Biocompatible Polymer Coating for Flexible Implants

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Solution Overview

Problem

Biomedical implants face issues with coating stability under mechanical forces, leading to cracking and potential biological complications, as existing methods fail to provide effective biocompatible coatings that resist deformation and bacterial biofilm formation.

Innovation Solution

A sequential dip coating and electrospinning process is employed to create a biocompatible polymer coating, where fibers of the polymer are partially embedded into the dip coating, enhancing the coating's resistance to mechanical forces such as bending, tensile stress, and torsion, using biopolymers like silk fibroin, PLA, and PCL.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a biocompatible polymer coating is applied to biomedical implants, then biocompatibility and prevention of bacterial biofilm formation are improved, but the coating cracks under mechanical forces such as bending and tensile stress

Engineering Contradiction:

ImprovebiocompatibilityVSAvoidcoating integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies composite materials by combining a dip-coated polymer layer with electrospun polymer fibers to create a hybrid coating structure. The dip coating provides a continuous base layer ensuring biocompatibility, while the electrospun fibers reinforce the coating to prevent cracking under mechanical stress, thus resolving the contradiction between biocompatibility and coating integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating regions with different properties within the coating: the dip-coated regions provide uniform biocompatible coverage, while the electrospun fiber regions provide enhanced mechanical reinforcement. This localized differentiation allows the coating to simultaneously achieve biocompatibility and resistance to mechanical cracking.

Inventive Principle:

Principle #3Local quality

2Strength

If the coating is made thinner to maintain flexibility, then resistance to cracking improves, but the protective function against bacterial biofilm formation decreases

Engineering Contradiction:

ImproveflexibilityVSAvoidbacterial biofilm formation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The composite structure of dip-coated polymer combined with electrospun fibers enables the coating to maintain adequate thickness for protective function while the fiber network provides structural reinforcement that prevents cracking. This allows the coating to be both thick enough to prevent bacterial biofilm formation and flexible enough to resist cracking.

Inventive Principle:

Principle #40Composite materials

3Strength

If reinforcement materials are added to the coating to prevent cracking, then coating integrity improves, but biocompatibility may be compromised due to material selection restrictions

Engineering Contradiction:

Improvecoating integrityVSAvoidbiocompatibility

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies homogeneity by using the same biocompatible polymer material for both the dip coating and the electrospun fibers. This ensures that the reinforcement fibers do not introduce foreign or incompatible materials that could compromise biocompatibility, while still providing the necessary mechanical strength to prevent cracking.

Inventive Principle:

Principle #33Homogeneity

4Strength

If a sequential dip coating and electrospinning process is used, then coating stability under mechanical forces improves, but manufacturing complexity increases

Engineering Contradiction:

Improvecoating stabilityVSAvoidmanufacturing process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges two coating techniques (dip coating and electrospinning) into a sequential process where the dip coating is applied first as a base layer, followed by electrospun fibers for reinforcement. This combination approach achieves superior coating stability under mechanical forces while maintaining a relatively straightforward manufacturing workflow.

Inventive Principle:

Principle #5Merging (Combining)

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 process results in a stable, non-cracking coating that maintains biocompatibility and mechanical integrity, preventing exposure of the substrate and reducing the risk of biological events like capsular contracture and bacterial biofilm formation, while allowing for the embedding of functional molecules for enhanced performance.

Implementation Method 1

dipping the implant in a solution of biocompatible polymer to obtain an implant with a dip coating

Methodology Applied

Scientific EffectDip coating: Deposition (physical)

Implementation Method 2

electrospinning the same polymer onto the implant with dip coating of step (a) to obtain an implant with a biocompatible polymer coating

Methodology Applied

Scientific EffectElectrospinning: Electrohydrodynamics

Data Source

PatentUS11439728B2Process for coating a biomedical implant with a biocompatible polymer and a biomedical implant therefrom

Publication Date: 2022.09.13 COUNCIL OF SCI & IND RES

AI summary

The present invention disclosed a process to coat the surface of flexible polymeric implant with biocompatible polymer such that the coating does not crack when the implant is subjected to mechanical forces such as tension, torsion or bending while retaining the inherent properties of the coated polymer.