BIOCOMPATIBLE POLYMERS POLYMER, TIE-COATS-, METHODS OF MAKING AND USING THE SAME, AND PRODUCTS INCORPORATING THE POLYMERS

• US 20100104880A1
• Filed: 02/13/2008
• Published: 04/29/2010
• Est. Priority Date: 02/13/2007
• Status: Abandoned Application

• Current Assignee: CorNova, Inc.
• Original Assignee: CorNova, Inc.
• Inventors: Garey, Harold E.
• Application Number:
  US12/526,874
• Publication Number:
  US 20100104880A1
• Time in Patent Office: Days
• US Class Current: 428/457
• CPC Class Codes: A61L 27/34 Macromolecular materials
• CPC Class Codes: A61L 31/10 Macromolecular materials
• CPC Class Codes: C08G 18/0852 the solvents being organic
• CPC Class Codes: C08G 18/10 Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• CPC Class Codes: C08G 18/12 using two or more compounds having active hydrogen in the first polymerisation step
• CPC Class Codes: C08G 18/307 Atmospheric humidity
• CPC Class Codes: C08G 18/3206 aliphatic
• CPC Class Codes: C08G 18/3225 Polyamines
• CPC Class Codes: C08G 18/3228 acyclic
• CPC Class Codes: C08G 18/348 Hydroxycarboxylic acids
• CPC Class Codes: C08G 18/44 Polycarbonates
• CPC Class Codes: C08G 18/6659 with compounds of group C08G18/34
• CPC Class Codes: C08G 18/758 containing two or more cycloaliphatic rings
• CPC Class Codes: C08L 69/00 Compositions of polycarbonates; Compositions of derivatives of polycarbonates
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09J 175/04 Polyurethanes
• CPC Class Codes: Y10T 428/31678 Of metal

Abstract

Biodurable, biocompatible polymers for coating applications and tie-coat polymers especially useful in tie-coat applications as an intermediate layer between two other layers or coatings or between a surface and a coating applied to that surface are disclosed, together with methods for preparing such biocompatible polymers and tie-coat polymers, methods for using such biocompatible polymers and tie-coat polymers, and products that use or incorporate such biocompatible polymers and tie-coat polymers. The biocompatible polymers generally comprise polyurethane polymers having polycarbonate backbones, and the tie-coat polymers useful with these biocompatible polymers generally comprise polyurea or polyurethane-polyurea polymers.

Claims

1. A first-type polycarbonate-polyurethane copolymer formed by the reaction of one or more polycarbonate polyols with one or more polyisocyanates.

2. A first-type polycarbonate-polyurethane copolymer according to claim 1 wherein the polycarbonate polyol is a polycarbonate diol formed by the reaction of an aliphatic diol with a dialkyl carbonate.

3. A first-type polycarbonate-polyurethane copolymer according to claim 1 wherein the polyisocyanate is selected from the group consisting of aliphatic and aromatic diisocyanates and polyisocyanates.

4. A first-type polycarbonate-polyurethane copolymer according to claim 2 wherein the polyisocyanate is selected from the group consisting of aliphatic and aromatic diisocyanates and polyisocyanates.

5. A first-type polycarbonate-polyurethane copolymer according to claim 1 wherein the polyisocyanate is selected from the group consisting of toluene diisocyanate (TDI);

methylene bis-phenylisocyanate (diphenylmethane diisocyanate) (MDI);

hexamethylene diisocyanate (HDI);

naphthalene diisocyanate (NDI);

methylene bis-cyclohexylisocyanate (hydrogenated MDI or HMDI);

isophorone diisocyanate (IPDI); and

tetramethylxylylene diisocyanate (TMXDI).

6. A first-type polycarbonate-polyurethane copolymer according to claim 1 prepared by the sequential steps of:

(a) premelting the starting solid polycarbonate;

(b) charging one or a mix of polyols into a reactor;

(c) optionally adding other ingredients selected from the group consisting of;

anti-oxidants;

waxes for aid in molding, pellerizing, and extruding;

phosphites as color stabilizers;

modifying polyols;

air-release additives;

dyes;

Cabosils or other platy or more spherical solids; and

metal salts;

(d) melting the polyol mix at a temperature of about 20°

C. to about 100°

C.;

(e) degassing the polyol mix under partial vacuum conditions of about 25 to 29 inches of mercury while it is being agitated thereby removing trapped gasses and moisture;

(f) breaking the vacuum by adding nitrogen gas;

(g) adding the polyisocyanate(s) and a polymerization catalyst to the polyol mix and mixing the ingredients to form a substantially homogeneous polymerization mixture, wherein the polymerization catalyst is selected from the group consisting of;

amines;

organo-metallic catalysts;

bismuth salts; and

titanium salts;

(h) establishing and maintaining a polymerization reaction temperature for a sufficient period of time for the polymerization mixture to teach a desired molecular weight; and

,

(i) degassing the reacted polymerization mixture to remove dissolved gasses.

7. A first-type polycarbonate-polyurethane copolymer prepared according to the steps of claim 6 wherein the starting polycarbonate has a molecular weight ranging from about 1000 to about 2000.

8. A first-type polycarbonate-polyurethane copolymer prepared according to the steps of claim 6 and additionally the step of adding an extender to the reacted polymerization mixture to form a thermoplastic polyurethane polymer mix having particular physical and/or chemical properties.

9. A first-type polycarbonate-polyurethane copolymer prepared according to the steps of claim 8 wherein the extender is selected from the group consisting of 1,4-butane diol and 1,6 hexane diol.

10. A first-type polycarbonate-polyurethane copolymer product comprising a predominant proportion of a first-type polycarbonate-polyurethane copolymer according to claim 1 mixed with an effective amount, effective to impart desired physical, chemical and/or medical properties to the copolymer product, of one or more additives selected from the group consisting of drugs, antioxidants, anti-inflammatory agents, stabilizers, UV absorbers, colorants, pigments and dyes.

11. A first-type polycarbonate-polyurethane copolymer product comprising a first-type polycarbonate-polyurethane copolymer according to claim 1 dissolved in a suitable solvent.

12. A first-type polycarbonate-polyurethane copolymer product according to claim 11 wherein the solvent is selected from the group consisting of dimethylformamide, dimethylacetamide, tetrahydrofuran, dimethylsulfoxide, acetates, ketones, and combinations thereof.

13. A polycarbonate-polyurethane copolymer according to claim 1 wherein at least an isocyanate-terminated chain of the first-type polycarbonate-polyurethane copolymer has been chain-extended by reaction with a diamine, a polyamine, or mixtures thereof to form a second-type polycarbonate-polyurethane copolymer.

14. A polycarbonate-polyurethane copolymer of a according to claim 1 wherein at least an isocyanate-terminated chain of the first-type polycarbonate-polyurethane copolymer has been chain-extended by reaction with a diamine, a polyamine, or mixtures thereof to form a second-type polycarbonate-polyurethane copolymer, wherein the chain-extension reaction is with a diamine selected from the group consisting of ethylene-diamine, 1,2 propylene diamine, 1,3 diaminocyclohexane, isophoronediamine and mixtures thereof, or with a polyamine selected from the group consisting of cyclohexylamines, benzyl amines, naphthyl amines, methylenebis (4-phenylamine), TMXD amines and mixtures thereof.

15. A second-type polycarbonate-polyurethane copolymer formed by chain-extending a first-type polycarbonate-polyurethane copolymer according to claim 1 by reacting at least an isocyanate-terminated chain of the first-type polycarbonate-polyurethane copolymer with a diamine, polyamine or mixture thereof.

16. A second-type polycarbonate-polyurethane copolymer product wherein a first-type polycarbonate-polyurethane copolymer according to claim 1 is formed by the reaction of one or more polycarbonate polyols with one or more polyisocyanates, the first-type polycarbonate-polyurethane copolymer is chain extended by reacting at least an isocyanate-terminated chain of the first-type polycarbonate-polyurethane copolymer with a diamine, polyamine or mixture thereof to form a second-type polycarbonate-polyurethane copolymer, and the second-type polycarbonate-polyurethane copolymer is dissolved in a suitable solvent.

17. A second-type polycarbonate-polyurethane copolymer according to claim 16 wherein the solvent is selected from the group consisting of aromatic solvents, polar solvents and mixtures thereof.

18. (canceled)

19. An article having an article surface, wherein at least a portion of the article surface is coated with a first-type polycarbonate-polyurethane copolymer or a first-type polycarbonate-polyurethane copolymer product, wherein the first-type polycarbonate-polyurethane copolymer is formed by the reaction of one or more polycarbonate polyols with one or more polyisocyanates.

23. An article according to claim 19 wherein the article surface is a metal surface.

24. An article according to claim 19 wherein the article surface comprises a metal is a selected from the group consisting of cobalt-chromium alloy and platinum.

20-22. -22. (canceled)

25-34. -34. (canceled)