Hydrophilic Coating Anchoring via Plasma-Prepared Substrate
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Solution Overview
Problem
Existing methods for creating lubricious coatings on medical devices struggle with secure anchoring to the substrate surface, often requiring multiple steps, toxic solvents, and limited polymer selection, which complicates biocompatibility and durability.
Innovation Solution
A method involving an interpenetrating polymer network formed by cross-linking water-soluble polymers or monomers on a water-swellable substrate surface, using water or alcohol-based solvents, which securely anchors the hydrophilic coating without covalent interactions, allowing for versatile polymer systems and biocompatible solvent use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydrophilic coating is applied to a substrate using conventional methods, then the coating can be formed on the substrate surface, but the coating attachment to the substrate lacks security and durability
Solution Approach 1:
The patent combines the coating application process with the substrate preparation process by using plasma treatment on the substrate before coating. The plasma treatment modifies the substrate surface to create better anchoring sites, and the coating is applied in the same processing sequence, merging surface modification and coating deposition into an integrated manufacturing step that improves attachment security without significantly complicating the overall process
Solution Approach 2:
The patent applies plasma treatment to the substrate surface before the coating is applied. This preliminary action modifies the substrate surface by creating micro-roughness and increasing surface energy, which prepares the surface for better coating adhesion. The plasma treatment is performed as a pre-step that enhances subsequent coating attachment security
2Reliability
If multiple coating steps and cross-linking agents are used to improve coating security, then the coating attachment improves, but the manufacturing process becomes more complex and requires multiple polymer solutions
Solution Approach 1:
The patent extracts the need for complex multi-step cross-linking processes by using a single-component coating formulation that achieves secure attachment through plasma-prepared substrate surfaces. The solution removes unnecessary intermediate steps and multiple polymer solutions, keeping only the essential plasma treatment and single coating deposition steps
Solution Approach 2:
The patent uses a universal coating formulation that can be applied to various substrate types after plasma treatment. The single-component coating system serves multiple functions: it provides the lubricious surface, ensures secure attachment through plasma-prepared anchoring sites, and eliminates the need for separate cross-linking steps, thereby simplifying the overall manufacturing process
3Ease of manufacture
If conventional solvents are used in the coating formulation, then the coating can be applied, but toxic solvent residuals remain requiring significant costs to drive off and achieve biocompatibility
Solution Approach 1:
The patent changes the solvent parameter from conventional organic solvents to water as the primary solvent in the coating formulation. This parameter change eliminates toxic solvent residuals, improves biocompatibility, and allows the coating to be applied and cured without expensive high-temperature drying processes. The water-based formulation maintains coating application ease while removing harmful factors
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 a securely anchored, highly lubricious coating with low friction coefficients, maintaining lubricity even after activation with water, and is applicable to various medical and non-medical devices, reducing discomfort and injury during insertion and removal.
Implementation Method 1
contacting the substrate surface with a solution comprising at least one of (i) a water-soluble polymer capable of being cross-linked to form a cross-linked, lubricious, hydrophilic coating and (ii) a water-soluble monomer capable of being polymerized to form a cross-linked, lubricious, hydrophilic coating
Implementation Method 2
The water-soluble polymer can be cross-linked in the presence of the swollen substrate surface to provide a cross-linked coating that is entangled with and securely anchored to the substrate surface
Implementation Method 3
the monomer can either form a crosslinked hydrogel network as it is polymerized, or can be polymerized and then subsequently cross-linked, in the presence of the swollen substrate surface
Data Source
AI summary
This invention relates to methods of applying to a substrate a hydrophilic coating that becomes lubricious when activated with water or water vapor, and to substrates having such a hydrophilic coating.