Solid state polymerized medical devices

Abstract

Device articles such as medical devices and parts thereof are thermoformed of a thermoplastic condensable polymer composition. After thermoforming the article is subjected to a solid state polymerization step.

1 . A device article thermoformed from a composition comprising a condensable thermoplastic polymer, wherein after thermoforming the article has been subjected to a solid state condensation polymerization reaction.  
     
     
         2 . An article as in  claim 1  wherein the device has been thermoformed by injection molding, extrusion or roto-molding.  
     
     
         3 . An article as in  claim 1  selected from the group consisting of tubing, bags, tube fittings, catheter proximal shafts, guide catheters, diagnostic catheters, catheter manifolds, syringe ports, syringe bodies, shafts, spoons, needles, valves, cell phone or lap-top computer housings or parts thereof, hinges and latches.  
     
     
         4 . A device article as in  claim 1  which is a medical device or component thereof.  
     
     
         5 . A device article as in  claim 1  wherein the condensable polymer is selected from the group consisting of polyesters; polyamides; polyurethanes; block copolymers incorporating a polyester, polyamide, polyurethane and/or polyether segment; polycarbonates; copolymers thereof; and blends thereof.  
     
     
         6 . A device article as in  claim 1  wherein the polymer composition further comprises a solid state polymerization catalyst.  
     
     
         7 . A device article as in  claim 1  having at least one thickness dimension of about 13 mm or less.  
     
     
         8 - 19 . (canceled)  
     
     
         20 . A medical device article formed from a thermoplastic polymer composition, the polymer composition comprising a condensable polymer and having a melt temperature, the device formed by a process comprising: 
 thermoforming the device article and    subsequently heating the device article at a temperature below the melt temperature of the polymer composition and at or above 120° C. under vacuum, dry inert gas flow or both.    
     
     
         21 . A medical device article as in  claim 20  wherein in said subsequently heating step the device is heated for a period of about 0.5 hours to about 72 hours at a temperature of at least 120° C. and at least 10° C. below the melting point of the polymer composition.  
     
     
         22 . A medical device article as in  claim 21  wherein said temperature is about 40° C. to about 70° C. below the melting point of the polymer composition.  
     
     
         23 . A medical device article as in  claim 21  wherein said temperature is between about 120° C. and 270° C.  
     
     
         24 . A medical device article as in  claim 21  wherein said condensable polymer includes at least one functional group selected from the group consisting of active hydrogen groups, ester, amine, ether and carboxylic acid groups.  
     
     
         25 . A medical device article as in  claim 20  wherein the device has been thermoformed by injection molding, extrusion or roto-molding.  
     
     
         26 . A medical device article as in  claim 20  selected from the group consisting of tubing, bags, tube fittings, catheter proximal shafts, guide catheters, diagnostic catheters, catheter manifolds, syringe ports, syringe bodies, shafts, spoons, needles, valves, cell phone or lap-top computer housings or parts thereof, hinges and latches.  
     
     
         27 . A medical device article as in  claim 20  wherein the condensable polymer is selected from the group consisting of polyesters; polyamides; polyurethanes; block copolymers incorporating a polyester, polyamide, polyurethane and/or polyether segment; polycarbonates; copolymers thereof; and blends thereof.  
     
     
         28 . A medical device article as in  claim 20  wherein the polymer composition further comprises a solid state polymerization catalyst.  
     
     
         29 . A medical device article as in  claim 20  having at least one thickness dimension of about 13 mm or less.