PECVD Lubricity Coating for Syringe Plunger Friction
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Solution Overview
Problem
Current plastic and glass syringes for pharmaceutical packaging face challenges such as non-uniform surface chemistry, contamination, breakage, and inadequate barrier properties, which affect the stability and shelf life of biologics, particularly due to leaching, gas permeability, and mechanical issues.
Innovation Solution
A method for coating plastic syringes with thin PECVD coatings made from organosilicon precursors, creating a SiOxCyHz lubricity coating that eliminates the need for traditional silicon oil lubricants and provides a SiOx barrier coating, enhancing lubricity, barrier properties, and dimensional tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional silicon oil is used as lubricant in glass syringes, then lubricity is improved, but contamination and non-uniform coating occur
Solution Approach 1:
The patent replaces the mechanical/physical application of silicon oil lubricant with a chemical vapor deposition process. The organosilicon precursor is deposited as a uniform coating through PECVD, eliminating the need for liquid lubricant application and subsequent contamination issues. The coating is applied at the molecular level, ensuring uniform distribution without the non-uniformity associated with oil application.
Solution Approach 2:
The patent changes the physical and chemical parameters of the lubricity coating by using organosilicon precursors that form a solid or semi-solid coating instead of liquid silicon oil. The deposition conditions (temperature, pressure, gas flow rates) are controlled to achieve a coating with optimal lubricity properties that is inherently uniform and free from contamination.
2Reliability
If borosilicate glass is used for syringes, then barrier properties are improved, but breakage and manufacturing complexity increase
Solution Approach 1:
The patent creates a composite structure by coating plastic syringes with organosilicon-based layers. The plastic substrate provides impact resistance and breakage prevention, while the deposited coating layer provides the barrier properties traditionally associated with glass. This composite approach combines the advantages of both materials without their respective disadvantages.
Solution Approach 2:
The organosilicon coating acts as an intermediary layer between the plastic syringe and the pharmaceutical product. This intermediate layer provides the barrier properties needed to protect biologics, while the underlying plastic provides mechanical strength. The coating mediates between the requirements for barrier performance and mechanical durability.
3Reliability
If PECVD coating is applied to improve barrier properties, then gas permeability is reduced, but coating uniformity and manufacturing precision are challenged
Solution Approach 1:
The patent replaces mechanical coating methods with plasma-enhanced chemical vapor deposition. The plasma process allows the organosilicon precursor to react and deposit uniformly on the syringe surface at the molecular level, achieving consistent coating thickness and composition that is difficult to obtain with mechanical application methods.
Solution Approach 2:
The patent carefully controls deposition parameters including plasma power, gas flow rates, pressure, and temperature to achieve uniform coating. By optimizing these parameters, the process produces consistent coating quality that meets the precision requirements for pharmaceutical packaging while maintaining excellent barrier properties.
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 coated syringes offer superior barrier properties and breakage resistance, reducing extractables, improving plunger sliding forces, and maintaining consistent performance over time, while preventing contamination and ensuring the stability of biologics.
Implementation Method 1
A method for coating a substrate surface by PECVD is provided, the method comprising generating a plasma from a gaseous reactant comprising an organosilicon precursor and O2
Data Source
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Figure 3A~3C
AI summary
A method for coating a substrate surface by PECVD is provided, the method comprising generating a plasma from a gaseous reactant comprising an organosilicon precursor and optionally O2. The lubricity, hydrophobicity and/or barrier properties of the coating are set by setting the ratio of the O2 to the organosilicon precursor in the gaseous reactant, and/or by setting the electric power used for generating the plasma. In particular, a lubricity coating made by said method is provided. Vessels coated by said method and the use of such vessels protecting a compound or composition contained or received in said coated vessel against mechanical and/or chemical effects of the surface of the uncoated vessel material are also provided.