Superhydrophobic Coating For Airway Mucus Plugging Prevention

Abstract

A method for reducing mucus accumulation in an airway including disposing an implantable device within an airway, wherein the implantable device has a first end, a second end, and an inner surface defining a lumen extending from the first end to the second end; wherein at least a portion of the inner surface has a hydrophobic polymer coating thereon, wherein a polymer coating surface has dynamic water contact angles of 145 degrees or greater; and wherein the implantable device is constructed and arranged to maintain patency of the airway; wherein accumulation of mucus is reduced as compared to a similar implantable device without the hydrophobic portion of the inner surface. An implantable medical device having a superhydrophobic surface and a method of making an implantable medical device having a superhydrophobic surface are also provided. An implantable medical device having a micropatterned surface with enhanced adhesion to tissue, optionally in combination with other region(s) having a superhydrophobic surface and a method of making such a device. Methods and devices for prevention of bacterial adhesion to implanted medical devices.

What is claimed is: 
     
         1 . A method for reducing mucus accumulation in an airway, comprising:
 disposing an implantable device within an airway, wherein the implantable device includes:
 a stent having a first end, a second end, an inner surface defining a lumen extending from the first end to the second end, and an outer surface; and 
 a polymer coating disposed on the inner surface of the stent, the polymer coating including a radially inward facing superhydrophobic surface having dynamic water contact angles of 145 degrees or greater; 
   wherein the superhydrophobic surface of the polymer coating reduces mucus buildup on the implantable device.   
     
     
         2 . The method of  claim 1 , wherein the polymeric coating further comprises an anti-migration micropattern on the outer surface of the stent. 
     
     
         3 . The method of  claim 2 , wherein the anti-migration micropattern includes pillars and holes between the pillars extending through the polymeric coating. 
     
     
         4 . The method of  claim 3 , wherein the holes are between 0.3 microns and 20 microns across. 
     
     
         5 . The method of  claim 3 , wherein the holes are between 1 micron and 10 microns across. 
     
     
         6 . The method of  claim 2 , wherein the anti-migration micropattern includes a first anti-migration end region proximate the first end and a second anti-migration end region proximate the second end, the first end region being spaced apart from the second end region. 
     
     
         7 . The method of  claim 1 , wherein the polymer coating and the stent are formed as an integral construction. 
     
     
         8 . The method of  claim 1 , wherein the superhydrophobic surface covers the inner surface entirely. 
     
     
         9 . The method of  claim 1 , wherein the superhydrophobic surface includes a plurality of protrusions extending from a base of the polymeric coating. 
     
     
         10 . The method of  claim 9 , wherein the plurality of protrusions have a width of 25-50 microns, a height of 100-200 microns, and are spaced 50-100 microns apart. 
     
     
         11 . The method of  claim 9 , wherein the plurality of protrusions have a width of 50 microns, a height of 150 microns, and are spaced 100 microns apart. 
     
     
         12 . A method for reducing mucus accumulation in an airway, comprising:
 disposing an implantable device within an airway, wherein the implantable device includes a stent having a first end, a second end, and an inner surface defining a lumen extending from the first end to the second end;   wherein at least a portion of the inner surface has a hydrophobic polymer coating thereon, wherein the polymer coating has a surface having dynamic water contact angles of 145 degrees or greater; and   wherein the implantable device is constructed and arranged to maintain patency of the airway;   wherein accumulation of mucus is reduced as compared to a similar implantable device without the hydrophobic polymer coating on the inner surface.   
     
     
         13 . The method of  claim 12 , wherein the hydrophobic polymer coating comprises a superhydrophobic micropattern formed on the surface thereof. 
     
     
         14 . The method of  claim 13 , wherein the superhydrophobic micropattern includes a plurality of protrusions extending from a base of the hydrophobic polymeric coating. 
     
     
         15 . The method of  claim 14 , wherein the plurality of protrusions have a width of 25-50 microns, a height of 100-200 microns, and are spaced 50-100 microns apart. 
     
     
         16 . The method of  claim 14 , wherein a spacing between adjacent protrusions of the plurality of protrusions is two times or more than a width of an individual protrusion of the plurality of protrusions. 
     
     
         17 . The method of  claim 12 , wherein the hydrophobic polymeric coating further comprises an anti-migration micropattern on the outer surface of the stent. 
     
     
         18 . The method of  claim 17 , wherein the anti-migration micropattern includes pillars and holes between the pillars. 
     
     
         19 . The method of  claim 12 , wherein the airway is a pulmonary airway. 
     
     
         20 . The method of  claim 19 , wherein the pulmonary airway is a main bronchus or a trachea.