Process for the preparation of slippery, tenaciously adhering, hydrophilic polyurethane hydrogel coatings, coated metal substrate materials, and coated medical devices
First Claim
1. A process for producing a material bearing thereon a coating of a lubricious, hydrated hydrophilic polyurethane-polyurea hydrogel, said process comprising the steps of:
- a) making a surface of a metal substrate reactive by affixing reactive chemical functional groups thereto, at least a portion of which are amine-containing groups;
b) coating a reactive metal substrate surface which results from step (a) with a first coating comprising a hydrophilic polyurethane prepolymer intermediate, containing terminal isocyanate groups, such that at least a portion of said terminal isocyanate groups are reacted with and are covalently bonded to said reactive chemical functional groups on said substrate surface, forming covalent polyurea bonds therewith, resulting in the formation of a tie coat of a polyurethane-polyurea hydrogel-forming polymer, on said substrate surface, that adheres to said substrate surface, and wherein at least a portion of said terminal isocyanate groups of said polyurethane prepolymer intermediate are present in said polyurethane-polyurea hydrogel-forming polymer such that they remain free to react with other species; and
c) coating a tie coat of the first-coated substrate surface which results from step (b) with a second coating comprising a moisture-containing, hydrogel-forming compound or mixture, which contains isocyanate-reactive functional groups, such that a barrier coat of a lubricious, hydrated hydrogel is formed upon the application of said second coating to said tie coat;
wherein said moisture of said hydrogel-forming compound or mixture is bound with said polyurethane-polyurea hydrogel-forming polymer of said tie coat to form a hydrogel of said barrier coat, on said tie coat, such that said hydrogel is a polyurethane-polyurea polymer hydrogel; and
wherein said isocyanate-reactive functional groups of said hydrogel-forming compound or mixture are reacted with and are covalently bonded to at least a portion of said terminal isocyanate groups of said polyurethane-polyurea hydrogel-forming polymer that remain free to react with other species, thereby directly attaching said polyurethane-polyurea polymer hydrogel to said tie coat and thus also indirectly attaching it to said substrate surface.
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Accused Products
Abstract
A process for the preparation of slippery, hydrophilic polyurethane hydrogel coating compositions, and materials composed of a polymeric plastic or rubber substrate or a metal substrate with a coating of a slippery, hydrophilic polyurethane hydrogel thereon, such that the coating composition tenaciously adheres to the substrate, are disclosed. The coating compositions and coated materials are non-toxic and biocompatible, and are ideally suited for use on medical devices, particularly, catheters, catheter balloons and stents. The coating compositions, coated materials and coated devices demonstrate low coefficients of friction in contact with body fluids, especially blood, as well as a high degree of wear permanence over prolonged use of the device. The hydrogel coating compositions are capable of being dried to facilitate storage of the devices to which they have been applied, and can be instantly reactivated for later use by exposure to water.
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Citations
60 Claims
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1. A process for producing a material bearing thereon a coating of a lubricious, hydrated hydrophilic polyurethane-polyurea hydrogel, said process comprising the steps of:
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a) making a surface of a metal substrate reactive by affixing reactive chemical functional groups thereto, at least a portion of which are amine-containing groups; b) coating a reactive metal substrate surface which results from step (a) with a first coating comprising a hydrophilic polyurethane prepolymer intermediate, containing terminal isocyanate groups, such that at least a portion of said terminal isocyanate groups are reacted with and are covalently bonded to said reactive chemical functional groups on said substrate surface, forming covalent polyurea bonds therewith, resulting in the formation of a tie coat of a polyurethane-polyurea hydrogel-forming polymer, on said substrate surface, that adheres to said substrate surface, and wherein at least a portion of said terminal isocyanate groups of said polyurethane prepolymer intermediate are present in said polyurethane-polyurea hydrogel-forming polymer such that they remain free to react with other species; and c) coating a tie coat of the first-coated substrate surface which results from step (b) with a second coating comprising a moisture-containing, hydrogel-forming compound or mixture, which contains isocyanate-reactive functional groups, such that a barrier coat of a lubricious, hydrated hydrogel is formed upon the application of said second coating to said tie coat; wherein said moisture of said hydrogel-forming compound or mixture is bound with said polyurethane-polyurea hydrogel-forming polymer of said tie coat to form a hydrogel of said barrier coat, on said tie coat, such that said hydrogel is a polyurethane-polyurea polymer hydrogel; and wherein said isocyanate-reactive functional groups of said hydrogel-forming compound or mixture are reacted with and are covalently bonded to at least a portion of said terminal isocyanate groups of said polyurethane-polyurea hydrogel-forming polymer that remain free to react with other species, thereby directly attaching said polyurethane-polyurea polymer hydrogel to said tie coat and thus also indirectly attaching it to said substrate surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58)
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59. A process for producing a sterilized coating of a reactivateable, dried, hydrophilic polyurethane-polyurea hydrogel, on the surface of a medical device fabricated from a metallic substrate, said process comprising:
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a) making at least a portion of an outer surface of said metallic substrate from which said medical device is fabricated, chemically reactive by affixing reactive chemical functional groups thereto; b) coating the resulting reactive outer surface of said substrate with a first coating comprising a hydrophilic polyurethane-urea prepolymer intermediate, which is capable of forming a polyurethane-polyurea hydrogel-forming polymer, and which contains terminal isocyanate groups, such that at least a portion of said terminal isocyanate groups are reacted with and are covalently bonded to said reactive chemical functional groups on said surface of said substrate, forming covalent polyurea bonds therewith, resulting in the formation of a tie coat of a polyurethane-polyurea hydrogel-forming polymer, that adheres to said reactive outer surface of said substrate, and wherein at least a portion of said terminal isocyanate groups of said polyurethane-urea prepolymer intermediate are present in said polyurethane-polyurea hydrogel-forming polymer, such that they remain free to react with other species; c) coating said tie coat with a second coating comprising a moisture-containing hydrogel-forming compound, further containing isocyanate-reactive chemical functional groups, such that a barrier coat of a lubricious, hydrated hydrogel is formed upon the application of said second coating to said tie coat of said first coated substrate; wherein said isocyanate-reactive functional groups of said moisture-containing hydrogel-forming compound are reacted with and are covalently bonded to at least a portion of said terminal isocyanate groups of said polyurethane-polyurea hydrogel-forming polymer that remain free to react with other species, to form a hydrated, hydrophilic polyurethane-polyurea polymer hydrogel, that is directly adhering to said tie coat, and thus also indirectly adhering to said substrate surface; d) drying said hydrated, hydrophilic polyurethane-polyurea hydrogel coating formed in step (c) to form a dried hydrogel coating thereof; and e) sterilizing the resulting coated medical device, bearing said dried hydrogel coating of step (d). - View Dependent Claims (60)
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Specification