Polysulfone Silane Fluorinated Coating for Inhaler Dosing Consistency
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Solution Overview
Problem
Medicinal delivery devices, such as inhalers, face variability in dosing from dose to dose and unit to unit, which is undesirable for consistent medication delivery.
Innovation Solution
A method involving a polysulphone base composition, a silane primer with reactive groups, and a fluorinated coating is applied to the components of medicinal delivery devices to reduce variability, utilizing a specific sequence of application and curing processes to enhance surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coating is applied to reduce dosing variability, then dosing consistency is improved, but the manufacturing process complexity increases
Solution Approach 1:
The coating system is segmented into multiple functional layers: a base composition layer providing adhesion to the component surface, a primer layer with reactive silane groups for chemical bonding, and a fluorinated topcoat layer providing the desired non-stick and low-friction properties. This segmentation allows each layer to be optimized for its specific function, achieving dosing consistency through the fluorinated layer while managing overall complexity through systematic layering.
Solution Approach 2:
The invention employs composite material structures where the coating system combines different material classes (polymers, silanes, fluorinated compounds) with complementary properties. The base composition provides structural foundation, the silane primer provides chemical bonding capability, and the fluorinated topcoat provides surface functionality. This composite approach achieves the dual goal of improved dosing consistency and controlled manufacturing complexity.
2Reliability
If multiple coating layers are applied to improve surface properties, then dosing variability is reduced, but the number of manufacturing steps increases
Solution Approach 1:
The base composition layer is applied first to prepare the surface and provide adhesion promotion before subsequent layers are applied. The silane primer layer is applied in advance to create reactive bonding sites that will chemically link the base layer and fluorinated topcoat. These preliminary actions ensure that each subsequent layer adheres properly, achieving reliable dosing performance while establishing a systematic manufacturing sequence that can be optimized for efficiency.
Solution Approach 2:
The manufacturing process utilizes parameter changes in the form of controlled curing conditions at different stages. The base layer is cured under specific conditions, then the silane primer is applied and cured, followed by the fluorinated topcoat application and curing. By optimizing curing parameters (temperature, time, humidity) for each layer, the process achieves reliable dosing consistency while managing the overall manufacturing cycle time and efficiency.
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 significantly reduces dose-to-dose and unit-to-unit variability, improving the consistency and accuracy of medication delivery in medicinal delivery devices.
Implementation Method 1
The reactive silane groups allow reaction of the partially fluorinated compound with one or more of the reactive silane groups of the primer. Often such reaction can be a condensation reaction.
Implementation Method 2
applying the coating composition to the portion of the surface of the component after application of the primer composition
Data Source
AI summary
Methods of making components for a medicinal delivery device are described, in which a base composition comprising a polysulphone is applied to the surface of a component to create a base layer, a primer composition comprising a silane having two or more reactive silane groups separated by an organic linker group is applied to the base layer to create primed surface, and a coating composition comprising an at least partially fluorinated compound is applied to the primed surface. Corresponding coated components and a medicinal delivery device are disclosed.