Inline application of coatings

• US 7,914,841 B2
• Filed: 02/01/2007
• Issued: 03/29/2011
• Est. Priority Date: 02/09/2006
• Status: Active Grant

• Current Assignee: Cook Medical Incorporated (Cook Group Incorporated)
• Original Assignee: Cook Medical Incorporated (Cook Group Incorporated)
• Inventors: Eells, Scott E., Lessard, David R.
• Primary Examiner(s): Meeks; Timothy H
• Assistant Examiner(s): Sellman; Cachet I
• Application Number:
  US11/700,984
• Publication Number:
  US 20070182055A1
• Time in Patent Office: 1,517 Days
• Field of Search: 427/2.1, 427/2.24, 427/2.25, 427/2.28, 427/2.3, 427/289, 427/293, 264/165, 264/176.1, 264/177.17, 264/177.18, 264/211.12, 264/211.13
• US Class Current: 427/2.1
• CPC Class Codes: B05D 2254/00 Tubes
• CPC Class Codes: B05D 2254/02 Applying the material on the exterior of the tube
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B29C 2035/046 dried air
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/1616 using liquids
• CPC Class Codes: B29C 2793/0027 Cutting off
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 37/0092 Drying moulded articles or half products, e.g. preforms, during or after moulding or cooling
• CPC Class Codes: B29C 48/0022 combined with cutting
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/151 Coating hollow articles
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/9115 of hollow articles
• CPC Class Codes: B29C 48/919 using a bath, e.g. extruding into an open bath to coagulate or cool the material
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/16 Laser beams
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/5221 : for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
• CPC Class Codes: B29D 23/001 : Pipes; Pipe joints pleated hoses B29D23/18
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2027/18 : PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/08 : PI, i.e. polyimides or derivatives thereof
• CPC Class Codes: B29K 2995/0092 : hydrophilic
• CPC Class Codes: B29L 2023/007 : Medical tubes other than catheters catheters B29L2031/7542
• CPC Class Codes: B29L 2031/7542 : Catheters
• CPC Class Codes: C23C 26/00 : Coating not provided for in groups C23C2/00 - C23C24/00

Abstract

A method of forming a coated medical device is described. A coating may be applied inline to a continuous tubing formed by extrusion, prior to cutting and secondary operations. Thus, inefficient and labor-intensive steps associated with preparing individual tubes for coating may be avoided. The method may include forcing a flowable material through an exit port of an extruder, depositing a coating onto at least a portion of the continuous length of extruded tubing after the tubing is forced through the exit port, cutting the coated tubing to a desired length after depositing the coating, and performing one or more secondary operations on the coated tube at a temperature in the range of from about 15° C. to about 375° C.

Claims

1. A method for producing a coated medical device, comprising:

forcing a flowable material through an exit port of an extruder, thereby forming a continuous length of extruded tubing;

passing the extruded tubing through a liquid bath to cool the extruded tubing;

depositing a coating onto at least a portion of the extruded tubing after the extruded tubing is cooled, thereby forming a coated tubing;

cutting the coated tubing to a desired length after depositing the coating, thereby forming a coated tube; and

performing one or more secondary operations on the coated tube at a temperature in the range of from about 15°

C. to about 375°

C., thereby forming a coated medical device.

2. The method according to claim 1, further comprising drying the extruded tubing after the cooling.

3. The method according to claim 1, further comprising curing the coating before cutting the coated tubing.

4. The method according to claim 3, wherein the curing is carried out using ultraviolet radiation.

5. The method according to claim 4, wherein the curing is carried out for a duration of time of about 60 seconds or less.

6. The method according to claim 1, wherein the temperature is in the range of from about 100°

C. to about 375°

C.

7. The method according to claim 1, wherein the temperature is in the range of from about 15°

C. to about 40°

C.

8. The method according to claim 1, wherein the secondary operations comprise bonding operations.

9. The method according to claim 1, wherein the secondary operations comprise forming operations.

10. The method according to claim 1, wherein the flowable material is a polymer and the extruded tubing is an extruded polymer tubing.

11. The method according to claim 1, wherein the coating is a hydrophilic coating.

12. The method according to claim 11, wherein the hydrophilic coating comprises a hydrogel.

13. The method according to claim 1, wherein the coating has a thickness in the range of from approximately 1 micron to 150 microns.

14. The method according to claim 1, wherein the desired length of the coated tube ranges from about 20 centimeters to about 200 centimeters.

15. The method according to claim 1, further comprising:

drying the extruded tubing after cooling;

curing the coating before cutting the coated tubing, wherein the curing is carried out using ultraviolet radiation and for a time duration of about 60 seconds or less.

16. The method according to claim 15, wherein the material is nylon and the extruded tubing is an extruded nylon tubing,

wherein the coating comprises a hydrogel, the coating having a thickness in the range of from approximately 1 micron to 150 microns,

wherein the desired length of the coated tube ranges from about 20 centimeters to about 200 centimeters, and

wherein the medical device is selected from the group consisting of diagnostic catheter, drainage catheter, guiding catheter, therapeutic catheter, introducer sheath, vessel dilator, stent, and tracheostomy tube.

17. The method according to claim 16, wherein the secondary operations comprise bonding operations.

18. The method according to claim 16, wherein the secondary operations comprise forming operations.