METHOD FOR COATING AN OBJECT WITH A GRAFT POLYMER LAYER

• US 20090176030A1
• Filed: 03/14/2006
• Published: 07/09/2009
• Est. Priority Date: 02/19/2003
• Status: Active Grant

• Current Assignee: Surmodics Incorporated
• Original Assignee: Surmodics Incorporated
• Inventors: Carlson, Mark F., Chappa, Ralph A., Stucke, Sean M., Porter, Steven J.
• Granted Patent: US 7,883,749 B2
• Time in Patent Office: Days
• US Class Current: 427/487
• CPC Class Codes: B05C 3/109 Passing liquids or other fluent materials into or through chambers containing stationary articles
• CPC Class Codes: B05C 9/14 the auxiliary operation involving heating or cooling
• CPC Class Codes: B05D 1/18 performed by dipping
• CPC Class Codes: B05D 2258/02 The objects being coated one after the other
• CPC Class Codes: B05D 3/061 using U.V.

Abstract

A method for coating a device, such as an industrially or medically applicable device, with a polymer layer is provided. The method includes contacting the device with a grafting initiator comprising at least one photoinitiator group, exposing the device to radiation, contacting the device with a polymerizable monomer, and again exposing the device to radiation.

Claims

1. A method for coating an object with a polymer layer comprising:

placing the object into a container;

filling the container with a first solution comprising a non-polymeric grafting initiator comprising at least one photoinitiator group selected from the group consisting of an initiator that is insoluble in polar solvent; and

a positively charged initiator;

irradiating the container having the first solution and the object, resulting in the grafting initiator binding to the object;

removing the first solution from the container;

filling the container with a second solution comprising a polymerizable monomer; and

irradiating the container having the second solution and the object, wherein the non-polymeric grafting initiator acts as a photoinitiator for a polymerization reaction, resulting in the formation of a polymer layer on the object.

2. The method of claim 1, further comprising bubbling an inert gas through the first solution to remove non-inert gas from the first solution.

3. The method of claim 1, further comprising bubbling an inert gas through the second solution to remove non-inert gas from the second solution.

5. The method of claim 1, further comprising rinsing the object.

6. The method of claim 1, wherein filling the container with the first solution includes adding an amount of the first solution sufficient to surround the object.

7. The method of claim 1, wherein filling the container with the second solution includes adding an amount of the second solution sufficient to surround the object.

21. The method of claim 1, wherein the initiator that is insoluble in polar solvent is selected from the group consisting of tetrakis(4-benzoylbenzyl ether), the tetrakis(4-benzoylbenzoate ester) of pentaerythritol, an acylated derivative of tetraphenylmethane.

22. The method of claim 1, wherein the positively charged initiator includes a quaternary ammonium group.

23. The method of claim 22, wherein the initiator that includes a quaternary ammonium group is selected from the group consisting of ethylenebis(4-benzoylbenzyldimethylammonium)dibromide (Diphoto-Diquat);

hexamethylenebis(4-benzoylbenzyldimethylammonium)dibromide (Diphoto-Diquat);

1,4-bis(4-benzoylbenzyl)-1,4-dimethylpiperazineadiium dibromide (Diphoto-Diquat);

bis(4-benzoylbenzyl)hexamethylenetetraminediium dibromide (Diphoto-Diquat);

bis[2-(4-benzoylbenzyldimethylammonio)ethyl]-4-benzoylbenzylmethylammonium tribromide (Triphoto-Triquat);

4,4-bis(4-benzoylbenzyl)morpholinium bromide (Diphoto-Monoquat);

ethylenebis[(2-(4-benzoylbenzyldimethylammonio)ethyl)-4-benzoylbenzylmethylammonium]tetrabromide (Tetraphoto-Tetraquat);

1,1,4,4-tetrakis(4-benzoylbenzyl)piperazinediium Dibromide (Tetraphoto-Diquat); and

N,N-bis[2-(4-benzoylbenzyloxy)ethyl]-2-aminoethanesulfonic acid, sodium salt (Diphoto-Monosulfonate), and analogues thereof.

4. (canceled)

8. A method for coating an object with a polymer layer comprising the steps of:

establishing fluid communication between a container and a fluid maintenance station, the container having the object disposed therein;

dispensing a first solution into the container from the fluid maintenance station, the first solution comprising a non-polymeric grafting initiator comprising at least one photoinitiator group selected from the group consisting of an initiator that is insoluble in polar solvent; and

a positively charged initiator;

interrupting fluid communication between the container and the fluid maintenance station;

irradiating the container resulting in the grafting initiator binding to the object;

re-establishing fluid communication between the container and the fluid maintenance station;

removing the first solution from the container and dispensing a second solution into the container from the fluid maintenance station, the second solution comprising a polymerizable monomer; and

interrupting fluid communication between the container and the fluid maintenance station; and

irradiating the container, wherein the non-polymeric grafting initiator acts as a photoinitiator for a polymerization reaction resulting in the formation of a polymer layer on the object.

9. The method of claim 8, further comprising conveying the container to an irradiation station.

10. The method of claim 8, further comprising bubbling inert gas through the first solution in the container to remove non-inert gas.

11. The method of claim 8, further comprising bubbling inert gas through the second solution in the container to remove non-inert gas.

13. The method of claim 8, further comprising conveying the container from the fluid maintenance station to an irradiation station.

14. The method of claim 8, further comprising conveying the container from an irradiation station to a fluid maintenance station.

24. The method of claim 8, wherein the initiator that is insoluble in polar solvent is selected from the group consisting of tetrakis(4-benzoylbenzyl ether), the tetrakis(4-benzoylbenzoate ester) of pentaerythritol, an acylated derivative of tetraphenylmethane.

25. The method of claim 8, wherein the positively charged initiator includes a quaternary ammonium group.

26. The method of claim 25, wherein the initiator that includes a quaternary ammonium group is selected from the group consisting of ethylenebis(4-benzoylbenzyldimethylammonium)dibromide (Diphoto-Diquat);

hexamethylenebis(4-benzoylbenzyldimethylammonium)dibromide (Diphoto-Diquat);

1,4-bis(4-benzoylbenzyl)-1,4-dimethylpiperazineadiium dibromide (Diphoto-Diquat);

bis(4-benzoylbenzyl)hexamethylenetetraminediium dibromide (Diphoto-Diquat);

bis[2-(4-benzoylbenzyldimethylammonio)ethyl]-4-benzoylbenzylmethylammonium tribromide (Triphoto-Triquat);

4,4-bis(4-benzoylbenzyl)morpholinium bromide (Diphoto-Monoquat);

ethylenebis[(2-(4-benzoylbenzyldimethylammonio)ethyl)-4-benzoylbenzylmethylammonium]tetrabromide (Tetraphoto-Tetraquat);

1,1,4,4-tetrakis(4-benzoylbenzyl)piperazinediium Dibromide (Tetraphoto-Diquat); and

N,N-bis[2-(4-benzoylbenzyloxy)ethyl]-2-aminoethanesulfonic acid, sodium salt (Diphoto-Monosulfonate), and analogues thereof.

12. (canceled)

15. A method for coating an object comprising the steps of:

placing the object into a translucent container attached to a conveyor mechanism;

conveying the translucent container to a fluid maintenance station and filling the translucent container with a first solution comprising a non-polymeric grafting initiator comprising at least one photoinitiator group selected from the group consisting of an initiator that is insoluble in polar solvent; and

a positively charged initiator;

conveying the translucent container to an irradiation station and irradiating the container;

conveying the translucent container to the fluid maintenance station and removing the first solution from the container and filling the container with a second solution comprising a polymerizable monomer, said filling sufficient to surround said object with second solution; and

conveying the translucent container to the irradiation station and irradiating the translucent container wherein the non-polymeric grafting initiator acts as a photoinitiator for a polymerization reaction, resulting in the formation of a polymer layer on the object.

16. The method of claim 15, the conveyor mechanism comprising a conveyor track.

18. The method of claim 15, further comprising bubbling inert gas through the first solution in the container to remove non-inert gas.

19. The method of claim 15, further comprising bubbling inert gas through the second solution in the container to remove non-inert gas.

20. The method of claim 15, further comprising rinsing the object.

27. The method of claim 15, wherein the initiator that is insoluble in polar solvent is selected from the group consisting of tetrakis(4-benzoylbenzyl ether), the tetrakis(4-benzoylbenzoate ester) of pentaerythritol, an acylated derivative of tetraphenylmethane.

28. The method of claim 15, wherein the positively charged initiator includes a quaternary ammonium group.

29. The method of claim 28, wherein the initiator that includes a quaternary ammonium group is selected from the group consisting of ethylenebis(4-benzoylbenzyldimethylammonium)dibromide (Diphoto-Diquat);

hexamethylenebis(4-benzoylbenzyldimethylammonium)dibromide (Diphoto-Diquat);

1,4-bis(4-benzoylbenzyl)-1,4-dimethylpiperazineadiium dibromide (Diphoto-Diquat);

bis(4-benzoylbenzyl)hexamethylenetetraminediium dibromide (Diphoto-Diquat);

bis[2-(4-benzoylbenzyldimethylammonio)ethyl]-4-benzoylbenzylmethylammonium tribromide (Triphoto-Triquat);

4,4-bis(4-benzoylbenzyl)morpholinium bromide (Diphoto-Monoquat);

ethylenebis[(2-(4-benzoylbenzyldimethylammonio)ethyl)-4-benzoylbenzylmethylammonium]tetrabromide (Tetraphoto-Tetraquat);

1,1,4,4-tetrakis(4-benzoylbenzyl)piperazinediium Dibromide (Tetraphoto-Diquat); and

N,N-bis[2-(4-benzoylbenzyloxy)ethyl]-2-aminoethanesulfonic acid, sodium salt (Diphoto-Monosulfonate), and analogues thereof.

17. (canceled)