Pecvd coated pharmaceutical package, coating process and apparatus

Abstract

An article is described including an article surface, a primer coating of SiOx, SiO x C y or SiN x C y applied to the article surface, and optionally a deposit of lubricant applied to the primer coating or layer. The primer coating of SiO x , SiO x C y or SiN x C y is applied by PECVD of an organosiloxane precursor. A deposit of lubricant is applied to the primer coating or layer. The primer coating improves the adhesion or wetting of the lubricant on the surface to be lubricated, as well as the recovery of the liquid contained in the vessel. Examples of such an article are a prefilled syringe having a barrel with a lubricated interior portion and a plunger tip that slides along it. Another example of such an article is a vial having a lubricated opening to receive a septum. Another aspect of the invention is a method of making such an article.

1 . A vessel having a lumen defined at least in part by a wall, the wall having an interior surface facing the lumen, an outer surface, and a coating set on the interior surface comprising:
 a plasma enhanced chemical vapor deposition (PECVD) primer coating or layer on the interior surface, in which the primer coating or layer consists essentially of SiO x C y , in which x is from about 0.5 to about 2.4 and y is from about 0.6 to about 3; and   optionally a barrier coating or layer between the primer coating or layer and the vessel wall, in which the barrier coating consists essentially of SiOx, in which x is from 1.5 to 2.9;   
       wherein, in the presence of a fluid composition contained in the lumen, the coating set presents a higher recovery rate for the fluid composition than an uncoated fluid contacting surface or a glass surface. 
     
     
         2 . The vessel of  claim 1 , wherein the fluid is an aqueous liquid. 
     
     
         3 . The vessel of  claim 1 , wherein the fluid is a high viscosity solution or a low viscosity solution. 
     
     
         4 . The vessel of  claim 1 , wherein the fluid contains a drug. 
     
     
         5 . The vessel of  claim 1 , wherein at least a portion of the wall of the vessel comprises a cyclic olefin polymer. 
     
     
         6 . The vessel of  claim 1 , wherein at least a portion of the wall of the vessel comprises glass. 
     
     
         7 . The vessel of  claim 1 , wherein the vessel is a syringe barrel, a vial, or a blister package. 
     
     
         8 . The vessel of  claim 1 , wherein the barrier coating or layer is from 4 nm to 500 nm thick. 
     
     
         9 . The vessel of  claim 1 , wherein the primer coating is applied by PECVD of a precursor feed comprising an acyclic siloxane, a monocyclic siloxane, a polycyclic siloxane, a polysilsesquioxane, a monocyclic silazane, a polycyclic silazane, a polysilsesquiazane, a silatrane, a silquasilatrane, a silproatrane, an azasilatrane, an azasilquasiatrane, an azasilproatrane, or a combination of any two or more of these precursors. 
     
     
         10 . The vessel of  claim 1 , wherein the primer coating or layer is between 10 and 1000 nm thick. 
     
     
         11 . The vessel of  claim 1 , further comprising an adhesion layer between the barrier coating or layer and the vessel wall. 
     
     
         12 . A vessel having a lumen defined at least in part by a wall, the wall having an interior surface facing the lumen, an outer surface, and a coating set on the interior surface comprising:
 a plasma enhanced chemical vapor deposition (PECVD) primer coating or layer on the interior surface, in which the primer coating or layer consists essentially of SiO x C y , in which x is from about 0.5 to about 2.4 and y is from about 0.6 to about 3; and   optionally a barrier coating or layer between the primer coating or layer and the vessel wall, in which the barrier coating consists essentially of SiOx, in which x is from 1.5 to 2.9;   
       wherein the coating set has a higher contact angle with water than an uncoated fluid contacting surface or a glass surface. 
     
     
         13 . The vessel of  claim 12 , wherein the primer coated surface has a contact angle (with distilled water) of from 0° C. to 35° C. greater than the contact angle (with distilled water) of the uncoated COP surface. 
     
     
         14 . The vessel of  claim 12 , wherein the primer coated surface has a contact angle (with distilled water) of from 0° C. to 20° C. greater than the contact angle (with distilled water) of the uncoated COP surface. 
     
     
         15 . The vessel of  claim 12 , wherein the primer coated surface has a contact angle (with distilled water) of at least 4° C. greater than the contact angle (with distilled water) of the uncoated COP surface. 
     
     
         16 . The vessel of  claim 12 , wherein the primer coated surface has a contact angle (with distilled water) of from 0° C. to 100° C. greater than the contact angle (with distilled water) of glass surface. 
     
     
         17 . The vessel of  claim 12 , wherein the primer coated surface has a contact angle (with distilled water) of from 0° C. to 80° C. greater than the contact angle (with distilled water) of glass surface. 
     
     
         18 . The vessel of  claim 12 , wherein the primer coated surface has a contact angle (with distilled water) of at least 70° C. greater than the contact angle (with distilled water) of glass surface. 
     
     
         19 . A vessel having a lumen defined at least in part by a wall, the wall having an interior surface facing the lumen, an outer surface, and a coating set on the interior surface comprising:
 a plasma enhanced chemical vapor deposition (PECVD) primer coating or layer on the interior surface, in which the primer coating or layer consists essentially of SiOxCy, in which x is from about 0.5 to about 2.4 and y is from about 0.6 to about 3;   optionally a barrier coating or layer between the primer coating or layer and the vessel wall, in which the barrier coating consists essentially of SiOx, in which x is from 1.5 to 2.9; and   a deposit of fluid lubricant on the PECVD treated surface; wherein the primer coated surface has a greater affinity for the fluid lubricant deposited thereon than an uncoated fluid contact surface or a glass surface.   
     
     
         20 . The vessel of  claim 19 , wherein the fluid lubricant comprises polydimethylsiloxane. 
     
     
         21 . The vessel of  claim 19 , wherein the deposit of fluid lubricant is formed on the PECVD treated surface by spraying a liquid lubricant. 
     
     
         22 . The vessel of  claim 19 , further comprising an adhesion layer between the barrier coating or layer and the vessel wall. 
     
     
         23 . The vessel of  claim 19 , wherein the vessel is a syringe having a barrel. 
     
     
         24 . The vessel of  claim 23 , wherein the syringe further comprises a plunger within the barrel. 
     
     
         25 . The vessel of  claim 24 , wherein at least a portion of the plunger comprises chlorobutyl rubber, bromobutyl rubber, silicone rubber, or a combination of any two or more of these. 
     
     
         26 . The vessel of  claim 24 , wherein the plunger has an outer sliding surface configured to slide within the inner surface of the lumen of the barrel. 
     
     
         27 . The vessel of  claim 26 , wherein the outer sliding surface is a PECVD treated surface. 
     
     
         28 . The vessel of  claim 19 , wherein at least a portion of the wall of the vessel comprises a cyclic olefin polymer. 
     
     
         29 . The vessel of  claim 19 , wherein the primer coating is applied by PECVD of a precursor feed comprising an acyclic siloxane, a monocyclic siloxane, a polycyclic siloxane, a polysilsesquioxane, a monocyclic silazane, a polycyclic silazane, a polysilsesquiazane, a silatrane, a silquasilatrane, a silproatrane, an azasilatrane, an azasilquasiatrane, an azasilproatrane, or a combination of any two or more of these precursors. 
     
     
         30 . The vessel of  claim 19 , wherein the primer coating or layer is between 10 and 1000 nm thick.