System and method for coating medical devices
One aspect of the present disclosure can include a method for grafting a coating polymer onto a surface of a device. The method can include the following steps: a) submerging the device into a photoinitiator solution; b) without first drying the device, submerging the device into a polymerizable solution; c) bubbling an oxygen-scavenging gas through the polymerizable solution; d) applying a UV light to the device to activate the photoinitiator, thereby grafting the coating polymer onto the device; and e) drying the device.
1. A method for grafting a coating polymer onto a surface of a device, the method comprising:
a) submerging said device into a photoinitiator solution in a first tank in the absence of monomer;
b) without first drying said device, submerging said device into a polymerizable solution in a second tank;
c) bubbling an oxygen-scavenging gas through said polymerizable solution;
d) applying a UV light to said device to activate said photoinitiator, thereby grafting said coating polymer onto said surface; and
e) drying said device,
wherein UV light is applied to the device only when the device is submerged into the second tank.
2. The method of claim 1 , wherein said device is submerged in said photoinitiator solution for from about 20 seconds to about 15 minutes.
3. The method of claim 1 , wherein said device is submerged in said polymerizable solution for from about 2 minutes to about 20 minutes.
4. The method of claim 1 , wherein bubbling said gas occurs prior to applying said UV light.
5. The method of claim 1 , wherein bubbling said gas occurs simultaneously with applying said UV light.
6. The method of claim 1 , wherein said device is dried for about 12 hours.
7. The method of claim 1 , further comprising submerging said device into a surface oxidation solution prior to submerging said device in said photoinitiator solution.
8. The method of claim 7 , wherein said device is submerged in said surface oxidation solution for from about 5 minutes to about 60 minutes at a temperature of from about 20° C. to about 90° C.
9. The method of claim 1 , further comprising submerging said device into a first wash solution prior to drying said device.
10. The method of claim 9 , wherein said device is submerged in said first wash solution for from about 5 to about 30 minutes.
11. The method of claim 1 , further comprising submerging said device into a first alkaline solution prior to drying said device.
12. The method of claim 11 , wherein said device is submerged in said first alkaline solution for from about 10 to about 15 minutes at a temperature from about 30° C. to about 70° C.
13. The method of claim 1 , further comprising submerging said device into an antimicrobial solution prior to drying said device.
14. The method of claim 13 , wherein said device is submerged in said antimicrobial solution for from about 1 minute to about 10 minutes.
15. The method of claim 1 , further comprising submerging said device into a second alkaline solution prior to drying said device.
16. The method of claim 15 , wherein said device is submerged in said second alkaline solution for from about 10 to about 15 minutes.
17. The method of claim 1 , further comprising submerging said device into a second wash solution prior to drying said device.
18. The method of claim 17 , wherein said device is submerged in said wash solution for from about 5 to about 20 minutes.
19. The method of claim 1 , comprising:
f) submerging said device into a surface oxidation solution;
g) submerging said device into said photoinitiator solution;
h) without first drying said device, submerging said device into said polymerizable solution;
i) bubbling said oxygen-scavenging gas through said polymerizable solution;
j) applying said UV light to said device to activate said photoinitiator, thereby grafting said coating polymer onto said surface; f) submerging said device into a first wash solution;
k) submerging said device into a first alkaline solution;
l) submerging said device into an antimicrobial solution;
m) submerging said device into a second alkaline solution;
n) submerging said device into a second wash solution; and
o) drying said device.
20. The method of claim 1 , further comprising packaging said device.
21. The method of claim 1 , further comprising sterilizing said device.
22. The method of claim 1 , wherein said device is disposed on a rail for submerging said device into each of said solutions.
23. The method of claim 1 , wherein said method is fully automated, semi-automated, or manual.
24. The method of claim 23 , wherein said method is fully automated.
25. The method of claim 1 , wherein said method is under the control of a computer.
26. The method of claim 1 , wherein the photoinitiator solution comprises a perester photoinitiator.
27. The method of claim 1 , wherein the device is formed from polytetrafluorethylene, polyetheretherketones, polyoxymethylene, or silicone materials.
28. The method of claim 1 , comprising grafting a coating polymer onto a surface of a plurality of devices simultaneously.