COATING SUITABLE FOR SURGICAL INSTRUMENTS

• US 20100222773A1
• Filed: 04/28/2010
• Published: 09/02/2010
• Est. Priority Date: 01/25/2006
• Status: Abandoned Application

• Current Assignee: Team Medical, LLC
• Original Assignee: Team Medical, LLC
• Inventors: Brassell, James, Heim, Warren P.
• Application Number:
  US12/768,962
• Publication Number:
  US 20100222773A1
• Time in Patent Office: Days
• US Class Current: 606/32
• CPC Class Codes: A61B 18/00 Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body eye surgery A61F9/007; ear surgery A61F11/00
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2018/00601 Cutting
• CPC Class Codes: A61L 2420/02 Methods for coating medical devices
• CPC Class Codes: A61L 2420/06 Coatings containing a mixture of two or more compounds
• CPC Class Codes: A61L 2420/08 Coatings comprising two or more layers
• CPC Class Codes: A61L 31/088 Other specific inorganic materials not covered by A61L31/084 or A61L31/086
• CPC Class Codes: A61L 31/14 Materials characterised by their function or physical properties , e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
• CPC Class Codes: B05D 1/36 Successively applying liquids or other fluent materials, e.g. without intermediate treatment
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: B05D 5/00 Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/30 Oxides other than silica ferrites C04B14/363
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/305 Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 14/322 Carbides
• CPC Class Codes: C04B 14/323 Boron carbide
• CPC Class Codes: C04B 14/324 Silicon carbide
• CPC Class Codes: C04B 14/325 Nitrides
• CPC Class Codes: C04B 14/328 : Silicon nitride
• CPC Class Codes: C04B 14/366 : Phosphates, e.g. apatite
• CPC Class Codes: C04B 18/146 : Silica fume
• CPC Class Codes: C04B 2103/40 : Surface-active agents, dispersants
• CPC Class Codes: C04B 2111/00482 : Coating or impregnation materials
• CPC Class Codes: C04B 2111/00525 : for metallic surfaces
• CPC Class Codes: C04B 2111/00836 : for medical or dental applications
• CPC Class Codes: C04B 24/2682 : Halogen containing polymers, e.g. PVC
• CPC Class Codes: C04B 24/42 : Organo-silicon compounds
• CPC Class Codes: C04B 28/26 : Silicates of the alkali metals
• CPC Class Codes: C04B 40/0263 : Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C09D 1/00 : Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: H01B 3/445 : from vinylfluorides or other fluoroethylenic compounds
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/259 : Silicic material

Abstract

A coating and devices using the coating are provided. The coating is applied in liquid form and dried or otherwise cured to form a durable adherent coating resistant to high temperatures and having optional hydrophobic properties. The coating formulation contains an aqueous formulation of silica, one or more fillers, and sufficient base, (e.g., potassium hydroxide), to have a pH exceeding about 10.5 during at least part of the formulation process. The formulation may contain a compound(s) that affects surface free energy, energy to make the cured coating hydrophobic. Such compounds include silanes containing halogens (e.g., fluorine or chlorine) and in particular silanes containing one or more hydrolyzable groups attached to at least one silicon atom and a group containing one or more halogens (e.g., chlorine or fluorine). A medical instrument (e.g., electrosurgical instrument) may be at least partially covered by a coating using the formulation.

Claims

1. A medical instrument have a surface coated with a coating formulation comprising:

silica;

at least one inorganic filler; and

a base in an amount so that the coating formulation has a pH of at least 10.5 during at least part of a formulation process, wherein said base comprises potassium hydroxide.

2. The medical instrument coating formulation of claim 1, wherein said coating formulation comprises a solution including water and at least 20 weight percent of said potassium hydroxide.

3. The medical instrument of claim 1, wherein the silica of the coating formulation comprises at least one of:

colloidal silica; and

amorphous silica.

4. The medical instrument of claim 1, the coating formulation further comprising:

at least one alkoxy silane.

5. The medical instrument of claim 4, wherein said at least one alkoxy silane of the coating formulation comprises:

at least one alkylalkoxysilane.

6. The medical instrument of claim 5, wherein said at least one alkylalkoxysilane of the coating formulation includes at least one halogen.

7. The medical instrument of claim 6, wherein said at least one halogen of the coating formulation includes at least one of:

chlorine; and

fluorine.

8. The medical instrument of claim 7, wherein said at least one alkylalkoxysilane of the coating formulation is selected from a group consisting of:

fluoroalkyalkoxysilanes; and

chloroalkyalkoxysilanes.

9. The medical instrument of claim 8, wherein said at least one alkylalkoxysilane of the coating formulation comprises at least one hydrolyzable inorganic alkylsilyl group.

10. The medical instrument of claim 9, wherein said hydrolyzable inorganic alkylsilyl of the coating formulation group is selected from a group consisting of:

a methoxysilyl group; and

an ethoxysilyl group.

11. The medical instrument of claim 6, wherein said at least one alkylalkoxysilane of the coating formulation comprises at least one of the following:

at least one straight halogenalkyl chain; and

at least one branched halogenalkyl chain.

12. The medical instrument of claim 11, wherein said at least one alkylalkoxysilane of the coating formulation comprises at least one of the following:

at least one chloroalkyl chain; and

fluoroalkyl chain.

13. The medical instrument of claim 4, the coating formulation further comprising at least one of the following:

water;

a surfactant; and

a solid.

14. The medical instrument of claim 4, wherein said coating formulation comprises fumed silica.

15. The medical instrument of claim 1, the coating formulation further comprising at least one of the following:

a material including a fluorinated carbon chain; and

a material including at least partially hydrolyzed fluorinated silanes; and

a material including at least partially cross-linked hydrolyzed silanes.

16. The medical instrument of claim 15, wherein the base material of the coating formulation comprises:

potassium hydroxide.

17. The medical instrument of claim 1, wherein said coating formulation comprises at least 10 weight percent of a solution comprising a colloidal silicate.

18. The medical instrument of claim 17, wherein said solution of the coating formulation comprises an alkali metal silicate solution.

19. The medical instrument of claim 17, wherein said solution of the coating formulation comprises at least 50 weight percent silica.

20. The medical instrument of claim 17, wherein an average particle size of said colloidal silicate of the coating formulation is between 5 nm and 100 nm.

21. The medical instrument of claim 1, wherein said inorganic filler of the coating formulation comprises at least one metal and at least one non-metal material selected from a group consisting of:

aluminum oxides;

zirconium nitrides;

zirconium carbides;

boron carbides;

silicon oxides;

magnesium-zirconium oxides;

zirconium-silicon oxides;

titanium oxides;

tantalum oxides;

tantalum nitrides;

tantalum carbides;

silicon nitrides;

silicon carbides;

tungsten carbides;

titanium nitrides;

titanium carbides;

nibobium nitrides;

niobium carbides;

vanadium nitrides;

vanadium carbides; and

hydroxyapatite.

22. The medical instrument of claim 1, wherein the surface of the medical instrument is a metallic surface.

23. The medical instrument of claim 22, wherein the metallic surface of the medical instrument comprises stainless steel.

24. The medical instrument of claim 23, wherein the medical instrument is an electrosurgical instrument.

25. The medical instrument of claim 24, wherein the coating formulation further comprises at least one of the following:

a material including a fluorinated carbon chain; and

a material including at least partially hydrolyzed fluorinated silanes; and

a material including at least partially cross-linked hydrolyzed silanes.

26. The medical instrument of claim 25, wherein said coating formulation comprises a solution including water and at least 20 weight percent of said potassium hydroxide.

27. The medical instrument of claim 26, wherein said coating formulation comprises at least 10 weight percent of a solution comprising a colloidal silicate.