Method of making blood gas sensors overcoats using permeable polymeric compositions

A method for making a coated blood gas sensor, the method comprising:

• (a) preparing a crosslinkable composition comprising a hydrophobic portion and a hydrophilic portion, wherein the hydrophobic portion of the crosslinkable composition comprises a hydrophobic polymeric material;
• (b) placing the crosslinkable composition and a portion of the sensor in a mold;
• (c) gelling the crosslinkable composition to form a shaped gelled composition comprising a hydrophobic portion, a hydrophilic portion, and a liquid portion;
• and
• (d) exchanging the liquid portion with an exchange liquid to form a shaped permeable polymeric material coated on the sensor having a tensile strength, when fully hydrated, of at least about 650 psi (4482 kPa).

A method for making a shaped permeable polymeric material, the method comprising:

• (a) preparing a crosslinkable composition comprising a hydrophobic polymeric material, a hydrophilic monomeric material, and an organic solvent, wherein the hydrophobic polymeric material is selected from the group consisting of a polysulfone, a polyethersulfone, a polyarylsulfone, a polyimide, a polyarylate, a cellulose acetate, a polyurethane, a polycarbonate, a polyester carbonate, a phenoxy resin, a polyether imide, a cellulose acetate butyrate, a nylon, a polyvinyl butyral, a polyarylene oxide, a poly(urea urethane), a polyphenyl quinoxaline, and mixtures thereof;
• (b) placing the crosslinkable composition in a mold;
• (c) gelling the crosslinkable composition to form a shaped gelled composition comprising a hydrophobic portion, a hydrophilic portion, and a liquid portion;
• and
• (d) exchanging the liquid portion with an exchange liquid to form a shaped permeable polymeric material having a tensile strength, when fully hydrated, of at least about 525 psi (3620 kPa).

A method for making a shaped permeable polymeric material, the method comprising:

• (a) preparing a crosslinkable composition comprising a hydrophobic portion and a hydrophilic portion, wherein the hydrophobic portion is a polymeric material selected from the group consisting of a polysulfone, a polyethersulfone, a polyarylsulfone, a polyimide, a polyarylate, a cellulose acetate, a polyurethane, a polycarbonate, a polyester carbonate, a phenoxy resin, a polyether imide, a cellulose acetate butyrate, a nylon, a polyvinyl butyral, a polyarylene oxide, a poly(urea urethane), a polyphenyl quinoxaline, and mixtures thereof;
• (b) placing the crosslinkable composition in a mold;
• (c) gelling the crosslinkable composition to form a shaped gelled composition comprising a hydrophobic portion, a hydrophilic portion, and a liquid portion;
• (d) evaporating the liquid portion;
• and
• (e) adding an exchange liquid to form a shaped permeable polymeric material having a tensile strength, when fully hydrated, of at least about 525 psi.

A method for making a coated blood gas sensor, the method comprising:

• (a) preparing a crosslinkable composition comprising a hydrophobic portion and a hydrophilic portion;
• (b) placing the crosslinkable composition and a portion of the sensor in a mold;
• (c) gelling the crosslinkable composition to form a shaped gelled composition comprising a hydrophobic portion, a hydrophilic portion, and a liquid portion;
• and
• (d) exchanging the liquid portion with an exchange liquid to form a shaped permeable polymeric material coated on the sensor having a tensile strength, when fully hydrated, of at least about 525 psi.

A method for making a coated blood gas sensor, the method comprising:

• (a) preparing a crosslinkable composition comprising a hydrophobic portion selected from the group consisting of a polysulfone, a polyethersulfone, a polyarylsulfone, a polyimide, a polyarylate, a cellulose acetate, a polyurethane, a polycarbonate, a polyester carbonate, a phenoxy resin, a silicone, a polyether imide, a cellulose acetate butyrate, a nylon, a polyvinyl butyral, a polyarylene oxide, a poly(urea urethane), a polyphenyl quinoxaline, and mixtures thereof, and a hydrophilic portion selected from the group consisting of N-vinyl pyrrolidone, N,N-dimethyl acrylamide, N-vinyl-N-methyl acetamide, N-vinyl valerolactam, N-vinyl caprolactam, acrylamide, acrylic acid, hydroxy ethyl acrylate, hydroxy ethyl methacrylate, poly(ethylene glycol) methyl ether acrylate, and mixtures or copolymers thereof;
• (b) placing the crosslinkable composition and a portion of the sensor in a mold;
• (c) gelling the crosslinkable composition to form a shaped gelled composition comprising a hydrophobic portion, a hydrophilic portion, and a liquid portion;
• and
• (d) exchanging the liquid portion with an exchange liquid to form a shaped permeable polymeric material coated on the blood gas sensor.