Medical device and method for producing medical device
A medical device including a lubricating coating film (surface lubricating layer) that exerts excellent lubricity and durability is provided. The medical device includes, on a base layer, a surface lubricating layer formed from a block copolymer having a hydrophilic portion and a hydrophobic portion that has a reactive functional group. The ratio of the hydrophobic portion of the block copolymer in an outermost surface of the surface lubricating layer is 20 to 45 mol %, and the viscosity of a 1 wt % chloroform solution of the block copolymer at a temperature of 30° C. is 8 to 30 mPa·s.
1. A medical device comprising, on a base layer, a surface lubricating layer formed from a block copolymer having a hydrophilic portion and a hydrophobic portion that has a reactive functional group, wherein
the ratio of the hydrophobic portion of the block copolymer in an outermost surface of the surface lubricating layer being 20 to 45 mol %, and
the viscosity of a 1 wt % chloroform solution of the block copolymer at a temperature of 30° C. being 8 to 30 mPa·s.
2. The medical device according to claim 1 , wherein the ratio between the hydrophilic portion and the hydrophobic portion that has a reactive functional group of the block copolymer used to form the surface lubricating layer is within a range of 20:1 to 50:1.
3. The medical device according to claim 2 , wherein the hydrophilic portion is derived from at least one member selected from the group consisting of acrylic acid, methacrylic acid, N-methylacrylamide, N,N-dimethylacrylamide, acrylamide, acryloylmorpholine, N,N-dimethylamino ethyl acrylate, vinylpyrrolidone, 2-methacryloyloxyethyl phosphorylcholine, 2-methacryloyloxyethyl-D-glycoside, 2-methacryloyloxyethyl-D-mannoside, vinyl methyl ether, 2-hydroxyethyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, 6-hydroxyhexyl (meth)acrylate, 1,4-cyclohexanedimethanol mono(meth)acrylate, 1-chloro-2-hydroxypropyl (meth)acrylate, diethylene glycol mono(meth)acrylate, 1,6-hexanediol mono(meth)acrylate, pentaerythritol tri(meth)acrylate, dipentaerythritol penta(meth)acrylate, neopentyl glycol mono(meth)acrylate, trimethylolpropane di(meth)acrylate, trimethylolethane di(meth)acrylate, 2-hydroxy-3-phenoxypropyl (meth)acrylate, 2-hydroxycyclohexyl (meth)acrylate, 4-hydroxycyclohexyl (meth)acrylate, cyclohexanedimethanol mono(meth)acrylate, poly(ethylene glycol) methyl ether acrylate, and poly(ethylene glycol) methyl ether methacrylate.
4. The medical device according to claim 1 , wherein the hydrophilic portion is derived from at least one member selected from the group consisting of acrylic acid, methacrylic acid, N-methylacrylamide, N,N-dimethylacrylamide, acrylamide, acryloylmorpholine, N,N-dimethylamino ethyl acrylate, vinylpyrrolidone, 2-methacryloyloxyethyl phosphorylcholine, 2-methacryloyloxyethyl-D-glycoside, 2-methacryloyloxyethyl-D-mannoside, vinyl methyl ether, 2-hydroxyethyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, 6-hydroxyhexyl (meth)acrylate, 1,4-cyclohexanedimethanol mono(meth)acrylate, 1-chloro-2-hydroxypropyl (meth)acrylate, diethylene glycol mono(meth)acrylate, 1,6-hexanediol mono(meth)acrylate, pentaerythritol tri(meth)acrylate, dipentaerythritol penta(meth)acrylate, neopentyl glycol mono(meth)acrylate, trimethylolpropane di(meth)acrylate, trimethylolethane di(meth)acrylate, 2-hydroxy-3-phenoxypropyl (meth)acrylate, 2-hydroxycyclohexyl (meth)acrylate, 4-hydroxycyclohexyl (meth)acrylate, cyclohexanedimethanol mono(meth)acrylate, poly(ethylene glycol) methyl ether acrylate, and poly(ethylene glycol) methyl ether methacrylate.
5. The medical device according to claim 4 , wherein the hydrophobic portion is derived from at least one member selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, acryloyloxymethyl isocyanate, acryloyloxyethyl isocyanate, methacryloyloxy methyl isocyanate, methacryloyloxy ethyl isocyanate, crotonaldehyde, acrolein, and methacrolein.
6. The medical device according to claim 3 , wherein the hydrophobic portion is derived from at least one member selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, acryloyloxymethyl isocyanate, acryloyloxyethyl isocyanate, methacryloyloxy methyl isocyanate, methacryloyloxy ethyl isocyanate, crotonaldehyde, acrolein, and methacrolein.
7. The medical device according to claim 2 , wherein the hydrophobic portion is derived from at least one member selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, acryloyloxymethyl isocyanate, acryloyloxyethyl isocyanate, methacryloyloxy methyl isocyanate, methacryloyloxy ethyl isocyanate, crotonaldehyde, acrolein, and methacrolein.
8. The medical device according to claim 1 , wherein the hydrophobic portion is derived from at least one member selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, allyl glycidyl ether, acryloyloxymethyl isocyanate, acryloyloxyethyl isocyanate, methacryloyloxy methyl isocyanate, methacryloyloxy ethyl isocyanate, crotonaldehyde, acrolein, and methacrolein.
9. The medical device according to claim 1 , wherein the ratio between the hydrophilic portion and the hydrophobic portion that has a reactive functional group of the block copolymer used to form the surface lubricating layer is within a range of 25:1 to 45:1.
10. The medical device according to claim 1 , wherein the ratio between the hydrophilic portion and the hydrophobic portion that has a reactive functional group of the block copolymer used to form the surface lubricating layer is within a range of 30:1 to 45:1.
11. The medical device according to claim 1 , wherein the viscosity of a 1 wt % chloroform solution of the block copolymer at a temperature of 30° C. is 8 to 27 mPa·s.
12. The medical device according to claim 1 , wherein the viscosity of a 1 wt % chloroform solution of the block copolymer at a temperature of 30° C. is 13 to 21 mPa·s.
13. A method for producing a medical device, comprising:
polymerizing a compound including a hydrophilic portion and a compound including a hydrophobic portion that has a reactive functional group in a molar ratio of 20:1 to 50:1 to give a block copolymer whose 1 wt % chloroform solution has a viscosity of 8 to 30 mPa·s at a temperature of 30° C.;
preparing a coating liquid containing the block copolymer; and
applying the coating liquid onto a base layer, followed by a heating treatment at a temperature within a range of 60 to 200° C., thereby forming a surface lubricating layer having an outermost surface in which the ratio of the hydrophobic portion of the block copolymer is 20 to 45 mol %.
14. The method for producing a medical device according to claim 13 , wherein the polymerization temperature is 50 to 100° C.
15. The method for producing a medical device according to claim 13 , wherein the polymerization temperature is 60 to 85° C.
16. The method for producing a medical device according to claim 13 , wherein the molar ratio of the compound including a hydrophilic portion to the compound including a hydrophobic portion is 20:1 to 50:1.
17. The method for producing a medical device according to claim 13 , wherein the concentration of the block copolymer in the coating liquid is 0.01 to 20 wt %.
18. The method for producing a medical device according to claim 13 , wherein the heating treatment temperature is 80 to 160° C.
19. The method for producing a medical device according to claim 13 , wherein the heating treatment temperature is 90 to 140° C.
20. The method for producing a medical device according to claim 13 , wherein the heating treatment time is 1 to 10 hours.
21. The medical device according to claim 1 , wherein the hydrophobic portion is condensed near an outermost surface of the surface lubricating layer.