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A process for preparing coating compositions of a commingled hydrogel of a polyurethane-polyurea polymer hydrogel and at least one other polymer hydrogel of a polymer different from polyurethane-polyurea; a process for making materials composed of a polymeric plastic or rubber substrate or a metalli

A process for preparing coating compositions of a commingled hydrogel of a polyurethane-polyurea polymer hydrogel and at least one other polymer hydrogel of a polymer different from polyurethane-polyurea; a process for making materials composed of a polymeric plastic or rubber substrate or a metallic substrate, with a coating of the commingled hydrogel thereon; and a process for making medical devices with a coating of the commingled hydrogel thereon, are disclosed. The coating compositions tenaciously adhere to the substrate materials and medical devices to which they are applied due to bonding of a tie coat to a reactive substrate surface and due to the commingling of the two hydrogel components. The coating compositions and coated materials and medical devices are non-toxic and biocompatible, making them ideally suited for use in applications such as for catheters, catheter balloons and stents. In such applications, the coating compositions, coated materials, and coated medical devices made therefrom demonstrate low coefficients of friction in contact with body fluids, especially blood, as well as a high degree of wear permanence over prolonged use. The commingled hydrogel coatings are capable of being dried to facilitate storage of the devices to which they have been applied, and can be instantly reactivated for later use by exposure to water.

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A process for producing a material bearing thereon a coating of a wet, slippery, tenaciously adhering, commingled hydrogel of a hydrophilic polyurethane-polyurea polymer hydrogel and at least one other polymer hydrogel different from said hydrophilic polyurethane-polyurea polymer hydrogel, said proc

A process for producing a material bearing thereon a coating of a wet, slippery, tenaciously adhering, commingled hydrogel of a hydrophilic polyurethane-polyurea polymer hydrogel and at least one other polymer hydrogel different from said hydrophilic polyurethane-polyurea polymer hydrogel, said process comprising: a) making the surface of a hydrophilic or hydrophilicized hydrophobic polymer substrate or a metal substrate reactive by affixing thereto reactive chemical functional groups, at least some of which are amine-containing groups; b) coating the resulting reactive surface with a first coating comprising a hydrophilic polyurethane-urea prepolymer intermediate, which is capable of forming a polyurethane-polyurea hydrogel-forming polymer, and which contains terminal isocyanate groups, such that at least some of said terminal isocyanate groups are reacted with and are covalently bonded to said reactive chemical functional groups on said substrate surface, forming covalent polyurea bonds therewith, resulting in the formation of a tie coat of a polyurethane-polyurea hydrogel-forming polymer on said substrate surface, which tie coat tenaciously adheres to said substrate surface, and wherein at least some of said terminal isocyanate groups of said polyurethane-urea prepolymer intermediate are present in said polyurethane-polyurea hydrogel-forming polymer of said tie coat, such that they remain free to react with other species; and c) coating the resulting tie coat of the first-coated substrate surface of (b) with a second coating comprising at least one other hydrogel-forming polymer, different from said polyurethane-polyurea hydrogel-forming polymer formed in (b), and a moisture-containing, hydrogel-forming substance, which contains isocyanate-reactive functional groups, such that a barrier coat of a wet, slippery, tenaciously adhering, commingled hydrogel forms upon the application of said second coating to said tie coat of said first-coated substrate; wherein said moisture of said hydrogel-forming substance binds with said polyurethane-polyurea hydrogel-forming polymer of said tie coat to form a first hydrogel of said commingled hydrogel barrier coat, on said tie coat, such that said first hydrogel of said commingled hydrogel barrier coat is a polyurethane-polyurea polymer hydrogel; wherein said isocyanate-reactive functional groups of said hydrogel-forming substance react with and covalently bond to at least some of said terminal isocyanate groups of said polyurethane-polyurea hydrogel-forming polymer of said tie coat that remain free to react with other species, thereby rendering said polyurethane-polyurea polymer hydrogel tenaciously adhering to said substrate surface; wherein said moisture of said hydrogel-forming substance binds with said at least one other hydrogel-forming polymer different from said polyurethane-polyurea hydrogel-forming polymer to form a second hydrogel of said commingled hydrogel barrier coat, such that said second hydrogel of said commingled hydrogel barrier coat is a hydrogel of said other hydrogel-forming polymer; and wherein said first hydrogel of said commingled hydrogel barrier coat and said second hydrogel of said commingled hydrogel barrier coat are commingled, thereby rendering said second hydrogel of said commingled hydrogel barrier coat tenaciously adhering to said tie coat and thus also tenaciously adhering to said substrate surface.