides continuous passive antimicrobial activity without requiring external intervention or replacement. The catheter self-protects against bacterial colonization through the inherent antimicrobial properties of copper, maintaining reliability over extended periods without additional patient procedures

Inventive Principle:

Principle #25Self-service

2Reliability

If copper-based antimicrobial coating is applied to catheter surfaces, then microbial colonization is reduced, but metal corrosion and elution occur

Engineering Contradiction:

Improveantimicrobial effectivenessVSAvoidmetal corrosion and elution into bodily fluids

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The catheter employs a composite coating structure with multiple layers: copper-based antimicrobial layers provide microbial protection, while biocompatible polymer layers (such as polyurethane or silicone) serve as protective outer coatings that prevent copper corrosion and control elution. This composite approach combines the antimicrobial benefits of copper with the corrosion resistance and biocompatibility of polymers

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Biocompatible intermediate layers are introduced between the copper-based antimicrobial coating and the bodily environment. These intermediary layers act as barriers that prevent direct contact between copper and bodily fluids, thereby reducing corrosion and controlling metal elution while allowing the copper layer to maintain its antimicrobial function

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multi-layer composite coating is applied to catheter, then antimicrobial performance and corrosion resistance are improved, but manufacturing complexity increases

Engineering Contradiction:

Improveantimicrobial and corrosion resistanceVSAvoidcoating structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The manufacturing process utilizes controlled parameter changes during sequential coating applications, where each layer is deposited with specific thickness parameters and material properties optimized for its function. By precisely controlling coating parameters such as thickness, composition, and deposition conditions, the process achieves reliable multi-layer structures while maintaining manufacturing efficiency

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The antimicrobial coating effectively reduces microbial colonization by at least 4 logs over extended periods, serving as a passive barrier against pathogens like MRSA and yeast, while minimizing metal elution into bodily fluids.

Implementation Method 1

The antimicrobial coating includes a copper-based layer between a corrosion-preventing layer and the internal or external surface of the catheter assembly

Methodology Applied

Scientific EffectAntimicrobial activity of copper:

Implementation Method 2

The antimicrobial coating includes an adhesion-promoting layer between the copper-based layer and the internal or external surface of the catheter assembly

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

The corrosion-preventing layer includes a corrosion-resistant metal selected from gold, palladium, and titanium

Methodology Applied

Scientific EffectCorrosion resistance:

Data Source

PatentUS20230372592A1Antimicrobial Catheter Assemblies and Methods Thereof

Publication Date: 2023.11.23 CR BARD INC

AI summary

An antimicrobial catheter assembly can include a non-eluting antimicrobial coating on an internal surface, an external surface, or both the internal surface and the external surface of the catheter assembly. The antimicrobial coating can be a composite of three or more layers including a copper-based layer between an outer corrosion-preventing layer of a corrosion-resistant metal and an inner adhesion promoting layer.