US6558409B1
Expired / Lapsed
US
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Plasma treated surgical needles and methods for their manufacture
Assignee: Covidien LP
•
Filing: 2001-09-28
•
Granted: 2003-05-06
•
Expires: 2021-09-28
Abstract
Abstract Methods for siliconizing surgical needles include a plasma polymerization coating process.
Inventors
- 👤 Mark S. Roby
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 11:48
CPC Classifications
A; A61; A61B; A61B17/00; A61B17/04; A61B17/06; A61L; A61L31/00; A61L31/08; A61L31/10; A61B17/06066; A61B17/06004; A61B2017/06028; A61B2017/0608
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
79 words
A method for coating a surgical needle comprising the steps of: providing a surgical needle having a surface; and forming a polymer coating on at least a portion of the surface of the needle by plasma polymerization of a hydrocyclosiloxane monomer of the general formula where R is an aliphatic group and n is an integer from 2 to about 10, preferably 4 to 6, whereby the polymer coated needle exhibits reduced penetration force compared to an uncoated needle.
Claim 2
Independent Claim
79 words
A method for coating a surgical needle comprising the steps of: providing a surgical needle having a surface; and forming a polymer coating on at least a portion of the surface of the needle by plasma polymerization of a hydrocyclosiloxane monomer of the general formula where R is an aliphatic group and n is an integer from 2 to about 10, preferably 4 to 6, whereby the polymer coated needle exhibits reduced penetration force compared to an uncoated needle.
Claim 3
Dependent Claim
27 words
The method of claim 1 wherein said hydrocyclosiloxane monomer is selected from the group consisting of 1,3,5,7-tetramethylcyclotetrasiloxane; 1,3,5,7,9-pentamethylhydrocyclopentasiloxane; 1,3,5,7,9,11-hexamethylhydrocyclohexasiloxane and a mixture of 1,3,5,7,9-pentamethylcyclopentasiloxane and 1,3,5,6,9,11-hexamethylcyclohexasiloxane monomers.
Claim 4
Dependent Claim
57 words
The method of claim 1 further comprising the step of adding an amine group onto the polymer coating by subjecting the needle to a gas containing a monomer selected from the group consisting essentially of unsaturated N-protected amines, unsaturated N-unprotected amines, N-protected cyclic aliphatic amines, and N-unprotected cyclic aliphatic amines, to produce an amine grafted polymer coating.
Claim 5
Dependent Claim
21 words
The method of claim 3 wherein the unsaturated or cyclic amine is copolymerized with the hydrocyclosiloxane monomer onto the needle surface.
Claim 6
Dependent Claim
22 words
The method of claim 3 wherein the unsaturated or cyclic amine is plasma grafted onto the polymer coating on the needle surface.
Claim 7
Dependent Claim
13 words
The method of claim 3 wherein said unsaturated or cyclic amine is N-trimethylsilylallylamine.
Claim 8
Dependent Claim
22 words
The method of claim 3 further comprising the step of contacting the amine grafted polymer coating with a carbonate-based polyalkylene oxide compound.
Claim 9
Dependent Claim
115 words
The method of claim 7 wherein the carbonate-based polyoxyalkylene oxide compound is a compound of the formula wherein R 1 is selected from an N-benzotriazole group, an N-2-pyrrolidinone group, or a 2-oxypyrimidine group; R 2 , R 3 and R 4 are independently selected alkylene groups of about 2 to about 3 carbon atoms and may be the same or different; R 5 is selected from hydrogen, methyl, a carbonyloxy-N-benzotriazole group, a carbonyloxy-N-2-pyrrolidinone group, and a carbonyl-2-oxypyrimidine group; a is an integer from 1 to 1000 and each of b and c is an integer from 0 to 1000, where a+b+c is an integer from 3 to 1000 to produce a polyoxyalkylene modified polymer coating.
Claim 10
Dependent Claim
15 words
The method of claim 8 wherein said carbonate-based polyalkylene oxide compound is polyoxyethylene bis-(N-hydroxybenzotriazolyl) carbonate.
Claim 11
Dependent Claim
23 words
The method of claim 1 further comprising the step of subjecting the needle surface to plasma etching prior to the plasma polymerization process.
Claim 12
Dependent Claim
18 words
The method of claim 10 wherein the plasma etching comprises treating the needle surface with an ammonia/oxygen plasma.
Claim 13
Dependent Claim
20 words
The method of claim 1 further comprising the step of applying a lubricant composition over the plasma polymerized polymer coating.
Claim 14
Dependent Claim
12 words
The method of claim 12 wherein the lubricant composition comprises a silicone.
Claim 15
Dependent Claim
13 words
The method of claim 13 wherein the lubricant composition comprises an aminoalkyl siloxane.
Claim 16
Dependent Claim
21 words
The method of claim 14 wherein the lubricant composition further comprises a second siloxane that is copolymerizable with the aminoalkyl siloxane.
Claim 17
Dependent Claim
22 words
The method of claim 14 wherein the lubricant composition further comprises a second siloxane that does not copolymerize with the aminoalkyl siloxane.
Claim 18
Dependent Claim
14 words
The method of claim 14 further comprising the step of curing the aminoalkyl siloxane.
Claim 19
Dependent Claim
18 words
The method of claim 13 wherein the lubricant composition comprises a polydimethylsiloxane having amino and alkoxy functional groups.
Claim 20
Dependent Claim
14 words
The method of claim 13 wherein the lubricant composition comprises a polydimethylsiloxane and hexane.
Claim 21
Dependent Claim
87 words
The method of claim 17 wherein the step of curing the lubricant composition comprises: subjecting the lubricant composition to an atmosphere of from about 20% to about 80% relative humidity, at a temperature from about 10° C. to about 50° C. for a time period ranging from about 1 hour to about 6 hours; and, heating to a temperature of from about 100° C. to about 200° C. for a time period ranging from about 2 hours to about 48 hours to effectively polymerize the lubricant composition.
Claim 22
Independent Claim
228 words
A method for coating a surgical needle comprising the steps of: providing a surgical needle having a surface; subjecting the surface of the needle to a plasma polymerization process wherein a polymer coating is formed on the needle surface from a hydrocyclosiloxane monomer of the general formula where R is an aliphatic group and n is an integer from 2 to about 10, preferably 4 to 6; adding an amine group onto the polymer coating by subjecting the needle to a gas containing a monomer selected from the group consisting essentially of unsaturated N-protected amines, unsaturated N-unprotected amines, N-protected cyclic aliphatic amines, and N-unprotected cyclic aliphatic amines, to produce an amine grafted polymer coating; and contacting the amine grafted polymer coating with a carbonate-based polyalkylene oxide compound of the formula wherein R 1 is selected from an N-benzotriazole group, an N-2-pyrrolidinone group, or a 2-oxypyrimidine group; R 2 , R 3 and R 4 are independently selected alkylene groups of about 2 to about 3 carbon atoms and may be the same or different; R 5 is selected from hydrogen, methyl, a carbonyloxy-N-benzotriazole group, a carbonyloxy-N-2-pyrrolidinone group, and a carbonyl-2-oxypyrimidine group; a is an integer from 1 to 1000 and each of b and c is an integer from 0 to 1000, where a+b+c is an integer from 3 to 1000 to produce a polyoxyalkylene modified polymer coating.
Claim 23
Independent Claim
228 words
A method for coating a surgical needle comprising the steps of: providing a surgical needle having a surface; subjecting the surface of the needle to a plasma polymerization process wherein a polymer coating is formed on the needle surface from a hydrocyclosiloxane monomer of the general formula where R is an aliphatic group and n is an integer from 2 to about 10, preferably 4 to 6; adding an amine group onto the polymer coating by subjecting the needle to a gas containing a monomer selected from the group consisting essentially of unsaturated N-protected amines, unsaturated N-unprotected amines, N-protected cyclic aliphatic amines, and N-unprotected cyclic aliphatic amines, to produce an amine grafted polymer coating; and contacting the amine grafted polymer coating with a carbonate-based polyalkylene oxide compound of the formula wherein R 1 is selected from an N-benzotriazole group, an N-2-pyrrolidinone group, or a 2-oxypyrimidine group; R 2 , R 3 and R 4 are independently selected alkylene groups of about 2 to about 3 carbon atoms and may be the same or different; R 5 is selected from hydrogen, methyl, a carbonyloxy-N-benzotriazole group, a carbonyloxy-N-2-pyrrolidinone group, and a carbonyl-2-oxypyrimidine group; a is an integer from 1 to 1000 and each of b and c is an integer from 0 to 1000, where a+b+c is an integer from 3 to 1000 to produce a polyoxyalkylene modified polymer coating.
Claim 24
Dependent Claim
27 words
The method of claim 21 wherein said hydrocyclosiloxane monomer is selected from the group consisting of 1,3,5,7-tetramethylcyclotetrasiloxane; 1,3,5,7,9-pentamethylhydrocyclopentasiloxane; 1,3,5,7,9,11-hexamethylhydrocyclohexasiloxane and a mixture of 1,3,5,7,9-pentamethylcyclopentasiloxane and 1,3,5,6,9,11-hexamethylcyclohexasiloxane monomers.
Claim 25
Dependent Claim
21 words
The method of claim 21 wherein the unsaturated or cyclic amine is copolymerized with the hydrocyclosiloxane monomer onto the needle surface.
Claim 26
Dependent Claim
22 words
The method of claim 21 wherein the unsaturated or cyclic amine is plasma grafted onto the polymer coating on the needle surface.
Claim 27
Dependent Claim
13 words
The method of claim 21 wherein said unsaturated or cyclic amine is N-trimethylsilylallylamine.
Claim 28
Dependent Claim
15 words
The method of claim 21 wherein said carbonate-based polyalkylene oxide compound is polyoxyethylene bis-(N-hydroxybenzotriazolyl) carbonate.
Claim 29
Dependent Claim
23 words
The method of claim 21 further comprising the step of subjecting the needle surface to plasma etching prior to the plasma polymerization process.
Claim 30
Dependent Claim
18 words
The method of claim 27 wherein the plasma etching comprises treating the needle surface with an ammonia/oxygen plasma.
Claim 31
Dependent Claim
17 words
The method of claim 21 further comprising applying a lubricant composition to the polyoxyalkylene modified polymer coating.
Claim 32
Dependent Claim
12 words
The method of claim 29 wherein the lubricant composition comprises a silicone.
Claim 33
Dependent Claim
13 words
The method of claim 30 wherein the lubricant composition comprises an aminoalkyl siloxane.
Claim 34
Dependent Claim
21 words
The method of claim 31 wherein the lubricant composition further comprises a second siloxane that is copolymerizable with the aminoalkyl siloxane.
Claim 35
Dependent Claim
22 words
The method of claim 31 wherein the lubricant composition further comprises a second siloxane that does not copolymerize with the aminoalkyl siloxane.
Claim 36
Dependent Claim
14 words
The method of claim 31 further comprising the step of curing the aminoalkyl siloxane.
Claim 37
Dependent Claim
18 words
The method of claim 29 wherein the lubricant composition comprises a polydimethylsiloxane having amino and alkoxy functional groups.
Claim 38
Dependent Claim
14 words
The method of claim 29 wherein the lubricant composition comprises a polydimethylsiloxane and hexane.
Claim 39
Dependent Claim
87 words
The method of claim 34 wherein the step of curing the lubricant composition comprises: subjecting the lubricant composition to an atmosphere of from about 20% to about 80% relative humidity, at a temperature from about 10° C. to about 50° C. for a time period ranging from about 1 hour to about 6 hours; and, heating to a temperature of from about 100° C. to about 200° C. for a time period ranging from about 2 hours to about 48 hours to effectively polymerize the lubricant composition.
Claim 40
Dependent Claim
32 words
A coated surgical needle comprising: a surgical needle having an outer surface; and a plasma polymerized polymer coating formed on at least a portion of said outer surface of said surgical needle.
Claim 41
Dependent Claim
32 words
A coated surgical needle comprising: a surgical needle having an outer surface; and a plasma polymerized polymer coating formed on at least a portion of said outer surface of said surgical needle.
Claim 42
Dependent Claim
20 words
A coated surgical needle as in claim 38 further comprising a silicone-containing coating applied to the plasma polymerized polymer coating.
Claim 43
Dependent Claim
16 words
A coated surgical needle as in claim 39 wherein the silicone-containing coating comprises an aminoalkyl siloxane.
Claim 44
Dependent Claim
24 words
A coated surgical needle as in claim 39 wherein the silicone-containing coating comprises a copolymer of an aminoalkyl siloxane and a second siliconization material.
Claim 45
Dependent Claim
45 words
A coated surgical needle comprising: a surgical needle having an outer surface; a polymer coating formed on at least a portion of said outer surface of said surgical needle, said polymer coating including a plasma polymerized amine substituted polymer coating having polyoxyalkylene groups bonded thereto.
Claim 46
Dependent Claim
45 words
A coated surgical needle comprising: a surgical needle having an outer surface; a polymer coating formed on at least a portion of said outer surface of said surgical needle, said polymer coating including a plasma polymerized amine substituted polymer coating having polyoxyalkylene groups bonded thereto.
Claim 47
Dependent Claim
23 words
A coated surgical needle as in claim 42 further comprising a silicone-containing coating applied to the amine grafted polymer coating having polyoxyalkylene groups.
Claim 48
Dependent Claim
16 words
A coated surgical needle as in claim 42 wherein the silicone-containing coating comprises an aminoalkyl siloxane.
Claim 49
Dependent Claim
24 words
A coated surgical needle as in claim 42 wherein the silicone-containing coating comprises a copolymer of an aminoalkyl siloxane and a second siliconization material.
Claim 50
Dependent Claim
81 words
A surgical needle having reduced penetration force comprising: a surgical needle having a polymer coating formed by a plasma polymerization process; and a silicone-containing coating over at least a portion of the polymer coating, whereby the surgical needle has a penetration force on a fifth pass through tissue that is at least 10% less than the penetration force on a fifth pass through tissue of a needle having the same silicone-containing coating on the same surgical needle having no polymer coating.
Claim 51
Dependent Claim
81 words
A surgical needle having reduced penetration force comprising: a surgical needle having a polymer coating formed by a plasma polymerization process; and a silicone-containing coating over at least a portion of the polymer coating, whereby the surgical needle has a penetration force on a fifth pass through tissue that is at least 10% less than the penetration force on a fifth pass through tissue of a needle having the same silicone-containing coating on the same surgical needle having no polymer coating.
Claim 52
Dependent Claim
15 words
A surgical needle as in claim 46 wherein the silicone-containing coating comprises an aminoalkyl siloxane.
Claim 53
Dependent Claim
23 words
A surgical needle as in claim 46 wherein the silicone-containing coating comprises a copolymer of an aminoalkyl siloxane and a second siliconization material.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2006-05-05 | 2006-11-04 | 2007-05-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2010-05-05 | 2010-11-04 | 2011-05-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2014-05-05 | 2014-11-04 | 2015-05-06 | $7700.00 | Window Closed / Lapsed |