Medical Device Plasma Coating to Prevent Webbing and Delamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing medical devices, such as stents, face issues with coating imperfections like webbing, delamination, and uneven layering, which can lead to thrombus formation and interfere with device expansion, compromising their antithrombotic efficacy.
Innovation Solution
A medical device with a coating that lacks webbing between elements, achieved through a plasma deposition method that forms a continuous, thin, and adherent antithrombogenic layer on the device's surface, ensuring no bridging across elements in contact and maintaining porosity for effective blood flow interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating is applied to the medical device to reduce thrombus formation, then antithrombotic properties are improved, but coating imperfections such as webbing, delamination and uneven layering occur
Solution Approach 1:
The patent applies plasma deposition parameters (power, pressure, gas flow, coating duration) to control the coating process, transforming the coating quality from imperfect to uniform and web-free through optimized physical and chemical parameters
Solution Approach 2:
The patent replaces conventional coating methods with plasma deposition, using plasma physics (ion bombardment, radical reactions) instead of mechanical or chemical dip-coating processes to achieve superior coating uniformity and adhesion
2Quantity of substance
If the coating is formed with small thickness to maintain device porosity, then blood flow interference is improved, but coating firmness deteriorates
Solution Approach 1:
The patent creates a composite structure where the plasma-deposited coating forms a tightly bonded multilayer system with the device surface, achieving enhanced firmness and adhesion even at thin coatings through strong interfacial bonding and cross-linked polymer networks
Solution Approach 2:
The patent uses plasma deposition parameters (power, pressure, gas flow, coating duration) to control coating thickness and firmness simultaneously, achieving the optimal balance where thin coatings maintain both porosity and adequate firmness
3Stability of the object's composition
If the coating material bridges across elements (webbing) to form continuous coverage, then coating continuity is improved, but device porosity and expansion efficacy deteriorate
Solution Approach 1:
The patent applies coating selectively to different regions of the device with different requirements - continuous coating on individual elements for antithrombotic protection, but controlled discontinuity at inter-element spaces to maintain porosity and prevent webbing
Solution Approach 2:
The plasma deposition process replicates the device's geometric structure at the coating level, creating conformal coating that follows element contours while naturally leaving inter-element spaces uncovered, thus copying the device topology without adding webbing
4Ease of manufacture
If conventional coating methods are used to apply coating material, then coating application is simplified, but coating adhesion and firmness deteriorate
Solution Approach 1:
The patent replaces conventional mechanical or chemical coating methods with plasma deposition, using plasma physics (ion bombardment, radical reactions) to achieve superior coating adhesion and firmness through strong interfacial bonding
Solution Approach 2:
The patent optimizes plasma deposition parameters (power, pressure, gas flow, coating duration) to control coating adhesion and firmness, achieving reliable coating attachment while maintaining process feasibility
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 solution provides a robust, non-thrombogenic coating that adheres well to the device, preventing peeling and maintaining efficacy over time, reducing the risk of blockages and enhancing antithrombotic performance by ensuring a uniform and continuous coating without webbing.
Implementation Method 1
achieved through a plasma deposition method that forms a continuous, thin, and adherent antithrombogenic layer on the device's surface
Data Source
AI summary
A medical device is provided, comprising: an expandable tubular member comprising a plurality of elements forming a sidewall, wherein each of the elements crosses one or more other elements and a plurality of pores are formed among the elements in the sidewall; wherein an antithrombogenic material is coated over the tubular member such that there is inherently no webbing of the antithrombogenic material between any two elements.