UHMWPE dip-coated tubes
The disclosure provides tubes comprising ultra high molecular weight poly(ethylene) (UHMWPE). Such tubes can have thin walls and be suitable for applications, e.g., as catheter liners. Methods for preparing such tubes include dip coating a core into a dispersion comprising the UHMWPE, where the dispersion advantageously further comprises an eco-friendly solvent and can optionally include one or more additional components (e.g., fillers and/or other polymers).
1 . An Ultra High Molecular Weight Polyethylene (UHMWPE) tube,
wherein the tube comprises distinct, partially fused UHMWPE particles,
wherein the tube exhibits:
a. an average wall thickness of 0.004″ or less; and
b. a tensile stress at break greater than 6 MPa, and
wherein the tube is formed by dip coating such that the tube exhibits little to no machine direction molecular orientation.
2 . The UHMWPE tube of claim 1 , wherein at least about 50% by weight of the tube comprises the UHMWPE.
3 . The UHMWPE tube of claim 1 , further comprising high density polyethylene (HDPE) and/or low density polyethylene (LDPE) in amounts of less than about 50% by weight, based on a total weight of the UHMWPE tube.
4 . The UHMWPE tube of claim 1 , further comprising one or more particulate fillers in amounts of less than about 50% by weight, based on a total weight of the UHMWPE tube.
5 . The UHMWPE tube of claim 1 , wherein the UHMWPE tube comprises no solvent.
6 . The UHMWPE tube of claim 1 , wherein the average wall thickness is 0.0002″ to 0.002″.
7 . The UHMWPE tube of claim 1 , wherein the UHMWPE tube exhibits a change in storage modulus between 23° C. and 37° C. of 10 MPa/° C. or less.
8 . The UHMWPE tube of claim 1 , wherein the UHMWPE tube has an abrasion-resistant inner surface.
9 . The UHMWPE tube of claim 1 , wherein the UHMWPE tube has a lubricious inner surface with a coefficient of friction less than 0.2.
10 . A catheter comprising the UHMWPE tube of claim 1 .
11 . The catheter of claim 10 , wherein the catheter is sterilized.
12 . The UHMWPE tube of claim 1 , wherein the UHMWPE tube is porous.
13 . A coated core, comprising a continuous Ultra High Molecular Weight Polyethylene (UHMWPE) layer in the form of a tube over a core,
wherein the UHMWPE layer comprises distinct, partially fused UHMWPE particles,
wherein the UHMWPE layer has an average thickness of about 0.002″ or less, and an average tensile stress at break greater than 6 MPa, when measured after removal from the core, and
wherein the UHMWPE layer is formed by dip coating such that the UHMWPE layer exhibits little to no machine direction molecular orientation.
14 . The coated core of claim 13 , wherein the core and UHMWPE layer are both substantially cylindrical in shape.
15 . The coated core of claim 13 , having a minimum continuous length of 50 ft.
16 . The coated core of claim 13 , wherein the core has a contact angle of less than 120 degrees.
17 . The coated core of claim 13 , wherein the core has a contact angle of less than 100 degrees.
18 . The coated core of claim 13 , wherein the UHMWPE layer exhibits a change in storage modulus between 23° C. and 37° C. of 10 MPa/° C. or less.
19 . An Ultra High Molecular Weight Polyethylene (UHMWPE) catheter liner, the catheter liner in the form of a tube exhibiting:
a. an average wall thickness of 0.004″ or less; and
b. a tensile stress at break greater than 6 MPa,
wherein the UHMWPE catheter liner comprises distinct, partially fused UHMWPE particles, and
wherein the UMHWPE catheter liner is formed by dip coating such that the tube exhibits little to no machine direction molecular orientation.
20 . The UHMWPE catheter liner of claim 19 , wherein the UHMWPE catheter liner is porous.