Tough hydrogel coating

Field of the invention

The present invention relates to a tough hydrogel coating and method of manufacture wherein robust bonds are formed between the hydrogel and the coated surface. One or more therapeutic agents and/or sensing materials may further be incorporated into the hydrogel coating to provide a coated structure having therapeutic agent release and/or environmental sensing capabilities.

Background of the invention

Hydrogels are hydrophilic polymeric materials capable of holding large amounts of water in their three-dimensional networks. They are typically made using natural polymers (e.g., collagen and alginate) or synthetic polymers (e.g., poly(vinyl alcohol) (PVA) and poly(acrylic acid) (PAA)). Depending on the nature of the hydrogel network, they can be categorized as either “physical” hydrogels, which means that the network formation is reversible, or “chemical” hydrogels, which means that the network formation is irreversible and is formed by covalent cross-links. Due to their high water content, porosity, and soft consistency, hydrogels closely resemble natural living tissue. These properties, along with their generally good biocompatibility and ease of fabrication, make hydrogels desirable for use in a number of biomedical applications. In particular, hydrogels have been widely used in biomedical applications such as drug delivery, tissue engineering, tissue bulking agents, and contact lenses. The use of hydrogels has more recently been explored as material candidates for medical tubing and catheters, control elements in fluidic devices, antifouling coatings, and soft electronics and machines. However, despite the many beneficial properties that hydrogels possess, their potential for use in these applications has been significantly hampered by their low mechanical robustness, permeability to various molecules, and weak hydrogel-solid interfaces.

For example, hydrogels possess low tensile strength which limits their use in applications requiring load-bearing. In such load-bearing applications, hydrogels are typically unable to maintain their shape and function in the long-term. Further, the strength and fracture toughness of common hydrogels are usually much lower than the corresponding elastomers (e.g., silicone rubbers and latex) traditionally used for the aforementioned applications. In addition, most hydrogels are brittle and possess very low stretchability, with typical fracture energies of hydrogels being about 10 J m .sup.−2 as compared with ˜1,000 J m .sup.2 for cartilage and ˜10,000 J M.sup.−2 for natural rubbers. Moreover, formation of weak hydrogel-solid interfaces results in a failure to integrate soft hydrogels and rigid components with adequate functionality and reliability. For example, coatings using conventional hydrogels can easily fracture and delaminate upon application of stress. In drug delivery applications, it may be problematic to load and effectively deliver certain drugs from hydrogels. In particular, in the case of hydrophobic drugs, the high water content and high porosity of most hydrogels can result in rapid drug release rather than a desired slower and sustained release of the drug. Further, hydrogels suffer from high permeability to small molecules, which presents a further challenge in the field.

Various attempts have been made to address these limitations. However, in view of the great potential that hydrogels possess, further improvements are still needed.

Summary of the invention

Embodiments of the present invention combine the permeable, compliant, tunable, and slippery nature of tough hydrogels with the non-permeable and relatively rigid properties of commonly-used engineering materials (e.g., elastomers, plastics, glass, ceramics and metals). Hydrogel-substrate combined structures are provided through robust bonding between the hydrogels and a substrate (e.g., substrates fabricated of elastomers, plastics, glass, ceramics, metals, etc.) resulting in a highly-hydrated, ultra-low friction laminate structure that is also tough enough to handle manipulation without rupture or delamination of the coating material. Of particular interest are structures where one or more thin hydrogel layers are coated onto elastomer substrates, termed hydrogel-elastomer laminates. According to methods of the present invention, the thickness of the hydrogel coating layer(s) in these laminates can be tuned to match a wide range of mechanical properties from pure elastomer (corresponding to a thinner hydrogel layer) to pure hydrogel (corresponding to a thicker hydrogel layer), while maintaining a surface with a very low coefficient of friction. In addition, the hydrogel-elastomer laminates are impermeable to small molecules across the laminate structure, enable controlled release of a variety of therapeutic agents, and provide for sensing of various stimuli surrounding the laminate structure. The present invention further provides hydrogel coated medical devices which can be used for environmental sensing and therapeutic agent release while reducing the surface friction of these devices.

According to one aspect, the present invention provides a hydrogel-substrate laminate comprising a layer of substrate having a top surface and a bottom surface, the substrate selected from elastomers, plastics, glass, ceramics and metals; at least one hydrogel coating layer disposed on one or more of the top surface and the bottom surface of the substrate; and one or more therapeutic agent disposed within the at least one hydrogel coating layer, and/or one or more sensing material disposed within the at least one hydrogel coating layer.

Embodiments according to this aspect can include one or more of the following features. A first hydrogel coating layer can be disposed on the top surface of the substrate layer, and a second hydrogel coating layer can be disposed on the bottom surface of the substrate layer. The layer of substrate can be impermeable to small molecules, a first therapeutic agent can be disposed within the first hydrogel coating layer, and a second therapeutic agent different than or the same as the first therapeutic agent can be disposed within the second hydrogel coating layer. The layer of substrate can be impermeable to small molecules, a first sensing material can be disposed within the first hydrogel coating layer, and a second sensing material different than or the same as the first sensing material can be disposed within the second hydrogel coating layer. The layer of substrate can be impermeable to small molecules, at least one therapeutic agent can be disposed within the first hydrogel coating layer, and at least one sensing material can be disposed within the second hydrogel coating layer. At least on therapeutic agent and at least one sensing material can be disposed within the at least one hydrogel coating layer, the at least one therapeutic agent and the at least one sensing material can be in communication, and release of the at least one therapeutic agent from the at least one hydrogel coating layer is controlled by one or more environmental conditions sensed by the at least one sensing material. A controller or the like can be provided so as to regulate release of the at least one therapeutic agent from the at least one hydrogel coating layer based upon the one or more sensed environmental conditions. The at least one therapeutic agent can be disposed within a first hydrogel coating layer, and the at least one sensing material can be disposed within a second hydrogel coating layer, wherein the first and second hydrogel coating layers are separated from each other by the layer of substrate. The thickness of the hydrogel coating layer can be predetermined to provide a hydrogel-substrate laminate having mechanical properties ranging from mechanical properties of the pure substrate to mechanical properties of the pure hydrogel. The at least one hydrogel coating layer can comprise a physically crosslinked dissipative polymer network selected from PVA, collagen, gelatin, agar, agarose, dextran, alginate, hyaluronan and chitosan; and a covalently crosslinked stretchy polymer network selected from polyacrylamide (PAAm), polyethylene glycol (PEG), polyethylene glycol derivatives, polyvinyl alcohol, poly-N,N-dimethylacrylamide (DMMA), polyacrylamide derivatives, and polyzwitterionic monomers. The substrate can be an elastomer material, and the stretchy polymer network in the hydrogel coating layer can be covalently grafted to elastomer chains of the elastomer material.

According to another aspect, the present invention provides a hydrogel coated medical device comprising a medical device having an outer surface; at least one hydrogel coating layer disposed on at least a portion of the outer surface of the medical device; and one or more therapeutic agent disposed within the at least one hydrogel coating layer to provide therapeutic agent release into an environment surrounding the at least one hydrogel coating layer, and/or one or more sensing material disposed within the at least one hydrogel coating layer to provide sensing of one or more environmental conditions surrounding the at least one hydrogel coating layer.

Embodiments according to this aspect can include one or more of the following features. The hydrogel coated medical device has a coefficient of friction less than the medical device without the hydrogel coating layer. At least on therapeutic agent and at least one sensing material can be disposed within the at least one hydrogel coating layer, wherein the at least one therapeutic agent and the at least one sensing material are in communication, and wherein release of the at least one therapeutic agent from the at least one hydrogel coating layer is controlled by one or more environmental conditions sensed by the at least one sensing material. A controller or the like can be provided so as to regulate release of the at least one therapeutic agent from the at least one hydrogel coating layer based upon the one or more sensed environmental conditions. A plurality of different therapeutic agents can be disposed within the at least one hydrogel coating layer so as to be independently released from the at least one hydrogel coating layer.

According to another aspect, the present invention provides a method for fabricating a hydrogel-substrate laminate comprising activating at least one surface of a pristine substrate material, the substrate material selected from elastomers, plastics, glass, ceramics and metals; coating at least one surface of the activated substrate material with a layer of hydrogel precursor solution; curing the hydrogel precursor solution to thereby form a tough, double network hydrogel coating layer of controllable thickness firmly grafted on the at least one surface of the activated substrate material.

Embodiments according to this aspect can include one or more of the following features. The hydrogel precursor solution can contain one or more therapeutic agent and/or one or more sensing material. Prior to curing the hydrogel precursor solution, desired mechanical properties of the hydrogel-substrate laminate ranging from mechanical properties of the pure substrate to mechanical properties of the pure hydrogel can be determined, based on the desired mechanical properties, a corresponding thickness of the hydrogel coating layer can be determined, and at least one spacer can be placed on the layer of hydrogel precursor solution to control a thickness of the hydrogel coating layer. Activating at least one surface of a pristine substrate material can comprise surface functionalization of the substrate surface. The hydrogel coating layer can be formed by grafting hydrogel polymer chains onto the substrate surface by generation of free radicals at the substrate-hydrogel interface.

Other systems, methods and features of the present invention will be or become apparent to one having ordinary skill in the art upon examining the following drawings and detailed description. It is intended that all such additional systems, methods, and features be included in this description, be within the scope of the present invention and protected by the accompanying claims.

Brief description of the drawings

The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principals of the invention.

FIG. 1A schematically illustrates the structure of an impermeable hydrogel laminate with a detailed hydrogel-elastomer interface network structure according to an embodiment of the present invention, FIG. 1B schematically illustrates sensing capabilities for different environments of an impermeable hydrogel laminate according to an embodiment of the present invention, FIG. 1C schematically depicts release capabilities to different environments of an impermeable hydrogel laminate according to an embodiment of the present invention, and FIG. 1D is an image of an impermeable hydrogel laminate according to an embodiment of the present invention in comparison to a hydrogel sheet.

FIG. 2 schematically illustrates a hydrogel coating process by dip-coating a device into a hydrogel precursor solution, according to an embodiment of the present invention.

FIGS. 3A-K illustrate exemplary coated medical devices, with FIGS. 3A-C illustrating a hydrogel coated silicone medical tubing according to an embodiment of the present invention which is manipulated and bent to test hydrogel toughness and bonding, FIGS. 3D-F illustrating a hydrogel coated latex condom according to an embodiment of the present invention which is inflated to test hydrogel toughness and bonding, FIGS. 3G-H illustrating hydrogel coated Foley Catheter according to an embodiment of the present invention which is inflated to test hydrogel toughness and bonding, and FIGS. 3I-K illustrating cross-sectional microscopic images of each of the coated devices of FIGS. 3A, 3D and 3G , respectively.

FIG. 4 illustrates bacterial adhesion experimental results, particularly comparison of controls (latex and glass) to hydrogel laminates after a 24 hour incubation period.

FIGS. 5A-D illustrate tensile properties of hydrogel and impermeable hydrogel laminates, with FIG. 5A illustrating nominal stress versus stretch curves of elastomer, hydrogel, and laminates of varying elastomer-to-hydrogel thickness, FIG. 5B illustrating an embodiment of the present invention hydrogel-elastomer interface which does not delaminate upon stretching up to seven times, FIG. 5C showing a microscope image of a nonpermeable hydrogel laminate with H.sub.E/H.sub.G=2.0 according to an embodiment of the present invention, and FIG. 5D showing an image of a nonpermeable hydrogel laminate with H.sub.E/H.sub.G=0.08 according to an embodiment of the present invention.

FIGS. 6A-E illustrate diffusion characteristics of impermeable hydrogel-elastomer laminate, with FIG. 6A schematically illustrating a two-chamber experimental setup, FIG. 6B showing diffusion curves of rhodamine B dye across an elastomer, a hydrogel slab, and impermeable hydrogel laminate samples according to embodiments of the present invention, FIG. 6C showing an image of an impermeable hydrogel laminate according to an embodiment of the present invention before a diffusion experiment. FIG. 6D showing an image of an impermeable hydrogel laminate according to an embodiment of the present invention after a diffusion experiment, wherein the dye does not diffuse past the elastomer layer, and FIG. 6E showing an image of a pure hydrogel sheet after the diffusion experiment, wherein the dye diffuses across the sample.

FIGS. 7A-D illustrate release characteristics of hydrogel laminates to different environments according to an embodiment of the present invention, with FIG. 7A schematically depicting a two-chamber experimental setup to study drug release from impermeable hydrogel laminates to different environments, FIG. 7B showing release profiles of rhodamine B and green food dye to the separate chambers with Fickian diffusion power law fits, FIG. 7C showing a loaded impermeable hydrogel laminate according to an embodiment of the present invention before a release experiment, with different drugs loaded into hydrogel layers on either side of an elastomer layer, and FIG. 7D showing the impermeable hydrogel laminate of FIG. 7C after the release experiment.

FIGS. 8A-D illustrate sensing capabilities of hydrogel laminates according to an embodiment of the present invention, where FIG. 7A depicts a color response chart for a pH sensitive dye used for sensing on both sides of the impermeable laminates, and FIGS. 8B-E illustrate the sensing of different pH conditions on different sides of the impermeable hydrogel laminate according to an embodiment of the present invention, wherein the hydrogel coatings show different colorimetric responses based on the pH of the solution that the hydrogel layer was exposed to.

Detailed description

The following definitions are useful for interpreting terms applied to features of the embodiments disclosed herein, and are meant only to define elements within the disclosure.

As used herein, the term “hydrogel laminate” refers to a structure composed of one or more thin hydrogel coating on a substrate (e.g. elastomer layer, plastic layer, glass layer, ceramic layer, metal layer, etc.). The hydrogel coating can be on both sides of the substrate or on one side.

As used herein, the term “pristine”, such as when referring to a pristine elastomer or pristine surface, means such a surface prior to any surface treatment or modification.

The present invention generally provides hydrogel coatings and methods of fabrication. The hydrogel coatings are robust, highly stretchable (provided the substrate is stretchable), and impart ultralow surface coefficients of friction on the surface that is coated. In addition, the composition and thickness of the hydrogel coating can be controlled to tune the stiffness of the hydrogel without sacrificing stretchability. In particular, the present invention provides a hydrogel coating layer that is firmly grafted to a surface and which consists of a crosslinked double network, which is in contrast with conventional methods which are limited to single materials and grafting polymer chains. As such, the present invention hydrogel coatings can be made of controllable thickness, and can be tuned to provide a number of predetermined desired characteristics. If desired, therapeutic agents and/or sensing mechanisms/substances may be incorporated into the hydrogel coatings to provide for release of the therapeutic agents and/or sensing of environmental conditions in which the hydrogel coating is disposed.

According to one embodiment, the hydrogel coating is bonded to a material to provide a laminate structure. In an exemplary embodiment, an impermeable material, such as an elastomer layer, is sandwiched between two opposing hydrogel layers. The resulting hydrogel elastomer laminate retains the high water content and slippery surface properties of the hydrogel and, unlike the hydrogel material itself, does not allow diffusion of various types of compounds (e.g., small-molecule chemicals, biomolecules, and nanoparticles) across the laminate structure due to the presence of the impermeable material layer. If desired, one or more therapeutic agents can be disposed within one or more of the hydrogel layers to provide therapeutic agent release, and/or one or more sensing mechanisms/substances can be disposed within the one or more hydrogel layers to provide sensing of various environmental conditions (e.g., pH, temperature, etc.) on one or more sides of the laminate structure.

The hydrogel is formed of a physically crosslinked dissipative polymer network and a covalently crosslinked stretchy polymer network. The covalently crosslinked polymer network is characterized in its high deformability, while the dissipative polymer network is characterized in its ability to dissipate significant mechanical energy under deformation. These two components (i.e., stretchy polymer networks and dissipative polymer network) are interpenetrated with each other after curing in such a way that they work synergistically, with the stretchy polymer networks functioning to maintain the integrity of the material, and the dissipative polymer network (e.g. ionic crosslinks, fiber filler, etc.) providing mechanical energy dissipation when the whole polymer network undergoes deformation.

The stretchy polymer networks can be selected from any known stretchy (preferably long-chain) polymer networks. Since the present hydrogels can be used in a wide variety of biomedical applications, the polymers used in the present invention are preferably biocompatible. Of course, it is to be understood that for non-biomedical applications, it would not be necessary to utilize only biocompatible polymer materials. In general, molecular weight determines the stretchability of the network, with larger molecular weights typically resulting in higher stretchability. As such, when high stretch is desired, polymers having a high molecular weight associated with higher stretchability are typically used to provide the stretchy polymer networks. Some examples of stretchy polymer networks include, but are not limited to, polyacrylamide (PAAm), polyethylene glycol (PEG) and polyethylene glycol derivatives (acrylated PEG, methacrylated PEG, PEG norbornene, PEG diacrylate, PEG dimethacrylate), polyvinyl alcohol, poly-N,N-dimethylacrylamide (DMMA), and polyzwitterionic monomers (sulfobetaine methacrylate, carboxybetaine methacrylate, phosphorylcholine methacrylate, and other methacrylate derivatives). According to an exemplary embodiment, these long-chain polymer networks are covalently crosslinked.

The dissipative component can, likewise, be any such known components. For example, according to various embodiments, mechanical dissipation is incorporated in the present materials by including ionic crosslinks, pull-out fibers, and/or transformation domain(s) in the polymer chains. In some embodiments, the dissipative component comprises dissipative polymer networks. According to particularly preferable embodiments, the dissipative material is reversibly dissipative, which means that the material can reform after damage to at least partially heal the strength of the material. Some examples of the dissipative components include, but are not limited to, PVA, collagen, gelatin, agar, agarose, dextran, alginate, hyaluronan and chitosan, which are all biocompatible materials. Such materials preferably contain reversible crosslinks, which enables the kinetics of zipping and unzipping of the dissipative materials (where the dissipative network acts to “unzip”—i.e., break—and “zip”—i.e., heal—the network), inhibits the propagation of cracks, and enhances anti-fatigue performance of the material. Thus, the reversible crosslinks not only provide energy dissipation from the breakage of the crosslinks, but also ensure the anti-fatigue performance due to reforming (i.e., healing) of the damaged crosslinks. Exemplary dissipative components can include alginate reversibly crosslinked by calcium sulfate, hyaluronan reversibly crosslinked by iron (III) chloride, and chitosan reversibly crosslinked by sodium tripolyphosphate. Of course, other combinations are possible and could be determined by one skilled in the art.

According to embodiments of the present invention, the stretchy polymer network in the hydrogel is covalently grafted to the elastomer chains of the elastomer material (or to the components of the other substrate materials, if utilized) to achieve robust bonding between the hydrogel and the elastomer layer. These robust bonds are formed by chemically anchoring the stretchy polymer in the tough hydrogels onto the surfaces of the elastomer layer. This chemical anchoring enables stable bonding of hydrogels having relatively high intrinsic adhesion energy and large enhanced surface toughness from the dissipative networks contained therein. Preferably, robust bonding of the hydrogels onto the elastomer layer (or other substrate material) is achieved by surface functionalization (i.e., modifying the surface using physical, chemical or biological mechanisms) of the elastomer layer surface(s). In preferred embodiments, the hydrogel polymer chains are grafted onto the solid surface by generation of free radicals at the solid-hydrogel interface.

Exemplary materials that can be used for the elastomer layer include silicone rubbers, such as polydimethyl siloxane (PDMS, Dow Corning®) and Ecoflex® (Smooth-On), latex, polyurethanes, and other natural or synthetic rubbers.

FIG. 1A illustrates an exemplary design strategy for an impermeable robust hydrogel laminate according to an embodiment of the invention. As shown, a layer of an impermeable elastomer 10 is sandwiched between two layers of a stretchable and robust hydrogel 12 . Prior to coating the elastomer layer 10 with the hydrogel 12 , the surface(s) of the elastomer layer 10 are activated. Any surface activating material, such as benzophenone or other radical sources (redox initiators such as cumene hydroperoxide/tetraethylenepentamine, tent-butyl hydroperoxide/tetraethylenepentamine, potassium persulfate/potassium metabisulfite and similar combinations), may be used to activate the surfaces of the elastomer layer 10 . For glass, metals and ceramics, 3-(trimethoxysilyl)propyl methacrylate or other acrylated silane, methacrylated silane or heterobifunctional molecule with a acrylate or methacrylate moiety with a may be used to activate the surfaces. Such activation enables covalent grafting of the stretchy networks of the hydrogels onto the elastomer chains, for example, as illustrated in the right inset of FIG. 1A .

According to one embodiment, one or more sensing or stimuli-responsive mechanisms/molecules may be incorporated into the hydrogel 12 to monitor environmental conditions (e.g., pH, temperature, and biomolecule concentration) surrounding the hydrogel laminate (particularly adjacent the hydrogel layer in which the stimuli-responsive mechanisms/molecules are disposed). For example, as depicted in FIG. 1B , a plurality of different sensing molecules (sensing molecules A 14 and sensing molecules B 16) may be incorporated into each of the opposing hydrogel layers to monitor environmental conditions on opposing sides of the hydrogel laminate. For example, sensing molecules A 14 may sense the pH on one side of the laminate, while sensing molecule B 16 may monitor the temperature on the other side of the laminate. It is to be understood that the present invention is not limited as such. For example, if desired, sensing or stimuli-responsive molecules may be incorporated into only one of the hydrogel layers, or identical sensing or stimuli-responsive molecules can be incorporated into each of the hydrogel layers. Further, a plurality of different sensing or stimuli-responsive molecules may be incorporated into a single hydrogel layer if they are capable of maintaining their intended function when combined as such (i.e., they do not negatively interact with each other in a way that alters their intended sensing capabilities).

According to another embodiment, a variety of different types of therapeutic agents and functional molecules may be incorporated into the hydrogel 12 to provide release of the therapeutic agents and functional molecules into the environment surrounding the hydrogel laminate. For example, as shown in FIG. 1C , different types of therapeutic agents and functional molecules (therapeutic molecules A 18 and therapeutic molecules B 20 ) are incorporated into each of the opposing hydrogel layers to provide for release of different therapeutic molecules on opposing sides of the hydrogel laminate. Such therapeutic molecules may be independently released from each hydrogel layer. It is to be understood that the present invention is not limited as such. For example, if desired, therapeutic agents and functional molecules can be incorporated into only one of the hydrogel layers, or identical therapeutic agents and functional molecules can be incorporated into each of the hydrogel layers. Further, a plurality of different therapeutic agents and functional molecules may be incorporated into a single hydrogel layer if they are capable of maintaining their intended therapeutic effects/functions when combined as such.

According to another embodiment, a combination of sensing or stimuli-responsive molecules/mechanisms and therapeutic agents/functional molecules are incorporated into the hydrogel laminate. For example, one of the hydrogel layers may incorporate sensing or stimuli-responsive molecules/mechanisms while another hydrogel layer may incorporate therapeutic agents/functional molecules. As such, environmental conditions may be monitored on one side of the hydrogel laminate, while therapeutic agents/functional molecules may be released on another side of the hydrogel laminate. In some embodiments, the sensing or stimuli-responsive molecules/mechanisms and the therapeutic agents/functional molecules may be combined into the same hydrogel layer if the components maintain their intended sensing/stimuli-responsive and therapeutic effects/functions when combined as such. The hydrogel laminate can further be configured such that the sensing or stimuli-responsive molecules/mechanisms are in communication with the therapeutic agents/functional molecules to provide for release of the therapeutic agents/functional molecules if certain environmental conditions are detected by the sensing or stimuli-responsive molecules/mechanisms.

As shown in FIG. 1D , a hydrogel-elastomer-hydrogel laminate according to an embodiment of the present invention, which incorporates a transparent elastomer layer (e.g., PDMS), looks almost identical to a sheet of hydrogel. However, the hydrogel laminates of the present invention possess a set of properties and capabilities not achievable in existing hydrogels: (a) the hydrogel laminates have high water content, slippery surfaces, and can be functionalized with biomolecules in the same fashion as common hydrogels, (b) the laminates are robust, highly stretchable, and impermeable to molecules of various types and sizes across the structure, similar to bulk elastomer sheets, (c) the modulus of the laminate (along in-plane directions) can be tuned by varying the types of elastomer, type and composition of the hydrogel layers, and the thicknesses of the different layers, (d) different sensing or stimuli-responsive molecules/mechanisms can be incorporated in different hydrogel layers of the laminate (e.g., as illustrated in FIG. 1B ) to monitor environmental conditions on different sides of the laminate (e.g., pH, temperature, and biomolecule concentration), (e) a variety of different types of therapeutic agents and functional molecules can be incorporated into different hydrogel layers of the laminate and released independently from different sides of the laminate (e.g., as shown in FIG. 1C ).

A general protocol for fabrication of the hydrogel laminates with an elastomer layer is as follows. It is noted that a similar protocol applies for hydrogel laminates with other substrate (i.e., plastics, glass, ceramics and metals). A pristine elastomer sheet is first activated, followed by coating of the activated sheet with a hydrogel precursor solution, and curing of the hydrogel precursor solution to form the hydrogel coating. This procedure may be carried out on individual sides of the elastomer sheet until a chosen number of sides of the elastomer sheet are coated with a desired number of hydrogel layers to form the laminate structure. Alternatively, if desired, multiple sides of the elastomer sheet (or the substrate) mat be coated in a single process. For example, a pristine elastomer sheet may be first activated by immersion in a suitable activating solution (e.g., a benzophenone solution in ethanol or the like), followed by rinsing (e.g., with isopropanol or the like), and drying (e.g., drying with compressed nitrogen or the like). A hydrogel precursor solution containing both stretchy and dissipative components (as described above), along with optional sensing/stimuli-responsive and/or releasable molecules, may then be disposed on the activated elastomer sheet. Typically, the precursor solution is disposed on one activated surface (generally the top surface) of the elastomer sheet (unless multiple sides of the elastomer/substrate are coated in the same process). The elastomer with the layer of hydrogel precursor solution disposed thereon is then covered with a glass plate and cured, preferably by placement in a UV oven. Upon exposure to UV light (preferred UV-A, 315-400 nm or UV-B, 280-315 nm), the adsorbed activating molecules (e.g., benzophenone molecules) on the elastomer sheet act as free radical sources and grafting agents to the elastomers. In some embodiments, heat may alternatively be used to cure the hydrogel and graft the polymer chains to the elastomer/substrate, particularly for glass, metal and ceramic substrates. The hydrogel precursor is thereby cured to form a first hydrogel layer on one surface of the elastomer sheet/substrate (or on multiple surfaces if multiple surfaces are coated in a single process).

After curing of the first hydrogel layer, if a second hydrogel layer is to be formed on the opposite side of the elastomer (and the second hydrogel layer was not formed at the same time as the first hydrogel layer), then the assembly (the elastomer/substrate with first hydrogel layer disposed thereon) may be suitably positioned (e.g., flipped over) to coat the opposite side with the second hydrogel layer. In particular, the exposed surface of the elastomer/substrate (i.e., surface not coated with the first hydrogel layer) is activated, followed by coating of the activated surface with a hydrogel precursor solution, and curing of the hydrogel precursor solution to form the second hydrogel coating. For example, as with the first hydrogel layer, the surface may be treated with benzophenone or the like to activate the second surface. Hydrogel precursor solution, containing both stretchy and dissipative components, along with optional sensing, stimuli-responsive and/or releasable molecules, is then placed on the treated surface and covered with a glass plate. The hydrogel is cured to form a second hydrogel layer on the elastomer/substrate. The result is a hydrogel-elastomer/substrate-hydrogel structure with robust hydrogel layers strongly bonded on opposing sides of the elastomer sheet/substrate. If desired, the thickness of the first and second hydrogel layers can be controlled, for example, by using spacers of different thicknesses.

The unique capabilities of the present invention hydrogel laminates to spatially control environmental sensing and drug release provides advantages in a variety of applications, particularly in the healthcare industry in which these properties play a major role. For example, the present hydrogel laminates can be used in wound and dermal care, as well as internal applications such as gastrointestinal and urinary tract treatments. For instance, hydrogel-coated catheters could be used to deliver anti-inflammatory drugs to the urethra while monitoring biomolecules present in the urine. The presence of hydrogel surfaces would also beneficially decrease friction, which would reduce irritation and discomfort of the catheters.

According to embodiments of the present invention, the outer surfaces of medical devices are coated using a modified hydrogel laminate coating technique. FIG. 2 depicts a general coating strategy for coating a medical device or other structure. Prior to coating with hydrogel precursor solution, the surface of the device is pre-treated. Pre-treatment includes steps to increase the hydrophilicity of the device surface (e.g., plasma treatment, corona discharge treatment, chemical modifications) and incorporation of grafting agent (e.g., heterobifunctional silanes, benzophenone, surface-bound ATRP initiators, or the like). The grafting agent will be adsorbed to the surface and enable grafting of the hydrogel polymer chains to the surface. The activated device is then rinsed and dried, followed by dip coating in a hydrogel precursor solution. The hydrogel precursor is a solution containing a polymerizable monomer (e.g., acrylamide, polyethylene glycol diacrylate, hydroxyethyl methacrylate or derivatives), an energy-dissipative component e.g., (polyvinyl alcohol, alginate, chitosan, hyaluronate or other high molecular weight polymers), the respective crosslinker molecule for each network, oxygen scavenger compounds (e.g., glucose oxidase, riboflavin, etc.), photoinitiator (e.g., Irgacures, phosphine oxides, aromatic ketones, etc.), releasable molecules (e.g., therapeutic agents, imaging agents, etc.) and/or sensing molecules or components. The viscosity of the precursor solution can be modified to achieve hydrogel coatings of different thicknesses. The hydrogel precursor coating is then crosslinked, preferably in an inert atmosphere (nitrogen or similar gas) under UV exposure. The hydrogel coated medical device can then be subjected to any desired post-treatment, such as removal of unreacted molecules and byproducts, achieving full swelling and incorporating sensing or releasable molecules.

FIGS. 3A-K illustrate several medical devices that were coated with a hydrogel in accordance with the present invention. In particular, silicone tubing (VWR International, stained by immersion in green food dye solution— FIGS. 3A-C ), a latex condom (Trojan®— FIGS. 3D-F ), and a latex Foley catheter (Bard Medical— FIGS. 3G-H ) were coated with a thin and uniform hydrogel layer.

As an example, the Foley catheter may be coated with chitosan-acrylamide through the use of a hydrogel precursor which is prepared by mixing chitosan (Sigma-Aldrich 740500), acrylamide, acetic acid, Irgacure I-2959, N, N-methylenebisacrylamide, sodium tripolyphosphate, glucose and glucose oxidase. The catheter is first cleaned (e.g., with isopropanol and plasma treatment for about 1 min/30 W at a pressure of 350 mtorr). The cleaned catheter is immersed in an activating solution (e.g., benzophenone solution) for a suitable time (e.g., about 2 min) to activate the surface of the catheter. Following activation, the catheter is rinsed and dried (e.g., rinsed with isopropanol and dried with nitrogen). The catheter is dip-coated in the hydrogel precursor and placed in a nitrogen environment. Crosslinking of the hydrogel may be done in a UV oven (e.g., for 60 min with 8 W power and 365 nm). Any unreacted molecules and byproducts may then be removed from the coated catheter (e.g., by immersion in sodium tripolyphosphate solution for an extended period, e.g., approximately 24 h).

The hydrogel coatings as formed are robust and strongly bonded to the tubing ( FIGS. 3A-C ). In particular, the hydrogel coatings of the present invention resist physical manipulation (stretching, bending, folding into a knot) without delamination and failure, as depicted in FIGS. 3B-C . Further, as shown in FIGS. 3E, 3F and 3H , the condom ( FIGS. 3D-F ) and catheter ( FIG. 3G-H ) having the present invention hydrogel coating thereon can be inflated to maximum size without delamination and failure of the hydrogel coating.

The description continues in the full USPTO document.