Patent Description:
Lubricious coatings for medical devices are intended to facilitate insertion, manipulation, articulation and removal of the device. Typical such devices are catheters and other tubes. It is common for such devices to be provided with a surface which is potentially lubricious, either by coating part or all of the device with a potentially lubricious coating material, or by manufacturing it from such a material. It is generally the case that immediately before insertion of such a device into the body, the potentially lubricious surface requires hydration, typically by immersing it in a sterile saline solution or water, in order to fully develop its lubricity.

It is desirable to be able to reliably store medical devices of this kind already in water or saline solution for an extended period, before use, for example in sealed ready-for-use bags or pouches. However, especially in relation to coated devices, this demands a stable and durable lubricious coating which will stand up to handling and storage during the time between packaging and use without appreciable deterioration in the coating or its lubricious properties.

Furthermore, current coating solutions for applying lubricious coatings to devices tend to be short-lived. Many coating solutions have a tendency to increase in viscosity over time, which is detrimental to consistent application in serial coating processes, and may even gel. Therefore, coating solutions need to be changed on a regular basis during use, which results in low production efficiency when a coating line needs to be interrupted to wash and refill a dip-tank, and high wastage.

Current lubricious coatings that need a cross-linking agent to be included in the coating solutions frequently require the cross-linker to be added just prior to use, and for additional cross-linker to be added during the production run to 'reactivate' the coating solution.

The elements of the invention which are the subject of this patent application include a method of making a coating solution, a coating solution made by the method, a coating solution in storage, a method of coating a substrate which is on, or is part of, a medical device or other article, a substrate, article or medical device having a coating so applied, a coated medical device packaged in a hydration solution, and a coated substrate, article or medical device wherein the coating has certain novel and advantageous features.

The invention addresses improvements in coating solutions, with the object of providing one or more of various advantages, which may include a coating solution with an extended pot-life (meaning both the storage life and the usage life of the coating solution); avoiding the need to mix in a cross-linker just prior to the application of the solution to a device; reduced frequency of having to discard and replace the coating solution during production; reduced waste; ease of use; and a stable coating after having been cured on the device that can be stored in water for extended periods of time, enabling the production of ready-to-use pre-hydrated products.

The various aspects of the invention specifically include those set out in the appended claims, and also include other aspects disclosed, mentioned and discussed in the following detailed description, as well as those set out in the specific Examples herein.

<CIT> discloses a coating composition which comprises an aqueous polymeric matrix, a hydrophilic polymer, a colloidal metal oxide and a crosslinker.

<CIT> discloses the coating of substrates with copolymers of N-vinyl pyrrolidinone and aryl ketones.

<CIT> discloses curable antimicrobial film forming compositions comprising a polymeric matrix, a carrier solvent and at least one long chain compound comprising a functional group capable of forming a chemical bond with the matrix upon evaporating the carrier solvent and drying or curing of the composition.

The method of making a coating solution includes the steps of polymerising an initial monomer feed comprising an N-vinyl pyrrolidone and an acrylate, preferably methacrylate, salt in water to synthesise a copolymer thereof, acidifying the resulting copolymer-water mixture to give free carboxylic acid groups along the copolymer backbone, diluting the aqueous solution down with alcohol, and adding a cross-linking agent which is capable of reacting with the carboxylic acid groups and curing the copolymer at a later stage after the coating solution has been applied to a substrate and the copolymer coated thereon.

The invention provides that during the time between adding the cross-linking agent and putting the solution to further use by applying it to the substrate, the aqueous-alcoholic solution may be stored for an extended period, suitably for at least one month and desirably for substantially longer.

It is to be understood that 'acrylate' here is used in its broad sense to mean substituted as well as unsubstituted derivatives of acrylic acid. Among the acrylate monomer salts that may be included for co-polymerisation with the selected N-vinyl pyrrolidone species are the salts of acrylic acid, methacrylic acid, <NUM>-carboxyethyl acrylate, <NUM>-carboxyethyl methacrylate, methacryloyl-L-lysine, mono-<NUM>-(methacryloyloxy)ethyl maleate. Among possible acrylate salts are barium methacrylate, lithium methacrylate, magnesium acrylate, sodium acrylate, zinc (di)methacrylate, sodium methacrylate, zinc acrylate, zirconium acrylate, potassium acrylate. Other salts include <NUM>-sulfopropyl acrylate potassium salt, <NUM>-sulfopropyl methacrylate sodium salt. Accordingly, suitable cations for the acrylate salts include lithium, sodium, potassium, magnesium, barium, and zinc, sodium being most generally preferred. Protected acrylic acids, namely acrylic anhydride, methacrylic anhydride, may also be included as co-monomers.

The initial monomer feed may specifically comprise from about <NUM> to <NUM>% by weight, and preferably about <NUM> to about <NUM>% by weight, of acrylate salt, based on the total monomer content, to yield a suitable acid content for the cross-linker to react with and stabilise the coating, without overly prejudicing the viscosity of the solution. For the purpose of consistently calculating weight proportions, the acrylate salt is taken to be a sodium salt. While the monomer species in the monomer feed may comprise solely an N-vinyl pyrrolidone, usually unsubstituted N-vinyl pyrrolidone and in many cases specifically <NUM>-vinyl-<NUM>-pyrrolidone, and an acrylate, preferably methacrylate, salt, the copolymer may also include minor proportions of additional monomer species compatible with the storage and coating benefits of the invention. Any such additional monomer species should also be included in the initial monomer feed.

Such additional co-monomers may include vinyl acetate (to aid coating adhesion), acrylamide (to aid lubricity), glycerol methacrylate (to increase hydrophilicity), <NUM>-hydroxethyl methacrylate (to increase hydrophilicity), methoxy polyethylene glycol methacrylate (to increase lubricity and flexibility), polyethylene glycol methacrylate (to increase lubricity and flexibility), <NUM>-methacryloyloxyethyl phosphorylcholine (to increase hydrophilicity). Zwitterionic co-monomers include [<NUM>-(methacryloyloxy)ethyl]dimethyl-(<NUM>-sulfopropyl)ammonium hydroxide, <NUM>-((<NUM>-(methacryloyloxy)ethyl)dimethylammonio)ethyl <NUM>-methoxyethyl phosphate, and <NUM>-((<NUM>-(methacryloyloxy)propyl)dimethylammonio)ethyl <NUM>-methoxyethyl phosphate.

Different combinations of co-monomers may be employed. Any additional monomers should not amount to more than <NUM>% by weight of the total monomer mixture, and preferably not more than <NUM>% by weight.

The co-polymerisation of the monomers is carried out under standard conditions, using a suitable initiator such as a radical initiator like an azo or peroxide initiator, which may be initiated by thermal (heat) or photo (UV or visible) initiation, as known in the art.

We have found it advantageous to synthesise the initial copolymer as a salt, but to crosslink it later in its acid form. We have found that polymerisation as the free acid (methacrylic acid for example) can lead to the formation of insoluble poly salts, whereby the poly(N-vinyl pyrrolidone) and poly(methacrylic acid) formed during the polymerisation form a poly salt together that precipitates out of solution. Thus, it is advantageous to form the co-polymer when the acid is present in its salt form. Conversion to the free acid is then required to enable cross-linking, otherwise no reaction with the cross-linker will occur. Acidification after polymerisation converts the synthesised copolymer salt to the free acid and generates sodium chloride as a by-product, which may be removed during purification. A preferred acid is hydrochloric acid, but many other acids are also feasible.

After acidification, the copolymer-water mixture is desirably purified by removal of unreacted monomer and low molecular weight components below, for example, <NUM>,<NUM> mol-<NUM>. To this end, the solution may be dialysed, or precipitated, to remove some, or substantially all, such low molecular weight species. The removal of unreacted monomer, oligomer and salts can be controlled by the molecular weight cut-off (MWCO) of the membrane used to carry out the dialysis. For example, a <NUM>-<NUM>,<NUM> mol-<NUM> MWCO membrane can be used to suitably remove species below <NUM>,<NUM> mol-<NUM>.

After acidification and optional purification, the pH of the solution is desirably about <NUM> or lower, typically in the range of <NUM> to <NUM>. A pH greater than <NUM> or <NUM> within this overall range could be acceptable, as could a pH of less than <NUM> or <NUM>.

The aqueous mixture suitably has a copolymer concentration of at least about <NUM>% and less than about <NUM>%, preferably <NUM>% or greater, and preferably <NUM>% or less, all by weight.

The step of diluting the aqueous copolymer solution down with alcohol is then carried out so that the diluted solution comprises typically <NUM> part copolymer-water mixture to <NUM>-<NUM> parts, typically <NUM>-<NUM> parts, e.g. <NUM> parts, of alcohol. These relative proportions may be measured by weight, or may more conveniently be measured by volume. The alcohol may be isopropyl alcohol (IPA, <NUM>-propanol) or other lower alkanol, for example a C1 to C5 alkanol, such as methanol, ethanol, propanol (<NUM>-propanol) or butanol (<NUM>-butanol, <NUM>-butanol, tert-butanol), pentanol or mixtures thereof. Other water and/or alcohol miscible solvents may be present in minor proportions in the final coating solution.

The cross-linking agent may be selected from among many that are commercially available, and is preferably a multifunctional carbodiimide, or polycarbodiimide (that is, one having at least two reactive functional carbodiimide groups per molecule) which selectively reacts with carboxylic acid groups. Or it may be a multifunctional aziridine, or polyaziridine (that is, one having at least two reactive functional aziridine groups per molecule). This cross-linker enhances coating stability on the surface of a coated device. The preferred cross-linking agents, compared with alternatives such as isocyanates, are less sensitive to the presence of water and are able to achieve long pot-life times. Their reactivity means they can be heat-cured using a standard oven.

In the preparation of coating solutions in accordance with the invention, the balance between the concentration of the aqueous copolymer (more specifically the free acid content) and the amount of cross-linker added should be such that a stable durable coating is achieved after subsequently coating an article and curing the coating thereon, whilst still maintaining an extended pot-life, meaning that the solution does not gel too quickly in storage before use. For example, if too much cross-linker is added, the coating will be extremely stable, but the coating solution will gel within a few days. Similarly, if the concentration of the aqueous polymer (free acid content) is too high, then again a stable coating will be afforded, but the pot-life will be significantly reduced (will become too viscous to use). Therefore, it is important to maintain a balance. We have found that a concentration between <NUM> to <NUM> % w/w for the aqueous copolymer works well (that is, <NUM> to <NUM> % w/w of copolymer in water).

The cross-linker would typically be added in an amount of between <NUM> and <NUM> % by weight relative to the copolymer, more preferably between <NUM> and <NUM> % by weight.

The proportion of cross-linker to the free acid content of the copolymer in each particular case will depend upon the specific cross-linker used. The concentration of the aqueous copolymer solution and the cross-linker content are accordingly managed so as to maintain the stability of the coating solution over an extended storage period while preserving the lubricity and adhesion (durability) of coatings deposited therefrom and cured after such storage. The solution preferably has a solids content of from about <NUM> to about <NUM> weight percent. A preferred minimum is about <NUM> weight percent. A preferred maximum is about <NUM> weight percent.

Additional method steps may include the addition of one or more further polymers to the aqueous-alcoholic copolymer mixture. These further polymers may be used to improve the film-forming properties and the overall coating stability. Such further polymers may include hydrophilic polyurethanes, e.g. polyether-based hydrophilic polyurethanes, examples of which are available commercially, and can be formulated in suitable solvents, such as water and isopropyl alcohol or other suitable solvents - e.g. lower (C1-C5) alkanols, including methanol, ethanol, propanol (for example <NUM>-propanol, <NUM>-propanol), butanol (for example <NUM>-butanol, <NUM>-butanol, tert-butanol), pentanol, and other water and/or alcohol miscible solvents, or mixtures thereof, such as <NUM>-butanone, tetrahydrofuran, tert-butyl methyl ether, <NUM>-methyl-<NUM>-pyrrolidone.

Other such further polymer additions may also include hydrophilic polymers such as poly(vinyl pyrrolidone), poly(ethylene glycol), poly(acrylamide), poly(vinyl alcohol), hyaluronic acid, poly(methyl vinyl ether), poly(methyl vinyl ether-alt-maleic acid), poly(methyl vinyl ether-alt-maleic anhydride), poly(acrylic acid), poly(N-vinyl pyrrolidone-co-<NUM>-benzoylphenyl methacrylate-co-methoxy polyethylene glycol methacrylate-co-butyl methacrylate) or any selection of mixtures thereof. These further polymers may be used to improve the lubricity and dry-out time of the coatings. Other cured coating properties that can be adjusted by the use of additional polymers in the coating solution include flexibility, durability, adhesion, compatibility, and colour, amongst others.

The foregoing further polymer additions are suitably made before a period of extended storage, though could be made later.

The aqueous-alcoholic coating solution afforded by the invention accordingly comprises a poly(N-vinyl pyrrolidone-co-acrylic, preferably methacrylic, acid) together with an effective proportion of a cross-linking agent, particularly a multifunctional carbodiimide, or polycarbodiimide, or multifunctional aziridine, or polyaziridine, it being noted that alternative species of N-vinyl pyrrolidones and alternative species of acrylates are envisaged. The alcohol content of the solution assists in solubilising the cross-linker and aiding in the coating process, e.g. depositing the coating onto the substrate. As noted above, the proportion of cross-linker added to the aqueous-alcoholic copolymer solution will depend on a number of factors, including the concentration of copolymer - the higher the concentration, the lower the amount of cross-linker required.

In coating solutions containing further polyurethane components, a hydrophilic polyurethane may typically be included in a weight proportion of about <NUM> part polyurethane to between <NUM> and <NUM> parts copolymer, more frequently <NUM> parts or more, or <NUM> parts or less, of copolymer per part of polyurethane, both dissolved in aqueous-alcoholic solution.

The further hydrophilic polyurethane may be present at an equal weight to four times the weight of the cross-linker, or from more than <NUM> times, or up to <NUM> times, the weight of the cross-linker.

A preferred coating solution contains the various components within the following ranges of percentages by weight:.

Other components may be included, with corresponding adjustments to the percentages. Such components may include physical modifiers, for example wetting agents to enhance coating characteristics, as well as chemical modifiers and antimicrobial agents.

The invention provides that during the time between adding the cross-linking agent and putting the solution to further use by applying it to the substrate, the aqueous-alcoholic solution may be stored in a closed vessel, suitably for at least one month (<NUM> days) and desirably for six months or more. During this period, and subject to appropriate protection from elevated temperatures, the solution remains usable for coating purposes. Suitable storage vessels may be of plastic such as high density polyethylene or polypropylene, and/or glass bottles and/or stainless steel or other containers, jerrycans, drums, typically containing from <NUM> to <NUM> of coating solution. During storage, the solution is desirably not exposed to temperatures above <NUM> for continuous periods longer than <NUM> days. Accordingly, the invention provides a coating solution, made by the methods of the invention, which has the property of remaining usable for applying coatings, without further adjustment, after storage in a closed vessel for at least <NUM> days at a temperature not exceeding <NUM>.

The method of coating a substrate comprises applying a coating solution according to the invention to a substrate, evaporating the solution to leave an uncured polymer coating thereon, and curing the coating on to the substrate. Curing comprises cross-linking the copolymer, and is suitably achieved with heating, suitably in an oven or by microwave radiation, to an elevated temperature, for example between <NUM> and <NUM> degrees Celsius, usually between <NUM> and <NUM>, for a suitable length of time, such as <NUM> to <NUM> hours, preferably <NUM> to <NUM> hours. In general, the curing time of a coating is related to temperature, so that many coatings can be cured in under <NUM> minutes if a temperature greater than <NUM> is employed. We have found that the main constraint is the underlying medical device itself and what maximum temperature it can withstand without damage, such as deforming or warping for example. Fast curing times are beneficial because production times can be reduced, so throughput can be increased.

The substrate may be a surface of a medical device, and may be the whole surface of the medical device. Devices include Foley catheters (latex, poly(urethane) and silicone), intermittent (urological) catheters (PVC and latex), PTCA (percutaneous transluminal coronary angioplasty) catheters, balloon catheters endotracheal tubes, rectal catheters, rectal cones, endoscopes, drainage catheters, dilators, introducer sheaths, intraocular lens inserters, tracheal dilators, cannulas, needles, orthopaedic implants and guidewires. The coating may be applied by standard techniques including dipping, spraying, painting, wiping, and rolling.

It has been found that, depending upon the formulation of the coating solution, from <NUM> to <NUM> months of pot life (storage life) for the solution can be achieved without a detrimental increase in solution viscosity or without the solution gelling, and that the solution remains usable during that period. The inconvenient need to add cross-linker just prior to or during use, or to repeatedly drain and re-fill the coating just prior to or during use, as can be the case with current coating solutions, may be reduced or wholly avoided by means of the invention, while still achieving a stable lubricious coating which is resistant to abrasion and delamination. The formulation can be adjusted to control and extend coating dry-out times.

Coated devices in accordance with the invention may be stored in hydration media including water or saline or other solutions, such as cleaning, disinfecting, antimicrobial or antibacterial solutions, for extended periods, making them especially suitable for ready-to-use and multi-use products including urological catheters. Accordingly, the invention extends to a packaged device having a lubricious coating in accordance with the invention stored in a hydration medium. The packaging may be selected from any packaging acceptable for containing the hydration medium and suitable for the device concerned. The device will normally be sealed into the packaging until it is required for use. Suitable packaging may include bags, pouches, foils, sleeves, envelopes, trays, sheaths, bottles, tubes, cartons and films.

Medical devices to which the coatings of the invention are intended to be applied are normally required to be sterile when they are used. Accordingly, the practice of the invention may include a sterilisation step. A coated device stored in a hydration medium should be sterile. Numerous means of sterilisation are known for use with medical devices; among those preferred for use with this invention are ethylene oxide sterilisation techniques, and gamma and electron beam irradiation.

Further aspects of the invention are disclosed below in a series of specific Examples, which include some identified as reference Examples for comparative purposes.

Examples <NUM> to <NUM> highlight the synthesis of the base polymer. They highlight the inclusion of additional monomer species, which are compatible with the storage and coating benefits of the invention. They also show a possible purification method, e.g. dialysis, and the typical concentrations obtained after acidifying and purifying.

This example demonstrates the synthesis of the base polymer.

To a <NUM> flask, fitted with a nitrogen (N<NUM>) inlet, was added N-vinyl pyrrolidone (NVP) (<NUM>), water (<NUM>) and sodium acrylate (<NUM>). The mixture was heated to <NUM> whilst being purged with N<NUM>. Once the temperature had reached <NUM>, <NUM>,<NUM>'-azobis(<NUM>-methylbutanenitrile) (AMBN) (<NUM>) (dissolved in <NUM> of NVP) was added in one portion to initiate the polymerisation. The polymerisation was carried out for <NUM> minutes, after which time water (<NUM>) containing HCl (<NUM>%) (<NUM>) was added to quench the reaction and acidify the resulting copolymer-water mixture, thereby providing free carboxylic acid groups along the copolymer backbone. The mixture was allowed to stir and cool and was then purified by membrane dialysis against water (~ <NUM>), using a molecular weight cut-off (MWCO) of <NUM>-<NUM>,<NUM> mol-<NUM>, for approximately <NUM> hours. Following dialysis, the final co-polymer solution had a concentration of <NUM> % w/w and a pH of <NUM>, thus indicating that the copolymer-water mixture was successfully acidified.

To a <NUM> flask, fitted with a N<NUM> inlet, was added NVP (<NUM>), water (<NUM>) and sodium methacrylate (<NUM>). The mixture was heated to <NUM> whilst being purged with N<NUM>. Once the temperature had reached <NUM>, AMBN (<NUM>) (dissolved in <NUM> of NVP) was added in one portion to initiate the polymerisation. The reaction was carried out for <NUM> minutes, after which time water (<NUM>) containing HCl (<NUM>%) (<NUM>) was added to quench the reaction and acidify the resulting copolymer-water mixture, thereby providing free carboxylic acid groups along the copolymer backbone. The mixture was allowed to stir and cool and was then purified by membrane dialysis against water (~ <NUM>), using a molecular weight cut-off (MWCO) of <NUM>-<NUM>,<NUM> mol-<NUM>, for approximately <NUM> hours. Following dialysis, the final co-polymer solution had a concentration of <NUM> % w/w and a pH of <NUM>, thus indicating that the copolymer-water mixture was successfully acidified.

This example demonstrates the synthesis of the base polymer, including an additional monomer.

To a <NUM> flask, fitted with a N<NUM> inlet, was added NVP (<NUM>), water (<NUM>), sodium methacrylate (<NUM>) and methoxy poly(ethylene glycol) methacrylate (MPEGMA) (<NUM>). The mixture was heated to <NUM> whilst being purged with N<NUM>. Once the temperature had reached <NUM>, AMBN (<NUM>) (dissolved in <NUM> of NVP) was added in one portion to initiate the polymerisation. The reaction was carried out for <NUM> minutes, after which time water (<NUM>) containing HCl (<NUM>%) (<NUM>) was added to quench the reaction and acidify the resulting copolymer-water mixture, thereby providing free carboxylic acid groups along the copolymer backbone. The mixture was allowed to stir and cool and was then purified by membrane dialysis against water (~ <NUM>), using a molecular weight cut-off (MWCO) of <NUM>-<NUM>,<NUM> mol-<NUM>, for approximately <NUM> hours. Following dialysis, the final co-polymer solution had a concentration of <NUM> % w/w and a pH of <NUM>, thus indicating that the copolymer-water mixture was successfully acidified.

Examples <NUM> to <NUM> highlight how the polymers are formulated (mixed) with the cross-linker. Two types of cross-linker are given, multifunctional carbodiimide and multifunctional aziridine. Example <NUM> shows how the polymer can be formulated without cross-linker, which has been included to highlight the cross-linker requirement, i.e. that the coating is not stable (durable) if no cross-linker is added to the formulation.

This example demonstrates how the base polymer is mixed with a carbodiimide cross-linker.

The co-polymer solution prepared in Example <NUM> (<NUM>) was mixed with isopropyl alcohol (IPA) (<NUM>) and stirred until homogenous. To this was added multifunctional polycarbodiimide cross-linker (<NUM>) and the solution was stirred until the cross-linker had dissolved (~ <NUM> minutes). The concentration of the solution was <NUM> % w/w.

This example demonstrates how the base polymer is mixed with an aziridine cross-linker.

The co-polymer solution prepared in Example <NUM> (<NUM>) was mixed with IPA (<NUM>) and stirred until homogenous. To this was added trimethylolpropane tris(<NUM>-methyl-<NUM>-aziridine propionate) (<NUM>) and the solution was stirred until the cross-linker had dissolved (~ <NUM> minutes). The concentration of the solution was <NUM> % w/w.

This example demonstrates how the base polymer is mixed with alcohol (no cross-linker).

The co-polymer solution prepared in Example <NUM> (<NUM>) was mixed with IPA (<NUM>) and stirred until homogenous. The concentration of the solution was <NUM> % w/w.

Examples <NUM> to <NUM> highlight the additional method step of adding one or more further polymers to the mixture, e.g. polyether-based hydrophilic and thermoplastic polyurethanes, which may be used to improve film-forming properties on certain substrates, thereby expanding the scope of materials that can be coated.

This example demonstrates how the additional polymer is formulated (added) to the base polymer formulation to provide a coating with enhanced film forming qualities.

Hydromed D640 (<NUM>) was dissolved in a mixture of IPA/water (<NUM>/<NUM>). To this was added the co-polymer prepared in Example <NUM> (<NUM>) and the solution was mixed until homogenous (~ <NUM> minutes). Separately, multifunctional polycarbodiimide cross-linker (<NUM>) was dissolved in IPA (<NUM>) and the mixture was added to the polymer solution and stirred for <NUM> hours. The final concentration of the solution was <NUM> % w/w.

HydroSlip C (<NUM>) was dissolved in a mixture of IPA/water (<NUM>/<NUM>). To this was added the co-polymer prepared in Example <NUM> (<NUM>) and the solution was mixed until homogenous (~ <NUM> minutes). Separately, multifunctional polycarbodiimide cross-linker (<NUM>) was dissolved in IPA (<NUM>) and the mixture was added to the polymer solution and stirred for <NUM> hours. The final concentration of the solution was <NUM> % w/w. Examples <NUM> to <NUM> highlight further polymer additions that may include hydrophilic polymers, which may be used to improve the lubricity and dry-out time of the coatings.

This example demonstrates how the additional hydrophilic polymer is formulated (added).

Hydromed D640 (<NUM>) was dissolved in a mixture of IPA/water (<NUM>/<NUM>). To this was added the co-polymer prepared in Example <NUM> (<NUM>) and the solution was mixed until homogeneous (~ <NUM> minutes). Separately, poly(vinyl pyrrolidone) (PVP) (<NUM>) was dissolved in IPA (<NUM>). Once dissolved, this was added to the polymer solution previously prepared and mixed until homogenous. The cross-linker solution was prepared by dissolving multifunctional carbodiimide cross-linker (<NUM>) in IPA (<NUM>). This was then added to the polymer mixture. The final solution was stirred for <NUM> hours. The concentration was <NUM> % w/w.

Hydromed D640 (<NUM>) was dissolved in a mixture of IPA/water (<NUM>/<NUM>). To this was added the co-polymer prepared in Example <NUM> (<NUM>) and the solution was mixed until homogeneous (~ <NUM> minutes). Separately, poly(ethylene glycol) (PEG) (<NUM>) was dissolved in IPA (<NUM>). Once dissolved, this was added to the polymer solution previously prepared and mixed until homogenous. The cross-linker solution was prepared by dissolving multifunctional carbodiimide cross-linker (<NUM>) in IPA (<NUM>) and then adding this to the polymer mixture. The final solution was stirred for <NUM> hours. The concentration was <NUM> % w/w.

A <NUM> % w/v solution of hyaluronic acid sodium salt (HA) was prepared by dissolving HA (<NUM>) in water (<NUM>). The co-polymer solution prepared in Example <NUM> (<NUM>) was combined with water (<NUM>) and the HA solution (<NUM>). IPA (<NUM>) was added to this mixture dropwise under stirring such that a clear solution resulted. Hydromed D640 (<NUM>) was then dissolved in this mixture. Separately, the multifunctional carbodiimide cross-linker (<NUM>) was dissolved in IPA (<NUM>) and then added to the coating solution. The solution was stirred for <NUM> hours. The concentration of the coating solution was <NUM> % w/w.

Examples <NUM> to <NUM> highlight how the polymers / formulations prepared in the previous examples are coated onto various substrates / medical devices using various techniques, such as dipping or wiping and how they are cured using various temperatures / times.

This example demonstrates how the coating formulation prepared in Example <NUM> can be applied to a particular substrate / device and how it can be cured at a particular temperature for a particular period of time.

PVC Intermittent Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example <NUM> and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> hour to cure the coating. The samples were allowed to cool before being packaged.

This example demonstrates how the coating formulation prepared in Example <NUM> (without cross-linker) can be applied to a particular substrate / device and how it can be heated at a particular temperature for a particular period of time. This example is included as a comparison to show the difference between a coating formulated with cross-linker and a coating formulated without cross-linker.

PVC Intermittent Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example <NUM> and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> hour. The samples were allowed to cool before being packaged.

This example demonstrates how the coating formulation prepared in Example <NUM> can be applied to a more challenging substrate through incorporation of an additional polyether-based polyurethane, which serves to improve the film-forming properties of the coating.

Silicone Foley Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example <NUM> and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> hour to cure the coating. The samples were allowed to cool before being packaged.

PVC Intermittent Catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example <NUM> and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> minutes to cure the coating. The samples were allowed to cool before being packaged.

Poly(urethane) catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example <NUM> and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> minutes to cure the coating. The samples were allowed to cool before being packaged.

Poly(amide) PTCA catheters were first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were wipe coated using the solution prepared in Example <NUM> and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> hours to cure the coating. The samples were allowed to cool before being packaged.

Thermoplastic elastomer (TPE) based catheters was first cleaned by wiping with an IPA soaked lint-free cloth. Once dry, they were dipped into the coating solution prepared in Example <NUM> and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> minutes to cure the coating. The samples were allowed to cool before being packaged.

Examples <NUM> to <NUM> demonstrate the properties / functionality of the coated devices prepared in previous examples, such as reduced friction (increased lubricity), coating stability (durability), and increased dry-out time.

The PVC catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. The coating demonstrated a dry-out time of approximately <NUM> minutes and a coefficient of friction below <NUM>.

The PVC catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. The uniformity and initial lubricity were adequate, however under mild abrasion the coating was easily removed from the surface of the catheter. Thus indicating the necessity for cross-linker to be added to the formulation.

The silicone catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed.

The PVC catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. The coating demonstrated a dry-out time of approximately <NUM> minutes, i.e. twice as long as that shown by coated Example <NUM>, as a result of the PVP inclusion. The coefficient of friction was typically below <NUM>. Also, a cure time of <NUM> minutes was sufficient to provide the desired coating properties.

The poly(urethane) catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. It was noted that the lubricity had increased in comparison with coated Example <NUM> as a results of the HA inclusion. The coefficient of friction was typically below <NUM>. Also, a cure time of <NUM> minutes was sufficient to provide the desired coating properties.

The poly(amide) catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed.

The TPE catheters coated in Example <NUM> were evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. Surprisingly, it was noted that the quality of the coating was akin to that achieved in coated Example <NUM>, thereby highlighting that the desired coating properties can be achieved after a shorter curing period (<NUM> minutes), when a higher cure temperature is employed.

Examples <NUM> to <NUM> demonstrate the increased pot-life of the coating formulations prepared in previous examples and include details of storage conditions, testing (e.g. viscosity), device coating and functional testing.

This example shows the comparative testing results for the formulation prepared in Example <NUM> tested on day <NUM> and after <NUM> months storage at ambient temperature.

After storage for <NUM> months, clean PVC Intermittent Catheters were dipped into the coating solution and submerged for approximately <NUM> seconds. After this time, they were extracted and allowed to dry under ambient conditions for at least <NUM> minutes. They were then transferred to an oven and heated at <NUM> for <NUM> hour to cure the coating. The samples were allowed to cool before being evaluated for their coating uniformity using crystal violet dye, their lubricity after hydration in water for <NUM> seconds and coating durability using a wet glove test and subsequent dye. In all cases the coating was uniform, lubricious and durable under the test conditions employed. Surprisingly, the performance of the coating was analogous to a sample coated with a freshly prepared solution, thereby highlighting the advantage of the present invention, to provide coating solutions with extended pot-life.

Example <NUM> demonstrates sterilisation (by ethylene oxide) and subsequent biocompatibility testing of a device coated with a formulation of the invention.

A coating formulation was prepared according to a similar procedure as that described in Example <NUM>. PVC Intermittent Catheters were then coated according to a similar procedure as that described in Example <NUM>. The coated samples were sterilised by ethylene oxide (EtO) gas and then tested according to ISO10993, whereby the cytotoxicity, irritation, acute systemic toxicity and sensitisation effects of the coated article were evaluated. The coating was considered non-cytotoxic to the subconfluent monolayer of L-<NUM> mouse fibroblast cells and non-irritant to the skin of New Zealand White Rabbits. It was also demonstrated that the coating did not reveal any systemic toxicity when administered to Swiss Albino mice and was non-sensitising to the skin of Guinea pigs under the experimental conditions and doses employed.

Example <NUM> demonstrates the stability of the coating when a coated device is left submerged in water for an extended period of time, i.e. the functionality is unaltered after this period. This is to exemplify the potential for this coating to be utilised on ready-to-use (pre-hydrated) products.

A coating formulation was prepared according to a similar procedure as that described in Example <NUM>. PVC Intermittent Catheters were then coated according to a similar procedure as that described in Example <NUM>. Coated catheters were tested on day <NUM> and demonstrated a uniform, lubricious and stable (durable) coating. The coated catheters were then incubated in a sealed tube containing water at ambient temperature and tested periodically to determine the long-term stability of the coating.

Unexpectedly, the samples incubated for <NUM> months still compared extremely well with a freshly coated catheter with regards to coating uniformity, lubricity and stability (durability). Thus demonstrating the long-term stability of the coating of the invention when incubated in water at ambient temperature.

This example demonstrates that the dry-out time of the coating can be extended further by hydrating the coating for longer periods of time, e.g. <NUM> hours. This may be particularly advantageous for ready-to-use products supplied in water or saline, for example.

Claim 1:
A method of making a coating solution, comprising the steps of :
polymerising an initial monomer feed comprising an N-vinyl pyrrolidone and an acrylate salt in water to synthesise a copolymer thereof, the initial monomer feed comprising from about <NUM> to <NUM>% by weight of acrylate salt, based on the total monomer content;
acidifying the resulting copolymer-water mixture to give free carboxylic acid groups along the copolymer backbone;
diluting the copolymer-water mixture with alcohol, wherein the copolymer-water mixture prior to dilution has a copolymer concentration of at least about <NUM>% by weight and less than about <NUM>% by weight, and wherein the step of diluting the copolymer-water mixture with alcohol is carried out such that the diluted mixture comprises <NUM> part copolymer-water mixture to <NUM>-<NUM> parts of alcohol by weight or volume;
and adding a cross-linking agent which is capable of reacting with the carboxylic acid groups such as to cure the copolymer as and when the coating solution is applied to a substrate and the copolymer coated thereon, wherein the cross-linking agent is added in an amount between about <NUM>% and <NUM>% by weight relative to the copolymer.