Multilayer thermoset polymer matrix and structures made therefrom

• US 6,485,735 B1
• Filed: 09/21/1999
• Issued: 11/26/2002
• Est. Priority Date: 08/31/1999
• Status: Expired due to Term

• Current Assignee: IWG High Performance Conductors Incorporated (International Wire Group Holdings, Inc.)
• Original Assignee: Phelps Dodge High Performance Conductors of SC and GA Incorporated
• Inventors: Steen, Brett, Gold, Floyd, Daniel, Stevie
• Primary Examiner(s): Page, Thurman K.
• Assistant Examiner(s): Bennett, Rachel M.
• Application Number:
  US09/400,419
• Time in Patent Office: 1,162 Days
• Field of Search: 424/422, 424/423, 424/443, 424/484, 623/1.1, 623/1.11, 623/1.44, 623/1.46
• US Class Current: 424/423
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61M 25/0012 with embedded structures, e.g. coils, braids, meshes, strands or radiopaque coils
• CPC Class Codes: A61M 25/005 with embedded materials for reinforcement, e.g. wires, coils, braids

Abstract

A composite thermoset polymer matrix structure having a plurality of homogeneously bonded thermoset polymer layers and a method of forming the same is disclosed. Each of the layers is formed from either a pure thermoset polymer resin or a composition of any of a variety of thermoset polymer resins and any of a variety of agents or combination of agents heterogeneously dispersed and suspended within the thermoset polymer resin. In this manner, each layer exhibits a distinct desirable functional property or characteristic depending upon an intended application. The agents are selected from a group of additives including but not limited to anti-microbial agents, anti-fungal agents, anti-viral agents, anti-thrombotic agents, friction reducing agents; radiopaque agents, and electrically conductive or resistive agents. The composite thermoset polymer matrix structure may be formed into any size or any shape, object, or structure.

Claims

1. A composite thermoset polymer matrix structure comprising:

a) a first layer comprising a suspension of a first thermoset polymer resin and a first additive agent heterogeneously disposed but substantially evenly mixed within said first thermoset polymer resin, said first layer being cured such that said first layer is substantially a solid; and

b) a second layer comprising a suspension of a second thermoset polymer resin and a second additive agent different from said first additive agent, said second additive agent heterogeneously disposed but substantially evenly mixed within said second thermoset polymer resin, said second layer being cured such that said second layer is substantially a solid and is homogeneously bonded to said first layer.

2. A composite thermoset polymer matrix structure according to claim 1, wherein:

said first thermoset polymer resin and said second thermoset polymer resin are selected from a group consisting of polyimide, polyurethane, polyester, polyamide-imide, and polyamide.

3. A composite thermoset polymer matrix structure according to claim 2, wherein:

said first and said second thermoset polymer resins are identical.

4. A composite thermoset polymer matrix structure according to claim 2, wherein:

said first and said second thermoset polymer resins are polyimide.

5. A composite thermoset polymer matrix structure according to claim 1, wherein:

said first additive agent and said second additive agent are selected from a group consisting of an anti-microbial agent, an anti-fungal agent, an anti-viral agent, an anti-thrombotic agent, a friction reducing agent, a radiopaque agent, and an electrically conductive agent.

6. A composite thermoset polymer matrix structure according to claim 5, wherein:

said anti-microbial agent is selected from a group of metal ion producing agents consisting of a silver ion producing agent, a zinc ion producing agent, a copper ion producing agent, and a gold ion producing agent.

7. A composite thermoset polymer matrix structure according to claim 6, wherein:

said metal ion producing agent releases silver ions in an aqueous environment, and is selected from a group consisting of zeolite, hydroxyl apatite, silica gel, glass, magnesium, aluminate silicate, and partially soluble phosphates.

8. A composite thermoset polymer matrix structure according to claim 6, wherein:

said anti-microbial agent is zeolite.

9. A composite thermoset polymer matrix structure according to claim 5, wherein:

said anti-thrombotic agent is selected from a group consisting of anti-thrombotic agents including heparin, phosphorylcholine, ibuprofen, acetylsalicylic acid, dipyridamole, indomethacin, prostaglandin, sulfinpyrazone, and warfarin.

10. A composite thermoset polymer matrix structure according to claim 5, wherein:

said friction reducing agent is one of polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), and graphite.

11. A composite thermoset polymer matrix structure according to claim 5, wherein:

said radiopaque agent is selected from a group which provides x-ray visibility consisting of metallic tungsten, metallic barium, and metallic gold.

12. A composite thermoset polymer matrix structure according to claim 5, wherein:

said electrically conductive agent is selected from a group which dissipates static charges and shields against electromagnetic interference consisting of carbon black and graphite.

13. A composite thermoset polymer matrix structure according to claim 1 wherein:

said additive agent is in powder form having a powdered particulate size of up to 5 microns.

14. A composite thermoset polymer matrix structure according to claim 13, wherein:

said powdered particulate size is up to approximately 1 micron.

15. A composite thermoset polymer matrix structure according to claim 1, wherein:

said first additive agent constitutes up to 30% by weight of said first layer.

16. A composite thermoset polymer matrix structure according to claim 1, wherein:

at least one of said first layer and said second layer is comprised of a plurality of sublayers.

17. A composite thermoset polymer matrix structure according to claim 16, wherein:

a thickness of each of said plurality of sublayers is between 0.00025 and 0.05 inches.

18. A composite thermoset polymer matrix structure according to claim 1, wherein:

said structure is a tube.

19. A composite thermoset polymer matrix structure according to claim 1, wherein:

said structure is a sheet.

20. A composite thermoset polymer matrix structure according to claim 1, further comprising:

c) an adhesive layer disposed on one of said first and second layers, such that said first layer, said second layer and said adhesive layer together form an adhesive tape.

21. A composite thermoset polymer matrix structure according to claim 1, further comprising:

c) at least one additional layer of a thermoset polymer resin, said at least one additional layer cured as a solid, and homogeneously bonded to at least one of said first and second layers.

22. A composite thermoset polymer matrix structure according to claim 21, wherein:

said at least one additional layer further comprises an additive agent heterogeneously disposed but substantially evenly mixed within said thermoset polymer resin of said at least one additional layer.

23. A composite thermoset polymer matrix structure comprising:

a) a metal substrate;

b) a first layer comprising a first thermoset polymer resin, said first layer being cured such that said first layer is substantially solid and is disposed around said metal substrate; and

c) a second layer comprising a second thermoset polymer resin and a first additive agent heterogeneously disposed but substantially evenly mixed within said second thermoset polymer resin, said second layer being cured such that said second layer is substantially a solid and is homogeneously bonded to said first layer and disposed around said first layer.

24. A composite thermoset polymer matrix structure according to claim 23, wherein:

said first thermoset polymer resin further comprises a second additive agent heterogeneously disposed but substantially evenly mixed within said first thermoset polymer resin, said second additive agent being different from said first additive agent.

25. A tubular structure, comprising:

a) a first layer comprising a suspension of a first thermoset polymer resin and a first additive agent heterogeneously disposed but substantially evenly mixed within said first thermoset polymer resin, said first layer being cured such that said first layer is substantially a solid; and

b) a second layer comprising a second thermoset polymer resin, said second layer being cured such that said second layer is substantially a solid and is homogeneously bonded to said first layer,

wherein said first and second layers together define a freestanding tubular structure having an open lumen.

26. A tubular structure according to claim 25, wherein:

said second layer is a suspension of said second thermoset polymer resin and a second additive agent different from said first additive agent, said second additive agent heterogeneously disposed but substantially evenly mixed within said second thermoset polymer resin.

27. A tubular structure according to claim 25, further comprising:

c) a third layer of a thermoset polymer resin, said third layer cured as a solid, and homogeneously bonded to at least one of said first and second layers.

28. A tubular structure according to claim 27, wherein:

said third layer further comprises an additive agent heterogeneously disposed but substantially evenly mixed within said thermoset polymer resin of said third layer.

29. A tubular structure according to claim 25, wherein:

said first and second thermoset polymer resins are polyimide.

30. A tubular structure according to claim 25, wherein:

said first additive agent is in powdered particulate form.

31. A tubular structure according to claim 26, wherein:

said first additive agent and said second additive agent are selected from a group consisting of an anti-microbial agent, an anti-fungal agent, an anti-viral agent, an anti-thrombotic agent, a friction reducing agent, a radiopaque agent, and an electrically conductive agent.

32. An adhesive sheet structure, comprising:

a) a first layer comprising a suspension of a first thermoset polymer resin and a first additive agent heterogeneously disposed but substantially evenly mixed within said first thermoset polymer resin, said first layer being cured such that said first layer is substantially a solid;

b) a second layer comprising a second thermoset polymer resin, said second layer being cured such that said second layer is substantially a solid and is homogeneously bonded to said first layer; and

c) an adhesive layer disposed on one of said first and second layers.

33. An adhesive sheet structure according to claim 32, wherein:

said second layer is a suspension of said second thermoset polymer resin and a second additive agent different from said first additive agent, said second additive agent heterogeneously disposed but substantially evenly mixed within said second thermoset polymer resin.

34. An adhesive sheet structure according to claim 32, further comprising:

c) a third layer of a thermoset polymer resin, said third layer cured as a solid, and homogeneously bonded to at least one of said first and second layers.

35. An adhesive sheet structure according to claim 34, wherein:

said third layer further comprises an additive agent heterogeneously disposed but substantially evenly mixed within said thermoset polymer resin of said third layer.

36. An adhesive sheet structure according to claim 32, wherein:

said first and second thermoset polymer resins are polyimide.

37. An adhesive sheet structure according to claim 32, wherein:

said first additive agent is in powdered particulate form.

38. An adhesive sheet structure according to claim 33, wherein:

said first additive agent and said second additive agent are selected from a group consisting of an anti-microbial agent, an anti-fungal agent, an anti-viral agent, an anti-thrombotic agent, a friction reducing agent, a radiopaque agent, and an electrically conductive agent.