METHOD AND APPARATUS FOR PROVIDING A CONDUCTIVE, AMORPHOUS NON-STICK COATING

• US 20010002000A1
• Filed: 04/30/1998
• Published: 05/31/2001
• Est. Priority Date: 04/30/1998
• Status: Active Grant

• Current Assignee: World Heart Corporation (Medtronic Plc), Utah State University
• Original Assignee: Utah State University
• Inventors: OLSEN, DON B., KUMAR, B. AJIT, KHANWILKAR, PRATAP
• Granted Patent: US 6,270,831 B2
• Time in Patent Office: Days
• US Class Current: 204/192.1
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 2017/0088 ceramic
• CPC Class Codes: A61B 2018/00077 high, i.e. electrically conducting
• CPC Class Codes: A61B 2018/00107 Coatings on the energy applicator
• CPC Class Codes: A61B 2018/00119 with metal oxide nitride
• CPC Class Codes: A61B 2018/00148 with metal
• CPC Class Codes: A61M 60/268 the displacement member being flexible, e.g. membranes, diaphragms or bladders
• CPC Class Codes: A61M 60/871 Energy supply devices; Converters therefor
• CPC Class Codes: C23C 14/0641 Nitrides C23C14/0617 takes precedence

Abstract

A conductive, non-stick coating is provided using a ceramic material which is conductive, flexible and provides a surface which exhibits the property of lubricity. A room or near room temperature manufacturing process produces a coating of titanium nitride on a substrate, where the coating is amorphous if the substrate is a solid material including plastics, composites, metals, magnets, and ceramics, enabling the substrate to bend without damaging the coating. The coating can also be applied as a conformal coating on a variety of substrate shapes, depending upon the application. The coating is bio-compatible and can be applied to a variety of medical devices.

Claims

1. A method for providing a wear-resistant ceramic coating on a substrate material which is used in an abrasive environment, such that the substrate material is not deformed during a process of applying the wear-resistant ceramic coating, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the wear-resistant ceramic coating to the substrate material such that the substrate material is not deformed.

2. The method as defined in

claim 1

wherein the method further comprises the step of applying a wear-resistant ceramic coating which is amorphous.

3. The method as defined in

claim 1

wherein the method further comprises the step of applying at least two ceramic materials which are transition metal nitrides.

4. The method as defined in

claim 1

wherein the method further comprises the step of applying (i) at least one ceramic to the substrate material which is a transition metal nitride, and (ii) at least one material which is not a transition metal nitride.

5. The method as defined in

claim 1

wherein the method further comprises the step of applying a wear-resistant ceramic coating which is conductive to thereby facilitate propagation of electrical energy along the substrate material.

6. The method as defined in

claim 1

wherein the method further comprises the step of applying a wear-resistant ceramic coating which is not worn away by application of RF energy thereto, by abrasion or by repeated sterilization thereof.

7. The method as defined in

claim 1

wherein the method further comprises the step of deforming the substrate material from a resting state, and wherein the wear-resistant ceramic coating is flexible so as to be deformed with the substrate material without damage to the wear-resistant ceramic coating.

8. The method as defined in

claim 1

wherein the method further comprises the step of depositing the wear-resistant ceramic coating on the substrate material using a room or near room temperature sputtering process.

9. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a continuous coating over the substrate material.

10. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a corrosion resistant coating over the substrate material.

11. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a fatigue resistant coating over the substrate material.

12. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a sterilizable and biocompatible coating over the substrate material.

13. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a radio frequency opaque coating over the substrate material.

14. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a conformal coating over the substrate material.

15. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a generally smooth and non-stick coating over the substrate material.

16. The method as defined in

claim 1

wherein the method further comprises the step of depositing the wear-resistant ceramic coating using room or near room temperature sputtering.

17. The method of manufacturing as defined in

claim 16

wherein the method comprises the further step of sputtering titanium nitride onto the substrate material.

18. The method as defined in

claim 1

wherein the method further comprises the step of selecting the substrate material for the substrate materials consisting of plastics, glass, ceramics, metals, composites, magnetic materials and semiconductors.

19. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as shielding against electro magnetic interference.

20. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as shielding against radio frequency interference.

21. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a chemically inert, non-reactive and stable coating.

22. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating as a diffusion barrier, wherein the diffusion barrier reduces a passing of fluids and gases therethrough.

23. The method as defined in

claim 22

wherein the method further comprises the step of selecting as the diffusion barrier a bio-compatible coating which is amorphous, to thereby enable the diffusion barrier to flex without damaging the bio-compatible coating.

24. The method as defined in

claim 22

wherein the method further comprises the step of terminating any exchange of gases or fluids through the diffusion barrier, thereby eliminating any exchange of gases or fluids.

25. The method as defined in

claim 22

wherein the method further comprises the step of forming the diffusion barrier on an otherwise permeable membrane which otherwise enables an exchange of fluids and gases therethrough.

26. The method as defined in

claim 1

wherein the method further comprises the step of applying an adherent ceramic coating which readily couples to the substrate material.

27. The method as defined in

claim 1

wherein the method further comprises the steps of:

(1) providing a plurality of different substrate materials in a single assembly; and

(2) applying the ceramic coating to the plurality of different substrate materials of the single assembly such that the ceramic coating is applied to all surfaces thereof.

28. The method as defined in

claim 18

wherein the magnetic materials are selected from the group of magnetic materials consisting of magnetic tape, ceramic magnets, rare-earth magnets, and metallic magnets, wherein the magnetic materials are thereby protected from moisture which can damage the magnetic materials.

29. The method as defined in

claim 1

wherein the method further comprises the step of applying the wear-resistant ceramic coating to components of a storage unit for a computer, wherein the storage unit includes a magnetic media which is caused to rotate, said wear-resistant ceramic coating reducing friction of movable components thereof.

30. The method as defined in

claim 29

wherein the method further comprises the step of at least partially coating the storage unit with the ceramic coating to thereby provide protection from EMI and RFI.

31. A method for providing a wear-resistant ceramic coating on a semiconductor material which is used as part of an integrated circuit, such that the semiconductor material achieves increased conductivity and reduces diffusion of components thereof, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the ceramic coating to the semiconductor material such that the semiconductor material is more conductive and so that there is reduced diffusion between elements of the semiconductor material.

32. A method for providing a wear-resistant ceramic coating on a magnetic material which can be damaged by application of thermal energy, such that the magnetic material retains its magnetic properties during a process of applying the wear-resistant ceramic coating, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the wear-resistant ceramic coating to the magnetic material such that the magnetic material is not deformed.

33. A method for providing a wear-resistant ceramic coating on a heat-sensitive material which is used in an abrasive environment, such that the heat-sensitive material is not deformed during a process of applying the wear-resistant ceramic coating, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the wear-resistant ceramic coating to the heat-sensitive material such that the heat-sensitive material is not deformed.

35. The method as defined in

claim 33

wherein the material is selected from the group of products including kitchen utensils, gears, spark plugs, molds, plumbing fixtures, eyeglass frames, cutting instruments, moisture barriers, sporting goods, writing instruments, drilling instruments, fasteners, bearings, bushings, electrical devices, semiconductors, jewelry, engine components, toys, packaging, optical instruments, fuel cells, and recording media.

34. A method for providing a wear-resistant ceramic coating on a material which is used in an environment which is detrimental to the material, such that the material is covered with a continuous, smooth and fatigue resistant ceramic coating after an application process thereof, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the wear-resistant ceramic coating to the material such that to thereby enhance properties of wear resistance, lubricity and strength.

36. A method for providing a wear-resistant ceramic coating on a ceramic material which can be damaged by application of thermal energy, such that the ceramic material retains its properties during a process of applying the wear-resistant ceramic coating, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the wear-resistant ceramic coating to the ceramic material such that the ceramic material is not deformed.

38. The audio playback head as defined in

claim 36

wherein the audio playback head is capable of recording analog signals to the analog medium.

39. The audio playback head as defined in

claim 36

wherein the audio playback head is capable of playback of video data stored as analog data on the analog medium.

37. An audio system including a playback head for use in reading data from an analog media which is disposed in contact with the audio playback head and moved thereover during playback, said audio playback head comprising:

the audio playback head which is capable of generating electrical signals in response to the analog media being moved thereover, said electrical signals being indicative of acoustical signals recorded on the analog media;

a wear-resistant ceramic coating disposed on the audio playback head to thereby increase resistance to wear thereof and to thereby extend a usable life of the audio playback head.

40. A container for use in cooking wherein the cooking container is exposed to heat to thereby heat the cooking container and food contents therein, said cooking container comprising:

an outer surface;

an inner surface on which the food contents are disposed to thereby enable transfer of heat from the inner surface to the food contents; and

a wear-resistant and non-stick ceramic coating disposed on the inner surface to thereby enable metal utensils to be used in movement of the food contents without damaging the inner surface of the cooking container.

41. A plastic gear for use in applications where weight is relevant, said plastic gear comprising:

a generally circular disk having a plurality of splines on an outer edge thereof, wherein the plurality of splines are designed so as to mesh with splines of another device to thereby transmit or receive force thereby;

a wear-resistant ceramic coating disposed on the plurality of splines to thereby provide enhance wear-resistance, maintain dimensional accuracy, and improve a useful lifespan thereof.

42. A razor blade for use in shaving, wherein said blade is relatively longer lasting because it is coated with a wear-resistant ceramic coating having improved lubricity, said razor blade comprising:

a substrate having at least one cutting edge, wherein the substrate is designed for being pulled across skin to thereby remove hair from the skin; and

a continuous ceramic coating disposed on the substrate to thereby cover the at least one cutting edge with an amorphous coating which resists wear caused by cutting hair, and which can flex with the substrate without damaging the continuity of the continuous ceramic coating.

43. A spark plug for use in generating an electrical spark for igniting a mixture of fuel and air in an internal-combustion engine, said spark plug comprising:

a first electrode for carrying an electrical charge from a power source;

a second electrode for receiving the electrical charge from the power source;

an electrically conductive, non-stick ceramic coating disposed on the first and the second electrodes to thereby increase conductivity and provide a surface which is resistant to a build-up of materials which can interfere with generation of the electrical spark.

44. A method for providing a wear-resistant ceramic coating on a ceramic material which can be damaged by application of thermal energy, such that the ceramic material retains its properties during a process of applying the wear-resistant ceramic coating, said method comprising the steps of:

(1) selecting the ceramic coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive; and

(2) using a generally room temperature application process to apply the wear-resistant ceramic coating to the ceramic material such that the ceramic material is not deformed and altered in its physical properties.

46. The method as defined in

claim 44

wherein the method further comprises the step of selecting the temperature-sensitive material from the group of temperature-sensitive materials including plastic, glass, and magnetic materials.

47. The method as defined in

claim 44

wherein the method further comprises the step of selecting the bio-compatible coating from the group of ceramics which provide corrosion resistance.

48. The method as defined in

claim 46

wherein the method further comprises the step of selecting the bio-compatible coating from the group of ceramics which provide a surface texture of lubricity.

49. The method as defined in

claim 47

wherein the temperature-sensitive material is a plastic introducer catheter which is able to be more easily inserted because of the plastic introducer'"'"'s lubricity.

50. The method as defined in

claim 44

wherein the method further comprises the step of applying the bio-compatible coating to a plurality of permanent magnets which are used in an implantable medical device requiring an electric motor, magnetic bearing, sensor and other electromagnetic devices for operation.

52. The method as defined in

claim 50

wherein the method further comprises the step of using less expensive nonbio-compatible materials to thereby reduce costs of the implantable devices.

54. The method as defined in

claim 52

wherein the method further comprises the step of selecting the implantable devices from the group of implantable devices consisting of stents, ventricular assist devices, pumps, impellers, balloons, diaphragms, volume displacement chambers, plastic tubes providing fluid paths, bearings, bearing components, catheters, occluders, soft-tissue implants, valves, shunts, pacemakers, defibrillators, cardioverters, electrodes, neural stimulators, filters, grafts, patches, contraceptive devices, sensors, transducers, needles, medical tubes, clips, surgical staples, prostheses and electrosurgical blades.

56. The method as defined in

claim 54

wherein the method further comprises the step of selecting a bio-compatible coating which is amorphous to thereby enable the diffusion barrier to flex without damaging the bio-compatible coating.

58. The method as defined in

claim 56

wherein the method further comprises the step of reducing the exchange of working fluids which are selected from the group of working fluids including silicone oil, other lubricants and air.

60. The diffusion barrier as defined in

claim 58

wherein the first membrane and the second membrane are comprised of a polymer.

62. The diffusion barrier as defined in

claim 58

wherein the amorphous, bio-compatible, ceramic coating is selected from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive, and which are also fatigue-resistant, corrosion-resistant, and abrasion-resistant.

63. The diffusion barrier as defined in

claim 58

wherein the working fluids are also comprised of working gases.

45. A method for providing a bio-compatible coating on a temperature-sensitive material which is used in a medical device, such that the temperature sensitive material is not damaged during a process of applying the bio-compatible coating, said method comprising the steps of:

(1) selecting the bio-compatible coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive;

(2) using a generally room temperature application process to apply the bio-compatible ceramic coating to the temperature-sensitive material such that the temperature-sensitive material is not damaged by thermal energy from the application process; and

(3) disposing the temperature-sensitive material with its bio-compatible coating in the medical device, to thereby enable the medical device to be utilized in a medical environment.

51. A method for utilizing nonbio-compatible materials in an implantable medical device, wherein the implantable medical device is made safe for implantation, said method comprising the steps of:

(1) selecting a bio-compatible coating from the group of ceramics consisting of transition metal nitrides which are both amorphous and conductive;

(2) using a generally room temperature application process to apply the bio-compatible ceramic coating to the nonbio-compatible materials such that the nonbio-compatible materials are covered completely by the bio-compatible ceramic coating; and

(3) implanting the nonbio-compatible material which is coated with the bio-compatible coating.

53. The method as defined in

claim 51

wherein the method further comprises the step of utilizing temperature-sensitive materials for the nonbio-compatible materials, wherein the temperature-sensitive materials are selected from the group of temperature-sensitive materials consisting of plastics, glass, and magnetic materials.

55. A method for creating a more effective diffusion barrier for a medical device, wherein the diffusion barrier is disposed on a permeable membrane through which fluids and gases are able to pass, said method comprising the steps of:

(1) selecting a bio-compatible coating for the diffusion barrier; and

(2) applying the bio-compatible coating to the diffusion barrier using a generally room temperature application process to thereby avoid damaging the permeable membrane, wherein the bio-compatible coating reduces penetration of the fluids and gases therethrough.

57. The method as defined in

claim 55

wherein the method further comprises the step of reducing an exchange of working fluids and body fluids.

59. A diffusion barrier for use in an implantable medical device which is exposed to body fluids, wherein the diffusion barrier reduces passage of working fluids between the implantable medical device and the body fluids, said diffusion barrier comprising:

a first membrane which is disposed between the body fluids and the working fluids;

an amorphous, bio-compatible, ceramic coating which is applied on a first side through a room or near room temperature process to a first side of the first membrane, wherein the amorphous, bio-compatible, ceramic coating is integrally bonded to the first membrane; and

a second membrane which is bonded to a second side of the amorphous, bio-compatible, ceramic coating.

61. The diffusion barrier as defined in

claim 59

wherein the polymer is comprised of polyurethane.

64. A method for preventing diffusion of fluids between an implantable medical device which is exposed to body fluids, and working fluids of the implantable medical device, said method comprising the steps of:

(1) providing a first membrane which is disposed between the body fluids and the working fluids;

(2) disposing an amorphous, bio-compatible, ceramic coating on a first side thereof to a first side of the first membrane through a room or near room temperature process, wherein the amorphous, bio-compatible, ceramic coating is integrally bonded to the first membrane; and

(3) disposing a second membrane to a second side of the amorphous, bio-compatible, ceramic coating, wherein said ceramic coating reduces diffusion of the body fluids and the working fluids through the first membrane and the second membrane.

65. A method for preventing diffusion of fluids between an implantable medical device which is exposed to body fluids, and working fluids of the implantable medical device, said method comprising the steps of:

(1) providing a first membrane which is disposed between the body fluids and the working fluids; and

(2) disposing an amorphous, bio-compatible, ceramic coating on a first side thereof to a first side of the first membrane through a room or near room temperature process, wherein the amorphous, bio-compatible, ceramic coating is integrally bonded to the first membrane, wherein said ceramic coating reduces diffusion of the body fluids and the working fluids through the first membrane.