WO2009018029A2 - Articles having ceramic coated surfaces - Google Patents
Articles having ceramic coated surfaces Download PDFInfo
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- WO2009018029A2 WO2009018029A2 PCT/US2008/070822 US2008070822W WO2009018029A2 WO 2009018029 A2 WO2009018029 A2 WO 2009018029A2 US 2008070822 W US2008070822 W US 2008070822W WO 2009018029 A2 WO2009018029 A2 WO 2009018029A2
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- ceramic
- coating
- coated article
- shells
- substrate
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/04—Hollow or tubular parts of organs, e.g. bladders, tracheae, bronchi or bile ducts
- A61F2/06—Blood vessels
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
- A61L31/08—Materials for coatings
- A61L31/082—Inorganic materials
- A61L31/088—Other specific inorganic materials not covered by A61L31/084 or A61L31/086
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/1204—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
- C23C18/1208—Oxides, e.g. ceramics
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/125—Process of deposition of the inorganic material
- C23C18/1254—Sol or sol-gel processing
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/125—Process of deposition of the inorganic material
- C23C18/1262—Process of deposition of the inorganic material involving particles, e.g. carbon nanotubes [CNT], flakes
- C23C18/127—Preformed particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2400/00—Materials characterised by their function or physical properties
- A61L2400/12—Nanosized materials, e.g. nanofibres, nanoparticles, nanowires, nanotubes; Nanostructured surfaces
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24926—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including ceramic, glass, porcelain or quartz layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
Definitions
- the present invention relates to articles, including medical articles, which have ceramic coated surfaces.
- articles which comprise a substrate and a ceramic coating that covers at least a portion of the substrate surface.
- the ceramic coating includes raised ceramic shells connected by an underlying ceramic layer that is conformal with the substrate.
- the shells may be partially or completely filled, or they may be hollow.
- carbon nanotubes are provided, which comprise a ceramic coating covering at least a portion of the carbon nanotubes.
- Fig. IA is a schematic perspective view of a stent in accordance with the prior art.
- Fig. IB is a schematic cross-sectional view taken along line b-b of Fig. IA.
- FIGs. 2A and 2B are schematic cross sectional views of stent struts, in accordance with two embodiments of the present invention.
- Fig. 3A is a schematic cross-sectional view of an article with a ceramic coating, in accordance with an embodiment of the present invention.
- Figs. 3B and 3C are SEM images of ceramic coatings in accordance with the present invention.
- Figs. 4A and 4B are schematic cross-sectional views of articles with ceramic coatings, which are further comprise polymeric layers, in accordance with two embodiments of the present invention.
- Fig 4C is schematic cross-sectional view illustrating a process for forming a polymeric layer like that of Fig. 4B.
- FIGs. 5A-5G are schematic cross-sectional views illustrating articles with ceramic coatings, and processes for forming the same, in accordance with various embodiments of the present invention.
- FIGs. 6A and 6B are schematic cross-sectional views of articles in accordance with two embodiments of the present invention.
- FIGs. 7A-7H, 8A-8C and 9A-9D are schematic cross-sectional views illustrating articles in accordance with various embodiments of the present invention and processes for forming the same.
- Figs. lOA-lOC are schematic cross-sectional views illustrating a process for forming a ceramic coated carbon nanotube, in accordance with the present invention.
- Fig. 11 is an SEM image of a ceramic coating in accordance with an embodiment of the present invention.
- articles which comprise a substrate and a ceramic coating that covers at least a portion of the substrate surface.
- the ceramic coating includes raised ceramic shells connected by an underlying ceramic layer that is conformal with the substrate.
- the shells may partially or completely filled, or they may be hollow.
- the ceramic coating constitutes a single ceramic structure extending over the entire substrate surface.
- a "layer" of a given material is a region of that material whose thickness is smaller than both its length and width.
- the length and width may each be at least 5 times the thickness, for instance, independently ranging from 5 to 10 to 30 to 100 to 300 to 1000 or more times the thickness.
- a layer need not be planar, for example, taking on the contours of an underlying substrate.
- the ceramic shells described herein are layers.
- a layer can be discontinuous (e.g., patterned).
- a "ceramic" region for example, a ceramic layer or a ceramic shell, is a region of material that contains a single ceramic species or a mixture of two or more different ceramic species.
- a ceramic region in accordance with the invention will typically comprise, for example, from 10 wt% or less to 25 wt% to 50 wt% to 75 wt% to 90 wt% to 95 wt% to 95 wt% or more of one or more ceramic species.
- a ceramic region in accordance with the invention can thus comprise species other than ceramic species, for example, in some embodiments, comprising from 1 wt% or less to 2 wt% to 5 wt% to 10 wt% to 25 wt% to 50 wt% or more polymeric species.
- Ceramic species for use in ceramic regions include metal and semi-metal oxides, metal and semi-metal nitrides, and metal and semi-metal carbides, among others.
- metal and semi-metal oxides, nitrides and carbides include oxides nitrides and carbides of Periodic Table Group 14 semi-metals (e.g., Si, Ge), and oxides nitrides and carbides of transition and non-transition metals such as Group 3 metals (e.g., Sc, Y), Group 4 metals (e.g., Ti, Zr, Hf), Group 5 metals (e.g., V, Nb, Ta), Group 6 metals (e.g., Cr, Mo, W), Group 7 metals (e.g., Mn, Tc, Re), Group 8 metals (e.g., Fe, Ru, Os), Group 9 metals (e.g., Co, Rh, Ir), Group 10 metals (e.g., Ni, Pd, Pt), Group 11 metals (e.g., Cu, Ag, Au), Group 12 metals (e.g., Zn, Cd, Hg), Group 13 metals (e.g., Al,
- FIG. 3 A One example of an article in accordance with the invention is illustrated schematically in the cross-section of Fig. 3 A, in which is shown a substrate 310, covered with a ceramic coating 320 that includes raised ceramic shells 320s connected by a conformal ceramic layer 320c.
- the interiors 350 of the ceramic shells 320s are hollow as shown.
- the conformal ceramic layer 320c can be made very thin (e.g., 100 nm or less), and therefore able to readily deform (e.g., flex or bend) with the underlying substrate.
- the ceramic shells 320 can be evenly spaced (see Fig. 3) such that they do not engage each other during moderate bending/flexing.
- Fig. 3B is an SEM of a structure like that illustrated schematically in Fig. 3A.
- Fig. 3 C is an SEM of a single raised ceramic shell. It is broken, demonstrating that it is hollow. Differences in surface roughness from sample to sample may arise from several parameters, including roughness of the underlying substrate as well as processing variations.
- the ceramic layer covering the substrate and the ceramic shell of the spheres is one continuous structure, as schematically illustrated in Fig. 3A.
- the ceramic shells are spherical. However, as discussed further below, the ceramic shells can take on a near infinite range of shapes, depending on the template particles that are used to form the shells.
- the interiors ceramic shells are hollow. However, the interiors of the ceramic shells can be partially or wholly filled with a near infinite array of substances, including metals, polymers, ceramics and combinations (hybrids) of the foregoing, among other materials, depending upon the template particle that is used to form the shells, and upon whether or not the template particle is wholly or partially removed during processing.
- the ceramic shells may comprise carbon nanotubes (e.g., providing mechanical reinforcement, etc.), among many other possibilities.
- Coated articles include articles with ceramic coatings that are either provided with or without shell structures, and where shell structures are provided, which shell structures may be hollow or contain reinforcing particles (e.g., carbon nanotubes, etc.).
- Such coatings may be provided for various reasons, including corrosion resistance, wear resistance, optical properties, anti-viral and anti-bacterial properties (e.g., anatase TiOx coatings, etc.) and photoactive behavior, among others.
- Example of articles include the following: automobile components, including complete car frames, may be coated with ceramic layers, the inside of transport pipes for gas, oil, other aggressive chemical media, photocatalytic and photovoltaic articles (e.g., by forming photoactive ceramic coatings, such as anatase coatings, on polymer substrates), aerospace articles (e.g., exterior panels of planes, space shuttles, rockets, etc.,), metallic firearm components, windows (e.g., nanometer-thick coatings formed in accordance with the invention may act as reflective coatings, etc.), doorknobs and door handles, telephones, floor tiles, vinyl wall paper, plastic banknotes (e.g., such as those used in certain countries such as Australia), coins, furniture, including furniture found in public places, seats (e.g., in cars, trains and buses), railings including stairway railings and the rubber hand belts of escalators, polymer based children toys (including those used in schools, daycare, etc.), and keypads on ATM machines, among many other
- the coated articles are medical articles.
- Medical articles include articles for exterior application to the body such as patches for delivery of therapeutic agent to intact skin and broken skin (including wounds) and implantable or insertable devices, for example, stents (including coronary vascular stents, peripheral vascular stents, cerebral, urethral, ureteral, biliary, tracheal, gastrointestinal and esophageal stents), stent coverings, stent grafts, vascular grafts, abdominal aortic aneurysm (AAA) devices (e.g., AAA stents, AAA grafts), vascular access ports, dialysis ports, catheters (e.g., urological catheters or vascular catheters such as balloon catheters and various central venous catheters), guide wires, balloons, filters (e.g., vena cava filters and mesh filters for distil protection devices), embolization devices including cerebral aneurysm filler coil
- stents
- the devices of the present invention include, for example, implantable and insertable medical devices that are used for systemic treatment, as well as those that are used for the localized treatment of any tissue or organ of a subject.
- Non-limiting examples are tumors; organs including the heart, coronary and peripheral vascular system (referred to overall as “the vasculature"), the urogenital system, including kidneys, bladder, urethra, ureters, prostate, vagina, uterus and ovaries, eyes, ears, spine, nervous system, lungs, trachea, esophagus, intestines, stomach, brain, liver and pancreas, skeletal muscle, smooth muscle, breast, dermal tissue, cartilage, tooth and bone.
- the vasculature the urogenital system
- the urogenital system including kidneys, bladder, urethra, ureters, prostate, vagina, uterus and ovaries, eyes, ears, spine, nervous system, lungs, trachea, esophag
- treatment refers to the prevention of a disease or condition, the reduction or elimination of symptoms associated with a disease or condition, or the substantial or complete elimination of a disease or condition.
- Subjects include vertebrate subjects, for example, humans, livestock and pets.
- Medical devices of the present invention include a variety of implantable and insertable medical devices for insertion into and/or through a wide range of body lumens, several of which are recited above, including lumens of the cardiovascular system such as the heart, arteries (e.g., coronary, femoral, aorta, iliac, carotid and vertebrobasilar arteries) and veins, lumens of the genitourinary system such as the urethra (including prostatic urethra), bladder, ureters, vagina, uterus, spermatic and fallopian tubes, the nasolacrimal duct, the eustachian tube, lumens of the respiratory tract such as the trachea, bronchi, nasal passages and sinuses, lumens of the gastrointestinal tract such as the esophagus, gut, duodenum, small intestine, large intestine, rectum, biliary and pancreatic duct systems,
- Medical device substrates which can be provided with ceramic coatings in accordance with the invention may correspond, for example, to an entire medical device (e.g., a metallic stent) or to only a portion of a medical device (e.g., corresponding to a component of a medical device, a material that is adhered to a medical device or device component, etc.).
- vascular stents for purposes of illustrating the invention.
- the invention is in no way limited to stents, or even medical articles, as seen from the above.
- coronary stents such as those commercially available from Boston Scientific Corp. (TAXUS and PROMUS), Johnson & Johnson (CYPHER), and others are frequently prescribed for use for maintaining blood vessel patency, for example, after balloon angioplasty.
- TAXUS and PROMUS Boston Scientific Corp.
- CYPHER Johnson & Johnson
- These products are based on metallic balloon expandable stents with biostable polymer coatings, which release antiproliferative therapeutic agents at a controlled rate and total dose, for preventing restenosis of the blood vessel.
- Fig. IA is a schematic perspective view of a stent 100 which contains a number of interconnected struts 101.
- Fig. IB is a cross-section taken along line b— b of strut 101 of stent 100 of Fig. IA, and shows a stainless steel strut substrate 110 and a therapeutic- agent-containing polymeric coating 120, which encapsulates the entire stent strut substrate 110, covering the luminal surface 1101 (blood side), abluminal surface 110a (vessel side), and side 110s surfaces thereof.
- the coating might nonetheless be rubbed from the surface of a self-expanding stent as a result of the high shear forces associated with the sliding removal of the stent from its delivery tube.
- Ceramic coatings in accordance with the invention, which as noted above, in some embodiments, include raised ceramic shells (which may be hollow, or partially or wholly filled with a variety of solid materials) connected by a ceramic layer.
- a ceramic coating 220 in accordance with the invention is provided over the luminal surface 2101, the ab luminal surface 210a, and the side surfaces 210s of the stent strut substrate 210.
- a drug-eluting polymeric layer 230 is provided on the ceramic coating 220, but only over the ab luminal surface 210a of the stent strut substrate 210 (and not over the luminal 2101 and side 210s surfaces).
- a ceramic coating 220 in accordance with the invention is again provided over the luminal 2101, abluminal 210a and side 210s surfaces of the stent strut substrate 210, whereas the drug-eluting polymeric layer 230 is provided over the abluminal surface 210a and side 210s surfaces of the stent strut substrate 210, but not over the luminal 2101 surface.
- the polymer used in the polymeric coating 230 is biodisintegrable, one is ultimately left in vivo with a ceramic coating, which can be selected from various materials that are biologically inert or bioactive (e.g., titanium oxide, zirconium oxide, iridium oxide, etc.).
- ceramic coatings 220 in accordance with the present invention promote polymer coating adhesion, for example, by increasing the interfacial surface area between the polymeric coatings 230 and the underlying ceramic coating 220 (i.e., relative to the interfacial surface area that would otherwise exist between the between the polymeric coating 230 and the substrate 210, in the absence of the ceramic structure 220).
- ceramic coatings in accordance with the invention interlock with the adjacent polymeric coating 230 to a lesser or greater degree.
- Fig. 4A is a schematic illustration of a substrate 410 (e.g., a stent strut, among innumerable other possibilities), having disposed thereon a ceramic coating 420 in accordance with the invention.
- the coating 420 includes raised ceramic shells 420s connected by a ceramic layer 420c that is conformal with the substrate 410.
- the raised ceramic shells 420s and ceramic layer 420c constitute a single ceramic structure.
- a polymeric coating 430 is shown, disposed over the ceramic coating 420. Due to the undercut beneath the ceramic shells 420s, the polymeric coating 430 interlocks to a degree with the ceramic coating 420. As seen from Figs.
- Fig. 4B which like Fig. 4A is a schematic illustration of a substrate 410, having disposed thereon a ceramic coating 420 in accordance with the invention, which includes raised ceramic shells 420s connected by a ceramic layer 420c that is conformal with the substrate 420.
- a polymeric coating 430 is shown, disposed over the ceramic coating 420.
- the polymeric coating 430 does not extend substantially beyond the height of the raised ceramic shells 420s. Consequently, the ceramic shells 420s are able to protect the polymeric coating 430 from being rubbed off, for example, as a result of abrasion, shear forces, and so forth.
- a process for producing a polymeric coating 430 like that of Fig. 4B is schematically illustrated in Fig. 4C. After covering the ceramic coating 420c,420s with a viscous polymer solution 43Ov, a blade is run over the structure (three blades 450 are illustrated in Fig. 4C, arranged in a manner analogous to a triple-edge razor).
- the ceramic shells 420s act to limit the extent to which the blades 450 can approach the ceramic layer 420c. Consequently, a polymeric layer is created that is essentially of the same height as the ceramic shells 420s. Because the viscous polymer solution 43Ov will loose volume upon evaporation of the solvent contained therein, one may repeat the process, as desired, to increase the thickness of the final polymeric layer. Of course other liquid polymeric compositions can be employed in the polymeric coating process, including polymer melts and curable polymeric compositions. [0040] Thus, where employed in conjunction with a stent, a ceramic coating like that shown in Fig. 4B allows a soft polymeric coating to be protected against mechanical forces, without affecting the mechanical qualities of the stent.
- Another option for protecting a polymer coating from mechanical forces would be to form depressions within the stent surface, which would shield the polymeric coating.
- the amount polymeric coating (and thus therapeutic agent) that can be loaded within these depressions is limited to the amount of material that is removed, with significant removal of material potentially weakening the stent.
- Another advantage of a ceramic coating like that shown in Fig. 4B, is that the coating allows for very good control over the height and total volume of any therapeutic- agent-containing polymer layer, and therefore over therapeutic agent content.
- the coating height is dependent on the height of the spherical shell, and this is defined by the size of the original template particles (e.g., polystyrene balls) which one can obtain with a variance in size of better than 2.0%.
- the volume taken up by the spheres can be done by taking into account the diameter and average density of the spherical shells, which are uniformly dispersed on the surface, as can be seen from Fig. 3B.
- ceramic coatings of the invention are readily formed with micron-scale and/or nanometer-scale features, which have been widely reported to promote cell attachment and/or cell proliferation as discussed below.
- ceramic coatings can be produced with topographical features having a wide variety of shapes and sizes.
- the surface features generally have widths that are less than 100 microns ( ⁇ m), ranging, for example, from 100 microns or more to 50 microns to 25 microns to 10 microns to 5 microns to 2 microns to 1 micron to 500 nm to 250 nm to 100 nm to 50 nm to 25 nm or less.
- the shapes and sizes of the surface features are dictated by the particles that are used as templates for the creation of the ceramic shells.
- Fujisawa et al., Biomaterials 20 (1999) 955-962 found that, upon implantation in ovine carotid arteries, textured polyurethane surfaces consisting of regularly spaced, protruding micro-fibers on a smooth base plane (length, pitch and diameter at the base of the fibers were 250, 100 and 25 ⁇ m, respectively) promoted the formation of a stabilized thrombus base onto which subsequent cellular migration and tissue healing occurred more rapidly than onto a smooth surface.
- Others have noted that by creating well-defined micro-textured patterns on a surface, fluid flow at the surface is altered to create discrete regions of low shear stress, which may serve as sanctuaries for cells such as endothelial cells and promote their retention. See S. C.
- Daxini et al. “Micropatterned polymer surfaces improve retention of endothelial cells exposed to flow-induced shear stress,” Biorheology 2006 43(1) 45-55.
- Texturing in the sub- 100 nm range has been observed to increase cell attachment and/or proliferation. See, e.g., the review by E.K.F Yim et al., "Significance of synthetic nanostructures in dictating cellular response," Nanomedicine: Nanotechnology, Biology, and Medicine 1 (2005) 10- 21, which reported that smooth muscle cells and endothelial cells have improved cell adhesion and proliferation on nanopatterned surfaces. Both types of cells were sensitive to nanotopography.
- feature sizes less than 100 nm are believed to allow adhesion of proteins such as fibronectin, laminin, and/or vitronectin to the nanotextured surface, and to provide a conformation for these proteins that better exposes amino acid sequences such as RGD and YGSIR which enhance endothelial cell binding.
- proteins such as fibronectin, laminin, and/or vitronectin
- nanotexturing increases surface energy, which is believed to increases cell adhesion. See, e.g., J.Y. Lim et al., J. Biomed. Mater. Res. (2004) 68A(3): 504-512.
- submicron topography including pores, fibers, and elevations in the sub- 100 nm range, has been observed for the basement membrane of the aortic valve endothelium as well as for other basement membrane materials. See R.G. Flemming et al., Biomaterials 20 (1999) 573-588, S. Brody et al., Tissue Eng. 2006 Feb; 12(2): 413-421, and S.L. Goodman et al., Biomaterials 1996; 17: 2087-95. Goodman et al.
- a first layer having a first surface charge is typically deposited on an underlying substrate (in the present invention, a medical device substrate or portion thereof), followed by a second layer having a second surface charge that is opposite in sign to the surface charge of the first layer, and so forth.
- the charge on the outer layer is reversed upon deposition of each sequential layer.
- 5 to 10 to 25 to 50 to 100 to 200 or more layers are applied in this technique, depending on the desired thickness of the multilayer structure.
- LBL techniques commonly employ charged species known as "polyelectrolytes," which are polymers having multiple charged groups. Typically, the number of charged groups is so large that the polymers are soluble in polar solvents (including water) when in ionically dissociated form (also called polyions).
- polyelectrolytes may be classified as polycations (which are generally derived from polyacids and salts thereof) or polyanions (which are generally derived from polybases and salts thereof).
- polyanions/polyacids include poly(styrene sulfonate) (PSS) (e.g., poly(sodium styrene sulfonate), polyacrylic acid, polyvinylsulfate, polyvinylsulfonate, sodium alginate, eudragit, gelatin, hyaluronic acid, carrageenan, chondroitin sulfate and carboxymethylcellulose, among many others.
- PSS poly(styrene sulfonate)
- polyacrylic acid polyvinylsulfate, polyvinylsulfonate, sodium alginate, eudragit, gelatin, hyaluronic acid, carrageenan, chondroitin sulfate and carboxy
- polycations/polybases include protamine sulfate, poly(allylamine) (e.g., poly(allylamine hydrochloride) (PAH)), polydiallyldimethylammonium species, polyethyleneimine (PEI), polyvinylamine, polyvinylpyridine, chitosan, gelatin, spermidine and albumin, among many others.
- poly(allylamine) e.g., poly(allylamine hydrochloride) (PAH)
- PHI polydiallyldimethylammonium species
- PEI polyethyleneimine
- polyvinylamine polyvinylpyridine
- chitosan chitosan
- gelatin spermidine and albumin
- ceramic regions may be formed using sol-gel processing techniques.
- precursor materials typically selected from inorganic metallic and semi-metallic salts, metallic and semi-metallic complexes/chelates, metallic and semi-metallic hydroxides, and organometallic and organo-semi-metallic compounds such as metal alkoxides and alkoxysilanes, are subjected to hydrolysis and condensation reactions in the formation of ceramic materials.
- an alkoxide of choice e.g., a methoxide, ethoxide, isopropoxide, tert-butoxide, etc.
- a semi-metal or metal of choice e.g., silicon, aluminum, zirconium, titanium, tin, iron, hafnium, tantalum, molybdenum, tungsten, rhenium, iridium, etc.
- a suitable solvent for example, in one or more alcohols.
- water or another aqueous solution such as an acidic or basic aqueous solution (which aqueous solution can further contain organic solvent species such as alcohols) is added, causing hydrolysis and condensation to occur.
- the sol-gel reaction is basically understood to be a ceramic network forming process as illustrated in the following simplified scheme from G. Kickelbick, "Prog. Polym. ScL, 28 (2003) 83-114):
- wet "gel” coatings can be produced by spray coating, coating with an applicator (e.g., by roller or brush), ink-jet printing, screen printing, and so forth. The wet gel is then dried to form a ceramic region. Further information concerning sol-gel materials can be found, for example, in G. Kickelbick supra and Viitala R. et al, "Surface properties of in vitro bioactive and non-bioactive sol- gel derived materials," Biomaterials, 2002 Aug; 23(15):3073-86, and portions of Pub. No. US 2006/0129215 to Helmus et al.
- a polyelectrolyte multilayer (PML) coating 512 is formed on a substrate 510 using the LBL process.
- PML polyelectrolyte multilayer
- certain substrates are inherently charged and thus readily lend themselves to layer-by-layer assembly techniques.
- a surface charge may nonetheless be provided.
- the substrate to be coated is conductive, a surface charge may be provided by applying an electrical potential to the same.
- substrates including metallic and polymeric substrates
- substrates may be chemically treated with various reagents, including reducing agents and oxidizing agents (e.g., sulfur trioxide for sulfonate formation), which modify their surfaces so as to provide them charged groups, such as amino, phosphate, sulfate, sulfonate, phosphonates and carboxylate groups, among many others.
- reducing agents and oxidizing agents e.g., sulfur trioxide for sulfonate formation
- groups such as amino, phosphate, sulfate, sulfonate, phosphonates and carboxylate groups, among many others.
- Other techniques for providing surface charge include techniques whereby a surface region is treated with a reactive plasma. Surface modification is obtained by exposing a surface to a partially ionized gas (i.e., to a plasma).
- the plasma phase consists of a wide spectrum of reactive species (electrons, ions, etc.) these techniques have been used widely for functionalization of surfaces, including polymeric surfaces among others.
- reactive species include glow discharge techniques (which are conducted at reduced pressure) and coronal discharge techniques (which are conducted at atmospheric pressure), with the former preferred in some cases, because the shape of the object to be treated is of minor importance during glow discharge processes.
- Lasers may also be used to create a localized plasma in the vicinity of the laser beam (e.g., just above the focal point of the beam). When gases like carbon monoxide (CO), carbon dioxide (CO 2 ), or oxygen (O 2 ) are used, functionalization with - COOH groups (which donate protons to form anionic groups) is commonly observed.
- CO carbon monoxide
- CO 2 carbon dioxide
- O 2 oxygen
- gas pairs examples include allylamine/NH 3 (which leads to enhanced production of -NH 2 groups) and acrylic acid/CO 2 (which leads to enhanced production of -COOH groups). Further information on plasma processing may be found, for example, in "Functionalization of Polymer Surfaces," Europlasma Technical Paper, 05/08/04 and in Pub. No. US 2003/0236323. As another example, plasma-based techniques such as those described above may first be used to functionalize a substrate surface, followed by removal of a portion of the functional groups at the surface by exposing the surface to a laser beam, for example, in an inert atmosphere or vacuum in order to minimize deposition.
- a substrate can be provided with a charge by covalently coupling with species having functional groups with a positive charge (e.g., amine, imine or other basic groups) or a negative charge (e.g., carboxylic, phosphonic, phosphoric, sulfuric, sulfonic, or other acid groups) using methods well known in the art. Further information on covalent coupling may be found, for example, in Pub. No. US 2005/0002865.
- a surface charge is provided on a substrate simply by adsorbing polycations or polyanions to the surface of the substrate as a first charged layer. PEI is commonly used for this purpose, as it strongly promotes adhesion to a variety of substrates. Further information can be found in Serial No. 11/322,905 to Atanasoska et al.
- the substrate can be readily coated with a layer of an oppositely charged material.
- layers include layers that contain (a) polyelectrolytes, (b) charged particles or (c) both polyelectrolytes and charged particles.
- Multilayer regions are formed by alternating exposure to solutions containing oppositely charged materials. The layers self-assemble by means of electrostatic layer-by-layer deposition, thus forming a multilayered region over the substrate.
- Polyelectrolyte solutions may be applied by a variety of techniques. These techniques include, for example, full immersion techniques such as dipping techniques, spraying techniques, roll and brush coating techniques, techniques involving coating via mechanical suspension such as air suspension, ink jet techniques, spin coating techniques, web coating techniques and combinations of these processes, among others. Stamping may also be employed, for example, as described in S. Kidambi et al, "Selective Depositions on Polyelectrolyte Multilayers: Self-Assembled Monolayers of m-dPEG Acid as Molecular Templates" J. Am. Chem. Soc.
- deposition or full immersion techniques may be employed where it is desired to apply the species to an entire substrate, including surfaces that are hidden from view (e.g., surfaces which cannot be reached by line-of-sight techniques, such as spray techniques).
- spraying, roll coating, brush coating, ink jet printing and micro- polymer stamping may be employed, for instance, where it is desired to apply the species only certain portions of the substrate (e.g., on one side of a substrate, in the form of a pattern on a substrate, etc.).
- a substrate 510 is provided with a PML coating 512 as shown, for example, by dipping in consecutive polyelectrolyte regions of opposite charge.
- the surface charge of the multilayer polyelectrolyte coating 512 at the end of this process is determined by whether the last solution to which the substrate was exposed was a polycationic solution or a polyanionic solution.
- a sol-gel-type process is carried out within the polyelectrolyte layers as described below.
- particles of choice are adsorbed to the surface.
- a charged particle is used which is either inherently charged or is charged, for example, using one of the techniques described above.
- particles may be exposed to a solution of PEI to create negatively charged particles.
- the charge on a particle can be reversed by exposing it to a solution containing a polyelectrolyte of opposite charge.
- a solution of particles may be employed, in which the particles are provided with a polyelectrolyte multilayer coatings.
- a substrate may, for example, be exposed to a suspension of charged particles using techniques such as those above (e.g., dipping, etc.). The result of this step is illustrated in Fig.
- FIG. 5B which schematically illustrates the medical device substrate 510, PML coating 512, and charged particles 515.
- the structure of Fig. 5B is then immersed in further polyelectrolyte solutions of alternating charge, to enclose the charged particles 515 in a PML coating 512.
- This process also increases the thickness of the polyelectrolyte coating that was previously applied to the substrate 510. The result of this process is illustrated in Fig. 5 C.
- a charged therapeutic agent is used to form one or more layers of the PML coating 512.
- charged therapeutic agent is meant a therapeutic agent that has an associated charge.
- a therapeutic agent may have an associated charge because it is inherently charged (e.g., because it has acidic and/or or basic groups, which may be in salt form).
- a therapeutic agent may have an associated charge because it has been chemically modified to provide it with one or more charged functional groups.
- paclitaxel As a specific example, various cationic forms of this drug are known, including paclitaxel N-methyl pyridinium mesylate and paclitaxel conjugated with N-2-hydroxypropyl methyl amide, as are various anionic forms of paclitaxel, including paclitaxel-poly(l-glutamic acid), paclitaxel-poly(l-glutamic acid)-PEO.
- paclitaxel-poly(l-glutamic acid) paclitaxel-poly(l-glutamic acid)-PEO.
- U.S. Patent No. 6,730,699 also describes paclitaxel conjugated to various other charged polymers (e.g., poly electrolytes) including poly(d-glutamic acid), poly(dl-glutamic acid), poly(l-aspartic acid), poly(d-aspartic acid), poly(dl-aspartic acid), poly(l-lysine), poly(d- lysine), poly(dl-lysine), copolymers of the above listed polyamino acids with polyethylene glycol (e.g., paclitaxel-poly(l-glutamic acid)-PEO), as well as poly(2- hydroxyethyl 1 -glutamine), chitosan, carboxymethyl dextran, hyaluronic acid, human serum albumin and alginic acid.
- poly electrolytes including poly(d-glutamic acid), poly(dl-glutamic acid), poly(l-aspartic acid), poly(d-aspart
- Still other forms of paclitaxel include carboxylated forms such as l'-malyl paclitaxel sodium salt (see, e.g. E. W. DAmen et al., "Paclitaxel esters of malic acid as prodrugs with improved water solubility," Bioorg. Med. Chem., 2000 Feb, 8(2), pp. 427-32).
- Polyglutamate paclitaxel in which paclitaxel is linked through the hydroxyl at the 2' position to the ⁇ carboxylic acid of the poly-L-glutamic acid (PGA), is produced by Cell Therapeutics, Inc., Seattle, WA, USA.
- This molecule is said to be cleaved in vivo by cathepsin B to liberate diglutamyl paclitaxel.
- the paclitaxel is bound to some of the carboxyl groups along the backbone of the polymer, leading to multiple paclitaxel units per molecule.
- paclitaxel and innumerable other therapeutic agents may be covalently linked or otherwise associated with a variety of charged species, including charged polymer molecules (e.g., poly electrolytes), thereby forming charged drugs and prodrugs which can be assembled in the PML process.
- charged species including charged polymer molecules (e.g., poly electrolytes), thereby forming charged drugs and prodrugs which can be assembled in the PML process.
- charged species may be adapted for cleavage from the drug/prodrug prior to administration or upon administration (e.g., due to enzymatic cleavage, etc.).
- a sol-gel-type process is carried out within the polyelectrolyte layers.
- the structure of Fig. 5C may be washed in an anhydrous solvent, for example, an anhydrous alcohol. This removes essentially all the water from the structure, except of the water that remains adsorbed within the PML coating 512.
- the structure is then immersed in a sol-gel precursor solution.
- the structure may be immersed in a solution of a semi-metal or metal alkoxide in anyhydrous alcohol solvent or in a water-alcohol solvent having a high alcohol content (i.e., a solvent in which the water concentration is too low for hydrolysis-condensation reactions to occur).
- the high charge density of the polyelectrolyte groups are believed to cause the PML coating 512 to have a water concentration that is higher than that of the surrounding sol-gel precursor solution (e.g., by attracting water molecules out of the sol-gel precursor solution and/or retaining water molecules during washing in anhydrous solvent).
- the sol-gel precursor Upon diffusion into the PML coating 512, the sol-gel precursor encounters an environment of increase water concentration, in which the hydrolysis and condensation can take place.
- the PML coating 512 swells, due to the in- situ reaction of the sol-gel precursor within the layers.
- the charge density also decreases due to the swelling, causing a reduction in water concentration, which eventually stops the sol-gel reaction.
- the resulting coating which is a polyelectrolyte/ceramic hybrid coating
- Fig. 5D shows the substrate 510, particles 515, and polyelectrolyte/ceramic hybrid coating 514.
- the structure of Fig. 5D may then heated, for example, to a temperature ranging anywhere from about 150 0 C to about 600 0 C or higher, to form a heat-treated ceramic coating 520 as shown in Figs. 5E-5G.
- the ceramic coating 520 has a high proportion of ceramic species (e.g., containing 90 wt% or more ceramic species, for example, from 95 wt% to 98 wt% to 99 wt% to 99.5 wt% to 99.9 wt% or more), with substantially all of the polyelectrolyte component of the coating having been out-gassed from the structure in a process sometimes referred to as calcination.
- the thickness of the resulting shell will generally be proportional to the number of polyelectrolyte layers that were deposited prior to sol-gel processing. For example, a thickness of about 1 nm per polyelectrolyte layer has been reported in D. Wang and F. Caruso, Chem. Mater. 2002, 14, 1909 - 1913.
- carbides and nitrides of metal and semi- metal oxides may be formed, for example, using high-temperature carbothermal reduction or nitridation processes, among others.
- the ceramic coating 520 contains substantial amounts of polymeric species (polyelectrolytes) in addition to ceramic species. In such cases, however, the heat treatment will act to strengthen the ceramic coating 520.
- ceramic coatings may be formed by water-vapor exposure.
- porous titania-based (TiO x -based) anatase coatings have been formed by exposing sol-gel-derived titania thin films that contained from 0-50 mol% silica to water vapor at 60°-180°C. H. Imai et al, J. Am. Ceram. Soc, 82(9), 1999, 2301-2304. Titanium oxide coatings have been reported to possess photocatalytic properties and a photovoltaic effect. Id. See also Margit J. Jensen et al., J. Sol-Gel Sci. Techn.
- Particle removal may also be conducted independently of heat treatment, for example, in the absence of heat treatment, prior to heat treatment, or after heat treatment (where the heat treatment does not remove the particles).
- particles may be removed via a dissolution process.
- polymeric particles may be removed using organic solvents (e.g., removal of polystyrene particles by tetrahydrofuran), and inorganic particles may be removed using acidic or basic aqueous solutions (e.g., removal of silica particles using HF).
- hybrid template particles are employed in which a portion of each particle is removed (e.g., by heat treatment, dissolution, etc.) and a portion of each particle remains within the hollow ceramic shell.
- a particle is a polystyrene sphere that contains one or more smaller paramagnetic particles (e.g., paramagnetic particles within a polystyrene matrix, a paramagnetic particle core with a polystyrene shell, etc.).
- the polystyrene portion of such a particle can be removed, for instance, by heat or by organic solvent dissolution.
- the charged particles 515 are electrostatically deposited onto the substrate 510 without first coating the substrate 510 with a polyelectrolyte multilayer coating (as is done in Fig. 5A), the result being that the particles 515 in the structure of Fig. 5 G are in closer proximity to the substrate 510 than are the particles 515 of Fig. 5E.
- ceramic coatings in accordance with the present invention are provided over the entire surface of a substrate. In some embodiments, ceramic coatings in accordance with the present invention are provided over only a portion of the surface of a substrate (e.g., only a luminal stent surface, only an ab luminal stent surface, only abluminal and side stent surfaces, etc.). Substrates may be partially coated, for example by exposing the various solutions employed (e.g., polyelectrolyte solutions, particle solutions, sol-gel solutions) to only a portion of the substrate.
- solutions employed e.g., polyelectrolyte solutions, particle solutions, sol-gel solutions
- Examples of techniques for doing so include the use of masking, partial dipping, roll-coating (e.g., where it is desired to apply the coating to the abluminal surface of a tubular device such as a stent) or other transfer coating technique, including the use of a suitable application device such as a brush, roller, stamp or ink jet printer, among other techniques.
- a suitable application device such as a brush, roller, stamp or ink jet printer
- Suitable substrate materials therefore may be selected from a variety of materials, including (a) organic materials (e.g., materials containing organic species, commonly 50 wt% or more organic species) such as polymeric materials and (b) inorganic materials (e.g., materials containing inorganic species, commonly 50 wt% or more inorganic species) such as metallic materials (e.g., metals and metal alloys) and non-metallic inorganic materials (e.g., carbon, semiconductors, glasses, metal- and non-metal-oxides, metal- and non-metal-nitrides, metal- and non-metal-carbides, metal- and non-metal- borides, metal- and non-metal-phosphates, and metal- and non-metal-sulfides, among others).
- organic materials e.g., materials containing organic species, commonly 50 wt% or more organic species
- inorganic materials e.g., materials containing inorganic species, commonly 50 wt% or
- Suitable substrate materials include biostable materials and biodisintegrable materials (i.e., materials that, upon placement in the body, are dissolved, degraded, resorbed, and/or otherwise removed from the placement site).
- specific examples of non-metallic inorganic materials may be selected, for example, from materials containing one or more of the following: metal oxides, including aluminum oxides and transition metal oxides (e.g., oxides of titanium, zirconium, hafnium, tantalum, molybdenum, tungsten, rhenium, and iridium, as well as other metals such as those listed above as examples of ceramic species); silicon; silicon- based materials, such as those containing silicon nitrides, silicon carbides and silicon oxides (sometimes referred to as glass ceramics); calcium phosphate ceramics (e.g., hydroxy apatite); carbon and carbon-based, ceramic-like materials such as carbon nitrides, among many others.
- metal oxides including aluminum oxides and transition metal
- metallic inorganic materials may be selected, for example, from substantially pure biostable and biodisintegrable metals (e.g., biostable metals such as gold, platinum, palladium, iridium, osmium, rhodium, titanium, tantalum, tungsten, and ruthenium, and biodisintegrable metals such as magnesium, zinc and iron) and biostable and biodisintegrable metal alloys, for example, biostable metal alloys comprising iron and chromium (e.g., stainless steels, including platinum-enriched radiopaque stainless steel), alloys comprising nickel and titanium (e.g., Nitinol), alloys comprising cobalt and chromium, including alloys that comprise cobalt, chromium and iron (e.g., elgiloy alloys), alloys comprising nickel, cobalt and chromium (e.g., MP 35N) and alloys comprising cobalt, chromium
- organic materials include biostable and biodisintegrable polymers, which may be selected, for example, from the following, among others: polycarboxylic acid polymers and copolymers including polyacrylic acids; acetal polymers and copolymers; acrylate and methacrylate polymers and copolymers (e.g., n- butyl methacrylate); cellulosic polymers and copolymers, including cellulose acetates, cellulose nitrates, cellulose propionates, cellulose acetate butyrates, cellophanes, rayons, rayon triacetates, and cellulose ethers such as carboxymethyl celluloses and hydroxyalkyl celluloses; polyoxymethylene polymers and copolymers; polyimide polymers and copolymers such as polyether block imides, polyamidimides, polyesterimides, and polyetherimides; polysulfone polymers and copolymers including polyarylsulfones and polyethersul
- Particles for use in the present invention varying widely in composition, size and shape (e.g., spheres, polyhedra, cylinders, tubes, fibers, ribbon-shaped particles, plate- shaped particles, and other regular and irregular particle shapes).
- the distance across the particles as-deposited is less than 100 microns ( ⁇ m) (the length is frequently much larger), ranging, for example, from 100 microns or more to 50 microns to 25 microns to 10 microns to 5 microns to 2 microns to 1 micron to 500 nm to 250 nm to 100 nm to 50 nm to 25 nm or less.
- the particles are sub-micron-particles in the sense that the distance across the particles as-deposited is less than 1000 nm, and more typically less than 100 nm.
- Suitable materials for the particles can be selected from the organic and inorganic materials set forth above for use as substrate materials.
- particles which are not exclusive of those materials, may be selected from polymer microspheres, including polymethyl methacrylate (PMMA) microspheres and polystyrene microspheres, such as those available from Microparticles, Berlin, Germany (l ⁇ ttll ⁇ '.>Y ⁇ Y.WJI ⁇ among many others, alumina particles, titanium oxide particles, tungsten oxide particles, tantalum oxide particles, zirconium oxide particles, silica particles, silicate particles such as aluminum silicate particles, synthetic or natural phyllosilicates including clays and micas (which may optionally be intercalated and/or exfoliated) such as montmorillonite, hectorite, hydrotalcite, vermiculite and laponite, and needle-like clays such as attapulgite, and further including particulate molecules such as polyhedral oligomeric silsequioxanes (POSS), including various functionalized POSS and polymerized POSS, polyoxometallates (e.g., Kevl)
- one or more therapeutic agents are disposed within the particles.
- a polymeric coating (e.g., a therapeutic - agent-eluting coating, a lubricious coating, etc.) may be disposed over all or a portion of a ceramic coating in accordance with the invention.
- a polymeric coating is one that comprises a single polymer or a mixture differing polymers, for example, comprising from 50 wt% or less to 75 wt% to 90 wt% to 95 wt% to 97.5 wt% to 99 wt% or more of one or more polymers.
- the polymer(s) may be biostable or biodisintegrable.
- Polymers suitable for this purpose may be selected, for example, from one or more of the polymers set forth above for use as substrate materials.
- Further examples of polymers, which are not exclusive of those materials, include thermoplastic elastomers such as poly(styrene-co-isobutylene) block copolymers, poly(methyl methacrylate-co-butyl acrylate) block copolymers and thermoplastic polyurethanes, fluoropolymers such as PTFE, FEP, ETFE and PVDF, crosslinked hydrogels such as crosslinked thiolated chondroitin sulfate, polyacrylic acid, polyvinyl alcohol or polyvinyl pyrrolidone, polyanhydrides including aliphatic polyanhydrides such as poly(sebacic acid) or poly(adipic acid), unsaturated polyanhydrides such as poly(4, 4'-stilbenedicarboxylic acid anhydride), aromatic polyanhydrides such as poly(terephthalic acid), copolymers of the
- the thickness of the therapeutic-agent-eluting polymeric coating may vary widely, typically ranging from 25 nm or less to 50 nm to 100 nm to 250 nm to 500nm to 1 ⁇ m to 2.5 ⁇ m to 5 ⁇ m to 10 ⁇ m to 25 ⁇ m to 50 ⁇ m to 100 ⁇ m or more in thickness.
- the thickness of the polymeric coating is dictated by the size of the ceramic shells that are present on the surface, whereas in others it is not.
- the polymeric coating is a therapeutic-agent-eluting polymeric coating.
- a "therapeutic-agent-eluting polymeric coating” is a coating that comprises a therapeutic agent and a polymer and from which at least a portion of the therapeutic agent is eluted, for example, upon contact with a subject, or upon implantation or insertion into a subject.
- the therapeutic-agent-eluting polymeric coating will typically comprise, for example, from 1 wt% or less to 2 wt% to 5 wt% to 10 wt% to 25 wt% to 50 wt% or more of a single therapeutic agent or of a mixture of therapeutic agents within the coating.
- Therapeutic agents may be selected, for example, from those listed below, among others.
- Polymeric coatings may be applied using any suitable method.
- the coating may be formed, for instance, by (a) providing a melt that contains polymer(s) and any other optional species such as therapeutic agent(s), as desired, and (b) subsequently cooling the melt.
- the coating may be formed from a curable composition (e.g., a UV curable composition), for instance, by (a) providing a curable composition that contains polymer(s), curing agents, and any other optional species such as therapeutic agent(s), as desired, and (b) curing the composition.
- a curable composition e.g., a UV curable composition
- a coating may be formed, for instance, by (a) providing a solution or dispersion that contains one or more solvent species, polymer(s), and any other optional species such as therapeutic agent(s), as desired, and (b) subsequently removing the solvent species.
- the melt, solution or dispersion may be applied, for example, by roll-coating (e.g., where it is desired to apply the coating to the abluminal surface of a tubular device such as a stent) or other transfer coating technique, including application using a suitable application device such as a brush, roller, stamp or ink jet printer, by dipping, and by spray coating, among other methods.
- a wide variety of therapeutic agents may be employed in conjunction with the present invention, including genetic therapeutic agents, non-genetic therapeutic agents and cells, which may be used for the treatment of a wide variety of diseases and conditions.
- Suitable therapeutic agents for use in connection with the present invention may be selected, for example, from one or more of the following: (a) anti-thrombotic agents such as heparin, heparin derivatives, urokinase, clopidogrel, and PPack (dextrophenylalanine proline arginine chloromethylketone); (b) anti-inflammatory agents such as dexamethasone, prednisolone, corticosterone, budesonide, estrogen, sulfasalazine and mesalamine; (c) antineoplastic/antiproliferative/anti-miotic agents such as paclitaxel, 5-fluorouracil, cisplatin, vinblastine, vincristine, epothilones, endostatin, angiostatin, angiopeptin, monoclonal antibodies capable of blocking smooth muscle cell proliferation, and thymidine kinase inhibitors; (d) anesthetic agents
- Preferred non-genetic therapeutic agents include taxanes such as paclitaxel (including particulate forms thereof, for instance, protein-bound paclitaxel particles such as albumin-bound paclitaxel nanoparticles, e.g., ABRAXANE), sirolimus, everolimus, tacrolimus, zotarolimus, Epo D, dexamethasone, estradiol, halofuginone, cilostazole, geldanamycin, ABT-578 (Abbott Laboratories), trapidil, liprostin, Actinomcin D, Resten- NG, Ap- 17, abciximab, clopidogrel, Ridogrel, beta-blockers, bARKct inhibitors, phospholamban inhibitors, Serca 2 gene/protein, imiquimod, human apolioproteins (e.g., AI-AV), growth factors (e.g., VEGF-2) , as well derivatives of the paclit
- agents are useful for the practice of the present invention and suitable examples may be selected from one or more of the following: (a) Ca-channel blockers including benzothiazapines such as diltiazem and clentiazem, dihydropyridines such as nifedipine, amlodipine and nicardapine, and phenylalkylamines such as verapamil, (b) serotonin pathway modulators including: 5-HT antagonists such as ketanserin and naftidrofuryl, as well as 5-HT uptake inhibitors such as fluoxetine, (c) cyclic nucleotide pathway agents including phosphodiesterase inhibitors such as cilostazole and dipyridamole, adenylate/Guanylate cyclase stimulants such as forskolin, as
- Fig. 6A The structure shown in the schematic, cross-sectional illustration of Fig. 6A is similar to those described in Figs. 4A and 4B in that it includes a substrate 610, having disposed thereon a ceramic coating 620 in accordance with the invention, which includes raised ceramic shells 620s connected by a ceramic layer 620c that is conformal with the substrate 610.
- a polymeric coating 630 is shown, disposed over the ceramic region 620, which in this embodiment contains a therapeutic agent.
- the hollow ceramic shells 620s of Fig. 6A contain paramagnetic particles 640.
- Paramagnetic particles may be selected from various paramagnetic materials, which are typically metals, alloys or compounds of certain transition, rare earth and actinide elements (e.g., iron, iron oxides including magnetite, etc.).
- Such a structure may be formed, for example, using polymeric particles (e.g., polystyrene spheres) that contain embedded paramagnetic particles as templates for the above-described LBL/sol-gel process.
- polymeric particles e.g., polystyrene spheres
- the paramagnetic particles remain inside of the ceramic shells 620s.
- the paramagnetic particles 640 are separated from the exterior environment by the ceramic shells 620s. Because they are paramagnetic, one can vibrate these particles 640 inside of their ceramic shells 620s using an external magnetic field. This will cause heat, which can, for example, increase the rate at which the therapeutic agent is released from the polymeric coating, among other effects.
- a magnetic material (e.g., one of those above) is placed on the outside of the polymeric particles (e.g., polystyrene particles may be provided, which have a magnetite coating). See, e.g., Marina Spasova et al., "Magnetic and optical tunable microspheres with a magnetite/gold nanoparticle shell," "J. Mater. Chem., 15, (2005) 2095-2098 for more information.
- the magnetic material is embedded with the ceramic shells that are ultimately formed.
- Fig. 6B is a structure like that of Fig. 6A, albeit without the polymeric coating 630. Like the structure of Fig.
- this structure can be heated using an external magnetic field.
- the high temperatures generated can be used, for example, to cause necrosis, thrombosis and other physiological effects within the body.
- a coating like that shown in Fig. 6B may be provided on an embolic coil for the treatment of an aneurism. After implantation into an aneurism, the coil can be heated, thereby causing thrombosis within the aneurism.
- such a structure is produced using two sizes of charged particles.
- a PML coating 712a is formed on a substrate 710 using the LBL process (e.g., by dipping into polyelectrolyte solutions of alternating charge).
- the top polyelectrolyte layer of the polyelectrolyte multilayer coating 712a is positively charged.
- spherical particles 715b each comprising a PML coating 712b whose top layer is negatively charged, are electrostatically assembled onto the PML coating 712a as shown in Fig. 7B.
- spherical particles 715c each comprising a PML coating 712c whose top layer is positively charged, are electrostatically assembled on the structure of Fig. 7B.
- the resulting structure is illustrated in Fig. 1C.
- Particles 715c are larger than particles 715b.
- one or more paramagnetic kernels 718 lies within each particle 715c in the embodiment shown.
- polystyrene spheres 715b, 715c may be employed. For instance smaller spheres having diameters of 200 nm and larger spheres having diameters of 500 with super-paramagnetic kernels may be purchased from Microparticles, Berlin, Germany.
- a magnetic force is generated (illustrated by the arrow in Fig. 7C), and the coated particles 715c are urged into a closer association with the underlying coated particles 715b as shown in Fig. 7D. This improves the likelihood that the larger coated particles 715c make contact with several smaller coated particles 715b, rather than just hanging onto one sphere only. Compare Figs. 7C and 7D.
- Fig. 7D The structure of Fig. 7D can then be subjected to further polyelectrolyte deposition steps (e.g., by dipping into polyelectrolyte solution of alternating charge) to increase the thickness of the various PML coatings 712a,712b,712c as desired and to better merge them into a single continuous PML structure.
- the result is a structure like that of Fig. 7E.
- a sol-gel-type process is carried out within the PML structure, using sol-gel precursor solutions as discussed above, thereby forming a poly electrolyte/ceramic hybrid structure 714 as shown in Fig. 7F.
- the structure of Fig. 7F may then be subjected to further processing to remove the particles 715b and 715c.
- the particles 715b and 715c are polymeric in nature (e.g., polystyrene)
- the structure of Fig. 7F may be heated to a temperature sufficient to substantially remove the polymeric particles 715b and 715c (and the polymeric components of the poly electrolyte/ceramic hybrid structure 714 as well), thereby creating the ceramic coating 720 shown in Fig. 7G.
- the coating 720 which is a continuous structure, includes a substrate covering portion 720c and numerous ceramic shells 720s.
- paramagnetic kernels 718 which can now be used to heat the medical device in vivo (or ex vivo), if desired.
- the structure of Fig. 7G contains spaces rl that are completely encapsulated/surrounded by the ceramic shells 720s as well as spaces r2 that are open to the outer environment.
- the spaces r2 afford the polymeric coating 730 the opportunity to form a fully interlocking interface with the ceramic coating 720.
- the large spheres described in the prior embodiment can be replaced with elongated particles such as carbon nanofibers or carbon nanotubes, among many others.
- the elongated particles are overcoated with PML coatings.
- PML coatings For example, one can employ polyelectrolyte- functionalized carbon nanotubes or one can employ carbon nanotubes with PML coatings as described in H. Kong et al. "Polyelectrolyte-functionalized multiwalled carbon nanotubes: preparation, characterization and layer-by-layer self-assembly," Polymer 46 (2005) 2472-2485. Following steps like those described above to create the structure of Fig.
- Fig. 8A includes a substrate 810, having disposed thereon a continuous ceramic coating 820 in accordance with the invention.
- the region 820 includes raised ceramic hollow spherical shells 820s 1 connected by a ceramic layer 820c that is conformal with the substrate 810. Unlike Figs.
- the continuous ceramic coating 820 of Fig. 8A further includes non-hollow, non-spherical ceramic shells 820s2, which contain elongated particles 815.
- the elongated particles may be carbon fibers, carbon nanotubes or any other elongated particle that survives processing.
- these ceramic-coated fibers 815,820s2 connect the hollow ceramic spheres 820s 1 to one another.
- elongated particles may be used which are removed during the heat treatment process, in which case a structure like that in Fig. 8B would result, wherein hollow ceramic fibers 820s2 connect the hollow ceramic spheres 820sl to one another.
- a structure like that of Figs. 8A and 8B should be more tolerant of bending or flexing that the structure of Fig. 7G.
- Fig. 8A and 8B contains spaces rl that are completely encapsulated/surrounded by ceramic shells (i.e., shells 820sl,820s2), as well as spaces r2 that are open to the outer environment. These spaces r2 afford a polymeric coating 830 the opportunity to form a fully interlocking interface with the ceramic coating 820 as seen in Fig. 8C.
- spheres are completely eliminated.
- a charged substrate e.g., an LBL coated substrate
- a layer of elongated particles of opposite charge e.g., LBL encapsulated particles
- particles may be, for example, heat-resistant particles such as a carbon nanotubes or heat-labile particles such as polystyrene fibers, among many other possibilities.
- LBL processing, sol-gel processing, and heat treatment may be conducted (see above) to produce a ceramic coating containing raised ceramic shells, which may contain the elongated particles, or which may be wholly or partially hollow.
- a substrate e.g., an LBL coated substrate having a given charge (e.g., a negative charge), a first layer of elongated particles (e.g., LBL coated particles) of opposite charge (e.g., a positive charge), followed by a second layer of elongated particles (e.g., LBL coated particles) of opposite charge (e.g., a negative charge), and so forth.
- LBL coated particles e.g., LBL coated particles
- LBL coated particles opposite charge
- e.g., a negative charge e.g., a negative charge
- a more regular architecture may be created by using an AC electric field to orient the elongated particles within the solution at the time of deposition.
- carbon nanotubes are known to align themselves as a result of the formation of an induced dipole in response to an electric field.
- a DC field will align and move the nanotubes, whereas an AC field only aligns them.
- M. Senthil Kumar et al "Influence of electric field type on the assembly of single walled carbon nanotubes," Chemical Physics Letters 383 (2004) 235-239. See also U.S. Serial No. 11/368,738.
- the particles of the various layers may all be aligned in a single direction.
- electrical field alignment may be used to align the positively and negatively charged layers orthogonally with respect one another. These steps may, again, be followed by LBL polyelectrolyte processing, sol-gel processing and heat treatment, thereby forming a strongly connected ceramic network with internal reinforcement based on carbon nanotubes.
- FIG. 9A A further embodiment of the invention is illustrated in conjunction with Figs. 9A- 9D.
- a substrate 910 having one or more depressions e.g., blind holes 910b
- a PML coating Two layers are schematically illustrated in Fig. 9A, an inner positive polyelectrolyte layer 912p and an outer negative polyelectrolyte layer 912n, although a single layer, or three or more layers may be applied.
- the outer layer can be a positive layer, rather than a negative layer as illustrated.
- the substrate may be, for example, a stent within which numerous blind holes are formed (e.g., via laser ablation).
- a positive polyelectrolyte layer 912p or multiple alternating polyelectrolyte layers terminating in a positive polyelectrolyte layer, is/are selectively applied to those portions of the negative polyelectrolyte layer 912n layer over the upper substrate surface, but not those portions within the blind hole 910b, resulting in a structure like that of Fig. 9B.
- This structure has a negative surface charge within the blind hole 919b and a positive surface charge outside the blind hole.
- the first layer adsorbed onto the stamp is cationic polyallylamine hydrochloride (PAH), followed by alternating layers of anionic sulfonated polystyrene (SPS) and cationic polydiallyldimethylammonium chloride (PDAC). The last layer is the cationic PDAC.
- PAH polyallylamine hydrochloride
- SPS anionic sulfonated polystyrene
- PDAC cationic polydiallyldimethylammonium chloride
- the stamp is then contacted with a substrate having a negative surface charge and the multilayer is transferred in its entirety from the stamp to the substrate.
- the top layer of the transferred pattern is the anionic PAH layer.
- the structure of Fig. 9B is exposed to particles having a negative surface charge.
- the particles are spheres 915 with PML coating layers, terminating in a positively charged polyelectrolyte layer 92 Ip.
- the structure of Fig. 9C can then be optionally provided with additional polyelectrolyte layers as desired, followed by sol-gel processing and heat treatment to produce a structure like that of Fig. 9D, which includes a substrate 910 having a ceramic coating that includes raised ceramic shells 920s (in Fig. 9D the shells are hollow, although they need not be, as note elsewhere herein) connected by a ceramic layer 920c that is conformal with the substrate.
- the raised ceramic shells 920s are found only in the blind holes.
- a carbon nanotube 1010 can be provided with a polyelectrolyte multilayer coating 1012. This structure is then exposed a sol-gel precursor, forming a polyelectrolyte/ceramic hybrid coating 1014 as shown in Fig. 1OB, followed by heat treatment to create carbon nanotubes 1010 with a ceramic coating 1020 as shown in Fig. 1OC.
- a sol-gel precursor forming a polyelectrolyte/ceramic hybrid coating 1014 as shown in Fig. 1OB
- heat treatment to create carbon nanotubes 1010 with a ceramic coating 1020 as shown in Fig. 1OC.
- Such carbon nanotubes would have applications in many fields, for example, finding use as reinforcement particles in polymers or metals. Carbon nanotubes normally are at risk for agglomeration due to ⁇ - ⁇ bonding, which is disrupted by the ceramic coating.
- PSS solution a solution of poly(sodium 4-styrenesulfonate) (PSS) (m.w.
- EX0285-3 EMD Chemicals, Gibstown, NJ, USA
- 10 mL DI water and 1 mL ammonium hydroxide (25% in water) (Sigma-Aldrich), followed by further mixing.
- the coupon is provided with 1.5 bi-layers (PAH/PSS/PAH), followed by a PS particle layer, followed by 1.5 bilayers (PAH/PSS/PAH).
- the resulting structures are analogous to those shown schematically in Figs. 5A-5C (described above).
- the coupon is immersed in a beaker of PAH or PSS solution (prepared as described above) and agitated on a shaker for 20 minutes.
- the coupon is immersed in a beaker of the PS particle solution (prepared as described above) and agitated on a shaker for 1 hour.
- Three DI water rinses are performed after each layer to remove non-adsorbed polyelectrolyte/particles and the coupon is placed directly into the next solution.
- This structure is then submerged in a beaker of sol-gel solution (prepared as described above) for approximately 16 hours. Three DI water rinses are performed after exposure to the sol-gel solution.
- the resulting structure which is analogous to that shown schematically in Fig. 5F (described above), is placed in an oven at ambient temperature and ramped to a final temperature of 540 0 C over a period of ⁇ 1.5 hrs. After a total cycle time of 6 hrs (ramp-up and 540 0 C hold), the oven is turned off, and the sample is allowed to cool in the oven overnight.
- the final structure is analogous to that shown schematically in Fig. 5F (described above).
- PAH solution PAH solution, PSS solution, and PS particle solution, are prepared as described in
- Example 1 For the sol gel solution, a solution was prepared in which the recipe of
- Attapulgite particle solution (Atta) is prepared as follows: 50 g/L
- Attapulgite Clay (ATTAGEL® 5O)(BASF) is provided in 25mM NaCl.
- the stent is provided with 3.5 bilayers (PAH/PSS/PAH/PSS/PAH/PSS/PAH), followed by 2 bilayers (Atta/PAH/Atta/PAH), followed by a PS particle layer, followed by 2 bilayers (PAH/PSS/PAH/PSS).
- PAH/PSS/PAH/PSS 3.5 bilayers
- Atta/PAH/Atta/PAH 2 bilayers
- PAH/PSS/PAH/PSS 2 bilayers
- the stent is immersed in a beaker of PAH, PSS or Atta solution (prepared as described above) and agitated on a shaker for 20 minutes.
- the stent is immersed in a beaker of the PS particle solution (prepared as described above) and agitated on a shaker for 1 hour. Three DI water rinses are performed after each layer to remove non-adsorbed polyelectrolyte/ particles and the stent placed directly into the next solution.
- This structure is then submerged in a beaker of sol-gel solution (prepared as described above) for approximately 16 hours, after which three DI water rinses are performed.
- the resulting structure is placed in an oven at ambient temperature ( ⁇ 23°C) and ramped to 540 0 C over a period of ⁇ 1.5 hrs. After a total time of 6 hrs in the oven
- Polyelectrolyte coated carbon nanotubes are prepared as an initial step.
- NaCl 5.8 g
- 100 mL of deionized water are placed in a 250 mL flask and stirred until the PDMAEMA and NaCl are completely dissolved.
- the pH value of the solution is adjusted to 3.7 by adding 2 M HCl.
- Multi-wall carbon nanotubes derivatized with carboxyl groups (MWNT-COOH) 80 mg) (Cheap Tubes, Inc.
Abstract
Description
Claims
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Also Published As
Publication number | Publication date |
---|---|
CN101808677A (en) | 2010-08-18 |
CA2694686A1 (en) | 2009-02-05 |
EP2175902A2 (en) | 2010-04-21 |
WO2009018029A3 (en) | 2009-05-28 |
US20090138077A1 (en) | 2009-05-28 |
US7931683B2 (en) | 2011-04-26 |
JP2010534518A (en) | 2010-11-11 |
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