Radiopaque coatings for polymer substrates

• US 20070178222A1
• Filed: 10/03/2006
• Published: 08/02/2007
• Est. Priority Date: 01/30/2006
• Status: Abandoned Application

• Current Assignee: Nanosurface Technologies Llc
• Original Assignee: Nanosurface Technologies Llc
• Inventors: Storey, Daniel, McGrath, Terrence
• Application Number:
  US11/542,557
• Publication Number:
  US 20070178222A1
• Time in Patent Office: Days
• US Class Current: 427/2.240
• CPC Class Codes: C23C 14/325 Electric arc evaporation
• CPC Class Codes: H01J 37/32412 Plasma immersion ion implantation

Abstract

Improved radiopaque coatings particularly suitable for polymer substrates are described. A modified ion plasma deposition (IPD) method is used to provide coatings with macroparticle-dense surfaces that have excellent radiopacity. The coatings are particularly adapted to polymer surfaces because of high adherence and resistance to peeling and flaking.

Claims

1. An ion plasma deposition (IPD) method for depositing a radiopaque coating on a polymer substrate, comprising:

depositing a first substantially macroparticle-free coating on a polymer substrate;

depositing a second macrodense macroparticle coating over the first coating;

forming a coating to a thickness between about 1 micron to about 100 microns;

wherein arc speed or distance of the substrate surface from the IPD target controls macroparticle production and density.

2. The method of claim 1 wherein the first and second coatings are formed continuously without interruption of the deposition.

3. The method of claim 2 wherein macroparticle density increases in the deposited coating relative to variation of arc speed or substrate surface distance from the IPD target.

4. The method of claim 1 wherein the substantially macroparticle-free first layer is distinctly delineated from the densely distributed macroparticle second layer.

5. The method of claim 1 wherein the densely distributed macroparticle layer comprises about 90,000/cm² macroparticles 1 micron or larger in size.

6. The method of claim 1 wherein the plastic substrate is PTFE, ePTFE, polypropylene, polyester, PEEK, UHMWPE, silocone, polyimide or ABS.

7. The method of claim 1 wherein the substrate is polyimide or PEEK.

8. The method of claim 1 wherein the substrate is a medical device selected from the group consisting of valves, implants, catheters, stents and tubes.

9. The method of claim 7 wherein the substrate is a PEEK spinal implant.

10. The method of claim 1 wherein the substrate is a catheter.

11. The method of claim 1 wherein the radiopaque coating is gold, titanium, niobium, molybdum or hafnium.

12. The method of claim 11 wherein the radiopaque coating is gold or titanium.

13. The method of claim 11 wherein the radiopaque coating is gold.

14. The method of claim 11 wherein the gold is deposited at a thickness of 1, 5, 10, 15 or 20 microns.

15. The method of claim 14 wherein the gold is deposited at a thickness of 5 microns.

16. A polymer substrate coated with a radiopaque film comprising a densely distributed macroparticulate film surface over a substantially macroparticle-free adherent base coating continuous with the film surface.

17. The polymer substrate of claim 16 wherein the coating is between about 100 nm and about 1 micron thick.

18. The polymer substrate of claim 16 wherein the substrate is a device used in medical applications selected from the group consisting of stents, catheters, valves, tubes and implants.