Gradient Crosslinked Polymer Coating for Dual-Substrate Adhesion
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Solution Overview
Problem
Existing coating technologies struggle to effectively bond coatings to both polymers and metals, often requiring multiple solutions due to differences in hydrophilicity and material compatibility, and often necessitate surface activation and multiple coating processes.
Innovation Solution
A method of coating a substrate that utilizes a crosslinked polymer with a variable concentration of crosslinkers between the substrate surface and the outer surface, allowing for a gradient of polar characteristics that enhances bonding and stratification based on polarity and hydrophobic/hydrophilic nature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single coating solution is used for both metal and polymer substrates, then process complexity is reduced, but bonding strength to both materials deteriorates
Solution Approach 1:
The patent applies local quality by creating a coating with spatially varying crosslinker concentration - higher concentration near the substrate interface for strong bonding, and lower concentration at the outer surface for desired surface properties. This gradient structure allows a single coating to achieve optimal bonding to both metal and polymer substrates while maintaining surface functionality.
Solution Approach 2:
The invention uses composite materials by combining multiple crosslinkers with different functionalities in a single coating formulation. The first crosslinker provides strong bonding to substrates, while the second crosslinker adjusts surface properties, creating a composite coating system that works universally on both metal and polymer substrates.
2Strength
If surface activation is applied to improve bonding, then bonding strength is improved, but process complexity and treatment steps increase
Solution Approach 1:
The patent applies preliminary action by incorporating surface activation agents directly into the coating formulation before application. This allows the coating itself to perform the surface activation function, eliminating the need for separate pre-treatment steps while achieving strong bonding to both metal and polymer substrates.
Solution Approach 2:
The coating composition achieves multi-functionality by combining bonding agents, crosslinkers, and surface activation components in a single universal formulation that works on both metal and polymer substrates without requiring substrate-specific pre-treatment, thereby simplifying the overall process.
3Strength
If multiple coating processes are used for different materials, then bonding performance is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent merges multiple coating functions into a single coating process by using a universal composition that can bond to both metal and polymer substrates. The coating achieves this through a gradient crosslinker structure and multi-functional ingredients, eliminating the need for separate coating processes for different materials and significantly improving manufacturing efficiency.
4Ease of manufacture
If crosslinker concentration is uniform throughout the coating, then manufacturing simplicity is maintained, but surface properties and bonding characteristics deteriorate
Solution Approach 1:
The patent applies parameter changes by creating a gradient in crosslinker concentration throughout the coating thickness. The first crosslinker concentration is higher near the substrate interface to maximize bonding strength, while the second crosslinker concentration varies to achieve desired surface properties such as hydrophobicity, lubricity, or drug release characteristics, thereby optimizing both bonding and surface performance.
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 method achieves strong bonding between the substrate and the coating, with bond strengths ranging from 1 g to 500 g, and allows for tailored coatings that adapt to specific applications, including medical devices used in contact with blood or plasma.
Implementation Method 1
The crosslinked polymer is formed from the crosslinker and the coating includes a variable concentration of the crosslinker between a substrate surface of the coating and an outer surface of the coating
Implementation Method 2
The substrate includes a polar characteristic on its exterior surface... The crosslinked polymer forms a coating including a variable concentration of the crosslinker... The substrate surface of the coating has a first coating polar characteristic and the outer surface of the coating has a second coating polar characteristic
Data Source
Figure 1
AI summary
The present invention relates to coatings for devices such as medical devices that are useful for coating a variety of different types of material surfaces, including polymer and metal surfaces. The present invention also includes the method of using the coated device and methods to make the coated device and coating.