Gels having permanent tack free coatings and method of manufacture

• US 9,642,608 B2
• Filed: 07/16/2015
• Issued: 05/09/2017
• Est. Priority Date: 07/18/2014
• Status: Active Grant

• Current Assignee: Applied Medical Resources Corporation (Applied Medical Corporation)
• Original Assignee: Applied Medical Resources Corporation (Applied Medical Corporation)
• Inventors: Bolanos, Eduardo, Bui, Dennis, Pravong, Boun, Pinel, Carlos, Chehayeb, Sam
• Primary Examiner(s): Philogene, Pedro
• Assistant Examiner(s): Comstock, David C
• Application Number:
  US14/801,553
• Publication Number:
  US 20160015425A1
• Time in Patent Office: 663 Days
• Field of Search: 600201-246, 606119, 128846, 128856, 2491141, 249115
• CPC Class Codes: A61B 17/0293 with ring member to support retractor elements
• CPC Class Codes: A61B 17/3423 Access ports, e.g. toroid shape introducers for instruments or hands access sites for liquids A61M39/0247
• CPC Class Codes: A61B 17/3462 with means for changing the diameter or the orientation of the entrance port of the cannula, e.g. for use with different-sized instruments, reduction ports, adapter seals expandable cannulas A61B17/3417
• CPC Class Codes: A61B 2017/3492 against the outside of the body
• CPC Class Codes: A61L 31/048 obtained by reactions only involving carbon-to-carbon unsaturated bonds A61L31/041 takes precedence
• CPC Class Codes: A61L 31/145 Hydrogels or hydrocolloids
• CPC Class Codes: B29C 33/56 Coatings , e.g. enameled or galvanised; Releasing, lubricating or separating agents in-mould coating B29C37/0028; using or applying separating agents B29C37/0067
• CPC Class Codes: B29C 33/62 based on polymers or oligomers
• CPC Class Codes: B29C 39/02 for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 45/1679 applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC] applying suface layers after ejection B29C45/0053
• CPC Class Codes: B29C 45/73 of the mould B29C45/2642 and B29C45/2737 take precedence
• CPC Class Codes: B29K 2025/08 Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene B29K2055/02 takes precedence
• CPC Class Codes: B29K 2995/0037 Other properties
• CPC Class Codes: B29L 2009/005 coated
• CPC Class Codes: C08L 53/02 of vinyl-aromatic monomers and conjugated dienes

Abstract

The present invention is directed to tack-free gels and to methods for manufacturing a tack-free gel pad, in which a discontinuous layer of fluorinated ultrahigh molecular weight polyethylene is permanently bonded to the gel pad to provide a tack-free coating. The gel pad may be incorporated into a gel cap to provide a surgical access device having a tack-free surface.

Claims

1. A method for making a tack-free gel, comprising the steps of:

providing a mold;

applying a fluorinated ultrahigh molecular weight polyethylene to the mold;

heating a gel slurry beyond its curing temperature to a molten state, to thereby produce a molten gel;

injecting the molten gel into the mold; and

cooling the mold until the gel is set to thereby produce a tack-free gel.

2. The method of claim 1, wherein the mold is textured prior to applying the fluorinated ultrahigh molecular weight polyethylene by spraying the mold with blast media.

3. The method of claim 1, wherein the mold is preheated to a temperature of approximately 220°

F. to approximately 260°

F. prior to applying the fluorinated ultrahigh molecular weight polyethylene.

4. The method of claim 1, wherein the fluorinated ultrahigh molecular weight polyethylene is applied to the mold by electrostatic coating.

5. The method of claim 1, wherein the fluorinated ultrahigh molecular weight polyethylene comprises a powder having a particle size of approximately 5 μ

m to approximately 100 μ

m.

6. The method of claim 1, wherein the mold is preheated to a temperature of approximately 110°

F. to approximately 160°

F. prior to injecting the molten gel.

7. The method of claim 1, wherein the gel slurry comprises an oil and an elastomer.

8. The method of claim 7, wherein the gel slurry comprises a ratio by weight of oil to elastomer from approximately 7:

1 to approximately 10;

1.

9. The method of claim 7, wherein the oil comprises a mineral oil and the elastomer comprises block copolymer styrene-ethylene/butylene-styrene polymer.

10. The method of claim 1, wherein the gel slurry is bulk degassed prior to heating the gel slurry to a molten state.

11. The method of claim 10, wherein the gel slurry is bulk degassed at a temperature of approximately 120°

F. to approximately 130°

F.

12. A method for making a tack-free gel, comprising the steps of:

providing a mold;

applying a fluorinated ultrahigh molecular weight polyethylene to the mold;

preheating the mold to a temperature of approximately 110°

F. to approximately 160°

F.;

heating a gel slurry to a temperature of approximately 125°

F.;

degassing the gel slurry;

dispensing the gel slurry into the mold;

degassing the gel slurry a second time; and

curing the gel in the mold at a temperature of approximately 140°

F. to approximately 160°

F. to provide a tack-free gel.

13. The method of claim 12, wherein the mold is textured prior to applying the fluorinated ultrahigh molecular weight polyethylene by spraying the mold with blast media.

14. The method of claim 12, wherein the gel slurry comprises an oil and an elastomer.

15. The method of claim 14, wherein the oil comprises a mineral oil and the elastomer comprises styrene-ethylene/butylene-styrene polymer.

16. A method for making a tack-free gel, comprising the steps of:

providing a mold;

spraying the mold with a polyethylene spray;

heating a gel slurry beyond its curing temperature to a molten state, to thereby produce a molten gel;

dispensing the molten gel into the mold; and

cooling the mold until the gel is set to thereby produce a tack-free gel.