One-Sided Initiator Application for Dual-Side Medical Device Coating
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Solution Overview
Problem
Conventional methods for coating medical devices with polymeric coatings require both sides of the device to be pretreated with an initiator for efficient graft polymerization, which is inefficient and uses excess initiator, whereas the method described applies the initiator only to one side of the device, allowing effective graft polymerization on both sides.
Innovation Solution
Applying a photoinitiator substantially only to the second side of the wall of a device, typically by aspirating it into the lumen, followed by immersion in a coating composition and subsequent UV polymerization, which allows for efficient graft polymerization on both sides of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If both sides of the device wall are pretreated with initiator for graft polymerization, then efficient coating on both sides is achieved, but excess initiator is used and efficiency is reduced
Solution Approach 1:
The device wall is segmented into two sides (lumen-facing and exterior-facing), and the initiator application is segmented accordingly. The initiator is applied only to the lumen-facing side through aspiration into the lumen, while the exterior-facing side receives initiator indirectly through diffusion or migration from the lumen-facing side, eliminating the need to apply initiator to both sides directly.
Solution Approach 2:
The initiator application process is nested within the device lumen. By aspirating the initiator solution into the lumen, the initiator is positioned inside the device structure, allowing it to act on the lumen-facing wall from the interior while potentially migrating to coat the exterior-facing wall, thus achieving dual-sided coating through a single nested application process.
2Manufacturing precision
If initiator is applied to both sides of the device wall, then complete coverage is achieved, but process efficiency is reduced
Solution Approach 1:
Instead of applying initiator to both exterior surfaces of the device wall, the method inverts the approach by applying initiator only to the interior lumen-facing surface. The initiator then migrates or diffuses through the wall structure to achieve coverage on the exterior-facing side, reversing the conventional outward application method.
Solution Approach 2:
The single initiator application step inside the lumen serves multiple functions: it coats the lumen-facing wall directly, provides initiator for graft polymerization on that surface, and potentially migrates to provide initiator for the exterior-facing wall as well. This single action achieves what would traditionally require separate application steps for each side.
3Ease of operation
If photoinitiator is aspirated into the lumen for initiator application, then precise one-sided application is achieved, but additional equipment is required
Solution Approach 1:
The device lumen itself serves as the application channel for initiator delivery. By utilizing the existing lumen structure of the device, the system eliminates the need for external complex application equipment. The aspiration process uses the device's own geometry to guide and contain the initiator solution, making the device structure serve the dual purpose of both product and application tool.
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
This method reduces the volume of initiator needed and improves efficiency while achieving effective graft polymerization on both sides of the device, resulting in a coating that is antimicrobial, antithrombogenic, lubricious, and resistant to cracking and delamination.
Implementation Method 1
applying a coating composition to the first side of the wall; and graft-polymerizing the coating composition
Data Source
AI summary
Provided herein is a method of grafting a polymeric coating onto a first side of a wall of a device. The method comprises: applying an initiator substantially only to a second side of the wall; applying a coating composition to the first side of the wall; and graft-polymerizing the coating composition.