US 6,017,577 AGranted

Slippery, tenaciously adhering hydrophilic polyurethane hydrogel coatings, coated polymer substrate materials, and coated medical devices

AssigneeSchneider (USA) Inc.

InventorsFritz Hostettler, David Rhum, Michael R. Forman, Michael N. Helmus, Ni Ding

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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.

Claims36

Dependent claims

A process for producing a material bearing thereon a coating of a lubricious, hydrated hydrophilic polyurethane-urea hydrogel, said process comprising the steps of:

a) making a surface of a hydrophilic or hydrophilicized hydrophobic polymer substrate reactive by affixing reactive chemical functional groups thereto, at least a portion of which are amine groups;
b) coating a reactive polymer substrate surface which results from step (a) with a first coating comprising a hydrophilic polyurethane prepolymer intermediate, containing terminal isocyanate groups, such that a first 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 urea bonds therewith, resulting in the formation of a tie coat of a polyurethane-urea hydrogel-forming polymer, on said substrate surface, that adheres to said substrate surface, and wherein a second portion of said terminal isocyanate groups of said polyurethane prepolymer intermediate are present in said polyurethane-urea hydrogel-forming polymer such that they remain free to react with other species;
and
c) coating the tie coat which results from step (b) with a second coating comprising a moisture-containing, hydrogel-forming compound or mixture, which contains isocyanate-reactive functional groups;
whereby said isocyanate-reactive functional groups of said hydrogel-forming compound or mixture react with at least a portion of said second portion terminal isocyanate groups of said polyurethane-urea hydrogel-forming polymer;
and whereby said moisture of said hydrogel-forming compound or mixture hydrates said polyurethane-urea hydrogel-forming polymer of said tie coat.

3 more elements

A process for producing a sterilized coating of a reactivatable, dried, hydrophilic polyurethane-polyurea hydrogel, on the surface of a medical device fabricated from a polymeric substrate, said process comprising the steps of:

a) making at least a portion of an outer surface of said polymeric substrate from which said medical device is fabricated, chemically reactive by affixing reactive chemical functional groups thereto, at least a portion of which are amine groups;
b) coating the resulting reactive outer surface of said substrate with a first coating comprising a hydrophilic polyurethane-urea prepolymer intermediate, which contains terminal isocyanate groups, such that a first 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 urea bonds therewith, resulting in the formation of a tie coat of a polyurethane-urea hydrogel-forming polymer, that adheres to said reactive outer surface of said substrate, and wherein a second portion of said terminal isocyanate groups of said polyurethane-urea prepolymer intermediate are present in said polyurethane-urea 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,
whereby said isocyanate-reactive functional groups of said hydrogel-forming compound or mixture react with at least a portion of said second portion terminal isocyanate groups of said polyurethane-urea hydrogel-forming polymer, and
whereby said moisture of said hydrogel-forming compound or mixture hydrates said polyurethane-urea hydrogel-forming polymer of said tie coat;
d) drying said hydrated, hydrophilic polyurethane-urea 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).

5 more elements

Dependencies are inferred from the claim text.