Systems and methods for applying an antimicrobial coating to a medical device

Abstract

Methods for applying an antimicrobial coating to a medical device is disclosed. Generally, the methods comprise providing a medical device, dispensing an antimicrobial coating onto the device, flushing excess coating from the device, and curing the coating onto the device. In one aspect, the coating includes a UV-curable, antimicrobial composition. In this aspect, the medical device can be coated and the coating can be cured with UV light in a manner of seconds. In another aspect, the coating includes an antimicrobial solution that contains an acrylate-type polymer or copolymer. In this aspect, the medical device can be coated and the coating can be heat-cured in a manner of minutes. Both the UV-curable composition and the antimicrobial solution can also include rheological modifiers, as necessary. Additionally, the compositions include one or more antimicrobial agents, which may be selected from a wide array of agents.

1 . A method for applying an antimicrobial coating to a medical device, the method comprising:
 providing a first medical device;   dispensing an antimicrobial coating onto the first device, wherein the coating is selected from:
 a) a UV-curable, antimicrobial composition, and 
 b) an antimicrobial solution comprising an acrylate polymer or copolymer; 
   flushing an excess amount of the coating from the first device; and   curing the coating.   
     
     
         2 . The method of  claim 1 , wherein the UV-curable composition comprises:
 a photoinitiator;   an oligomer;   a monomer;   a Theological modifier; and   an antimicrobial agent.   
     
     
         3 . The method of  claim 2 , wherein the photoinitiator is selected from the group consisting of benzoin ether, acetophenone, benzoyl oxime, acyl phosphine oxide, Michler's ketone, thioxanthone, anthroguionone, benzophenone, methyl diethanol amine, 2-N-butoxyethyl-4-(dimethylamino) benzoate, and combinations thereof. 
     
     
         4 . The method of  claim 2 , wherein the oligomer is selected from an acrylated aliphatic urethane, an acrylated aromatic urethane, an acrylated polyester, an unsaturated polyester, an acrylated polyether, an acrylated acrylic, and combinations thereof. 
     
     
         5 . The method of  claim 2 , wherein the monomer is selected from the group consisting of 2-ethyl hexyl acrylate, isooctyl acrylate, isobomylacrylate, 1,6-hexanediol diacrylate, diethylene glycol diacrylate, triethylene glycol diacrylate, pentaerythritol tetra acrylate, penta erythritol tri acrylate, dimethoxy phenyl acetophenone hexyl methyl acrylate, 1,6 hexanidiol methacrylate, and combinations thereof. 
     
     
         6 . The method of  claim 1 , wherein the antimicrobial solution further comprises:
 a solvent selected from an alcohol having from 1 to 6 carbons, an alkane having from 1 to 6 carbons, acetone, and combinations thereof;   a rheological modifier; and   an antimicrobial agent.   
     
     
         7 . The method of  claim 6 , wherein the acrylate polymer or copolymer is selected from the group consisting of an alkyl acrylate, an alkyl methacrylate, an alkyl hydroxyl (meth) acrylate, an alkyl methoxycinnamate, and combinations thereof. 
     
     
         8 . The method of claim,  1  wherein the flushing of the excess coating comprises blowing the excess coating from the device with a pressurized, inert gas. 
     
     
         9 . The method of  claim 8 , wherein the excess coating is recycled and dispensed onto a second medical device. 
     
     
         10 . The method of  claim 1 , wherein the curing of the coating comprises exposing the first device having the UV-curable composition disposed thereon to UV light. 
     
     
         11 . The method of  claim 1 , wherein the curing comprises exposing the first device having the antimicrobial solution to heat. 
     
     
         12 . A method for applying an antimicrobial coating to a medical device, the method comprising:
 providing a medical device;   dispensing a UV-curable, antimicrobial composition onto the medical device, wherein the coating comprises an oligomer, a monomer, a photoinitiator, a Theological modifier, and an antimicrobial agent;   flushing an excess amount of the composition from the device; and   curing the composition by exposing the composition to UV light.   
     
     
         13 . The method of  claim 12 , wherein the dispensing, flushing, and curing of the composition is completed in less than about 30 seconds. 
     
     
         14 . The method of  claim 12 , wherein the dispensing, the flushing, and the curing of the composition is completed in less than about 10 seconds. 
     
     
         15 . A method for applying an antimicrobial coating to a medical device, the method comprising:
 providing a medical device;   dispensing an antimicrobial solution onto the medical device;   flushing an excess amount of the composition from the device; and   curing the composition with a heat source,   wherein the antimicrobial solution comprises an acrylate polymer or acrylate copolymer.   
     
     
         16 . The method of  claim 15 , wherein the antimicrobial solution further comprises a solvent selected from an alcohol having from 1 to 6 carbons, an alkane having from 1 to 6 carbons, acetone, and combinations thereof. 
     
     
         17 . The method of  claim 15 , wherein the antimicrobial solution further comprises a Theological modifier and an antimicrobial agent. 
     
     
         18 . The method of  claim 15 , wherein the dispensing, flushing, and curing of the composition are completed in less than about 10 minutes. 
     
     
         19 . The method of  claim 15 , wherein the dispensing, flushing, and curing of the composition are completed in less than about 5 minutes. 
     
     
         20 . The method of  claim 17 , wherein the antimicrobial agent is selected from cetyl pyridium chloride, cetrimide, benzalkonium chloride, alexidine, chlorhexidine diacetate, phthalaldehyde, and combinations thereof.