Anti-Microbial Medical Materials and Devices

Abstract

The present disclosure relates generally to materials and medical devices impregnated with antimicrobial compounds. More specifically, the materials are medical matrix materials comprising nanopores or nanochannels in which the antimicrobial compounds are disposed. In other embodiments, medical matrix materials comprises nanomaterials and antimicrobials distributed throughout the material. The materials described herein are useful for a broad spectrum of medical devices and consumer products. The present disclosure further provides methods of making the antimicrobial materials and medical devices disclosed herein.

What is claimed is: 
     
         1 . An antimicrobial medical device comprising a medical matrix material having nanopores or nanochannels and an antimicrobial agent incorporated therein. 
     
     
         2 . The antimicrobial medical device of  claim 1 , wherein the medical matrix material is selected from the group consisting of silicone rubber, latex, polyisoprene, neoprene, polypropylene, polyurethane, poly(methyl methacrylate), poly(lactine-co-glycolide), ε-caprolactone, and gelatin/ε-caprolactone, collagen-GAG, PLA, PGA, PLA-PGA co-polymers, poly(anhydrides), poly(hydroxy acids), poly(ortho esters), poly(propylfumerates), poly(caprolactones), poly(hydroxyvalerate), polyamides, polyamino acids, polyacetals, polycyanoacrylates, polysaccharides, polypyrrole, polyanilines, polythiophene, polystyrene, polyesters, polyureas, poly(ethylene vinyl acetate), polypropylene, polymethacrylate, polyethylene, polycarbonates, poly(ethylene oxide), co-polymers of the above, mixtures thereof, and adducts thereof. 
     
     
         3 . The antimicrobial medical device of  claim 1  or  2 , wherein the medical matrix material is a silicone rubber. 
     
     
         4 . The antimicrobial medical device of any one of  claims 1  to  3 , wherein the antimicrobial agent is disposed within the nanopores or nanochannels. 
     
     
         5 . The antimicrobial medical device of any one of  claims 1  to  4 , wherein the nanopores or nanochannels comprise calcium carbonate, liposomes, carbon nanotubes, nano-gold particles, silica nanoparticles or a combination thereof. 
     
     
         6 . The antimicrobial medical device of any one of  claims 1  to  5 , wherein the nanopores or nanochannels are disposed on a surface of the device. 
     
     
         7 . The antimicrobial medical device of any one of  claims 1  to  6 , wherein the nanopores or nanochannels have a diameter ranging from about 5 nm to 200 nm, about 10 nm to about 50 nm, or about 50 to about 200 nm. 
     
     
         8 . The antimicrobial medical device of any one of  claims 1  to  7 , wherein the nanotubes have a diameter to length ratio ranging from about 1:10 to 1:5000. 
     
     
         9 . The antimicrobial medical device of any one of  claims 1  to  10 , wherein the nanopores or nanochannels comprise about 0.1% to about 10% of the volume of the medical matrix. 
     
     
         10 . The antimicrobial medical device of any one of  claims 1  to  9 , wherein the antimicrobial agent is selected from the group consisting of an antibacterial agent, an antiviral agent, an antifungal agent and combinations thereof. 
     
     
         11 . The antimicrobial medical device of any one of  claims 1  to  10 , wherein the antimicrobial agent is selected from the group consisting of a silver compound, chlorohexidine, a quaternary ammonium compound, an alcohol, chlorine, chlorine dioxide, peroxides, aldehydes, triclosan, triclocarban, benzalkonium chloride, and mixtures thereof. 
     
     
         13 . The antimicrobial medical device of claim  12 , wherein the silver compound is selected from the group consisting of silver chloride, silver sulfadiazine, silver nitrate and combinations thereof. 
     
     
         14 . The antimicrobial medical device of  claim 13 , wherein the chlorhexidine is chlorhexidine diacetate, chlorhexidine gluconate, or mixture thereof. 
     
     
         15 . The antimicrobial medical device of claim  12 , where the quaternary ammonium compound is poly(diallyldimethylammonium chloride) (polyDADMAC). 
     
     
         16 . The antimicrobial medical device of claim  12 , wherein the antimicrobial agent comprises a silver compound and a chlorhexidine. 
     
     
         17 . The antimicrobial medical device of claim  12 , wherein the antimicrobial agent comprises a silver compound and polyDADMAC. 
     
     
         18 . The antimicrobial medical device of claim  12 , wherein the antimicrobial agent comprises chlorhexidine and polyDADMAC. 
     
     
         19 . The antimicrobial medical device of any one of  claims 1  to  18 , wherein the nanopores or nanochannels are derived from calcium carbonate, liposomes, carbon nanotubes, nano gold particles, silica nanoparticles or a combination thereof. 
     
     
         20 . The antimicrobial medical device of any one of  claims 1  to  19 , wherein the nanopores or nanochannels are derived from calcium carbonate nanospheres or nanotubes. 
     
     
         21 . The antimicrobial medical device of any one of  claims 1  to  20 , wherein the device is a septum, a needle-free injection port connector, a valve, tubing, an implantable medical device, a surgical instrument, a consumer product, a wound care product, a urology product, an orthopedic device, an oral care product, a women's health product, a hemodialysis product, a vision care product, a diabetes care product, a cardiovascular device or a prosthetic. 
     
     
         22 . An antimicrobial medical material comprising a medical matrix material having nanopores or nanochannels and an antimicrobial agent incorporated therein. 
     
     
         23 . The antimicrobial medical material of  claim 22 , wherein the material is provided in a solid form having a surface, and wherein the nanopores or nanochannels are disposed on the surface. 
     
     
         23 . An antimicrobial medical material comprising a medical matrix, an antimicrobial agent and a nanomaterial. 
     
     
         24 . The material of  claim 23 , wherein the nanomaterial and antimicrobial agent are dispersed throughout the matrix material. 
     
     
         25 . The antimicrobial medical material of any one of  claims 23  to  24 , wherein the medical matrix material is selected from the group consisting of silicone rubber, latex, polyisoprene, neoprene, polypropylene, polyurethane, poly(methyl methacrylate), poly(lactine-co-glycolide), ε-caprolactone, and gelatin/ε-caprolactone, collagen-GAG, PLA, PGA, PLA-PGA co-polymers, poly(anhydrides), poly(hydroxy acids), poly(ortho esters), poly(propylfumerates), poly(caprolactones), poly(hydroxyvalerate), polyamides, polyamino acids, polyacetals, polycyanoacrylates, polysaccharides, polypyrrole, polyanilines, polythiophene, polystyrene, polyesters, polyureas, poly(ethylene vinyl acetate), polypropylene, polymethacrylate, polyethylene, polycarbonates, poly(ethylene oxide), co-polymers of the above, mixtures thereof, and adducts thereof. 
     
     
         26 . The antimicrobial medical device of any one of  claims 23  to  25 , wherein the medical matrix material is a silicone rubber. 
     
     
         27 . The antimicrobial medical device of any one of  claims 23  to  26 , wherein the nanomaterial has a diameter ranging from about 5 nm to 200 nm, about 10 nm to about 50 nm, or about 50 to about 200 nm. 
     
     
         28 . The antimicrobial medical device of any one of  claims 23  to  27 , wherein the nanomaterial is nanotubes having a diameter to length ratio ranging from about 1:10 to 1:5000. 
     
     
         29 . The antimicrobial medical device of any one of  claims 23  to  28 , wherein the nanomaterial comprises about 0.1% to about 10% of the volume of the medical matrix. 
     
     
         30 . The antimicrobial medical device of any one of  claims 23  to  29 , wherein the antimicrobial agent is selected from the group consisting of a silver compound, chlorohexidine, a quaternary ammonium compound, an alcohol, chlorine, chlorine dioxide, peroxides, aldehydes, triclosan, triclocarban, benzalkonium chloride, and mixtures thereof. 
     
     
         31 . The antimicrobial medical device of  claim 30 , wherein the silver compound is selected from the group consisting of silver chloride, silver sulfadiazine, silver nitrate and combinations thereof. 
     
     
         32 . The antimicrobial medical device of  claim 30 , wherein the chlorhexidine is chlorhexidine diacetate, chlorhexidine gluconate, or mixture thereof. 
     
     
         33 . The antimicrobial medical device of  claim 30 , wherein the antimicrobial agent comprises a silver compound and a chlorhexidine. 
     
     
         34 . The antimicrobial medical device of any one of  claims 23  to  33 , wherein the nanomaterials comprise calcium carbonate, liposomes, carbon nanotubes, nano gold particles, silica nanoparticles or a combination thereof. 
     
     
         35 . The antimicrobial medical device of any one of  claims 23  to  34 , wherein the nanomaterials comprise calcium carbonate nanospheres or nanotubes. 
     
     
         36 . A method of preparing an antimicrobial medical material having nanopores or nanochannels and an antimicrobial agent disposed therein comprising:
 providing a prepolymeric material,   polymerizing a the prepolymeric material in the presence of a nanomaterial to form a medical polymer having the nanomaterial disposed therein;   removing the nanomaterial to provide the medical matrix having nanopores or nanochannels, and   loading the medical matrix material with the antimicrobial agent to provide the antimicrobial medical device.   
     
     
         37 . The method of  claim 36 , further comprising forming the medical matrix into a predetermined shape. 
     
     
         38 . The method of  claim 36  or, wherein the prepolymeric material comprises a liquid silicone rubber. 
     
     
         39 . The method of any one of  claims 36  to  38 , wherein the nanomaterial is selected from the group consisting of calcium carbonate, liposomes, carbon nanotubes, nano gold particles, silica nanoparticles or a combination thereof. 
     
     
         40 . The method of any one of  claims 36  to  38 , wherein the removing of the nanomaterials from the medical matrix comprises dissolving the nanomaterials with a dilute acid. 
     
     
         41 . The method of  claim 40  wherein the dilute acid is selected from the group consisting of 1 to 5% citric acid, 0.1 to 0.5% hydrochloric acid, 0.1 to 2% sulfuric acid, 0.1 to 2% phosphoric acid or a mixture thereof. 
     
     
         42 . The method of any one of  claims 36  to  40 , wherein the medical matrix having the nanomaterial disposed therein comprises about 0.5% to about 20% by weight of the nanomaterial. The method of any one of  claims 36  to  42 , wherein the antimicrobial agent is loaded into the medical matrix by contacting the medical matrix with a solution of the antimicrobial agent.