Antimicrobial Coagulant for Powder-Free Glove Manufacturing
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Solution Overview
Problem
Current antimicrobial solutions for healthcare articles, such as gloves, are ineffective in preventing microbial growth due to contamination and are not compatible with high-speed, high-volume manufacturing processes, leading to inefficiencies and environmental concerns.
Innovation Solution
A coagulant formulation incorporating a powder-free mold release agent and antimicrobial agent is used to create an antimicrobial elastomeric article, where the antimicrobial is evenly distributed throughout the manufacturing process, ensuring a high kill rate with minimal antimicrobial usage and eliminating the need for additional washing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimicrobial substances are impregnated or sprayed onto device surfaces to enhance antimicrobial effect, then antimicrobial effectiveness is improved, but manufacturing complexity and drying time increase significantly
Solution Approach 1:
The patent combines the antimicrobial agent with the mold release agent into a single formulation. This merging eliminates the need for separate antimicrobial application and drying steps, reducing manufacturing complexity while maintaining antimicrobial effectiveness. The combined formulation is applied during the existing molding process, integrating two functions into one step.
Solution Approach 2:
The antimicrobial agent is incorporated into the mold release agent before the molding process begins. This preliminary incorporation ensures that the antimicrobial protection is established during manufacturing rather than requiring post-manufacturing treatment, thereby simplifying the overall process and reducing drying time requirements.
2Reliability
If high concentrations of antimicrobial chemicals are used to achieve effective kill rate, then antimicrobial effectiveness is improved, but cost and environmental impact increase
Solution Approach 1:
The patent applies antimicrobial protection locally at the mold surface where it is most needed during the molding process. The mold release agent with incorporated antimicrobial is applied only to the mold surface, providing concentrated antimicrobial action where microbial contamination would occur during manufacturing, rather than requiring high concentrations throughout the entire glove material.
Solution Approach 2:
The mold release agent serves dual functions: it enables easy mold release during manufacturing and simultaneously provides antimicrobial protection. This self-service approach eliminates the need for separate high-concentration antimicrobial treatments, reducing overall antimicrobial chemical usage while maintaining effectiveness.
3Ease of manufacture
If powder such as calcium carbonate is used as mold release agent, then ease of manufacture is improved, but additional washing and drying steps are required
Solution Approach 1:
The patent merges the mold release function with antimicrobial protection into a single liquid formulation. This eliminates the need for powder application and subsequent washing steps, as the liquid formulation can be applied and the gloves can proceed directly to curing and packaging, thereby increasing manufacturing speed while maintaining ease of mold release.
Solution Approach 2:
The patent changes the physical state of the mold release agent from powder (calcium carbonate) to liquid formulation. This parameter change eliminates the need for washing steps required to remove powder residues, allowing for continuous high-speed manufacturing without compromising mold release capability.
4Manufacturing precision
If organic solvents are used in coating/impregnation solution, then antimicrobial distribution is improved, but drying time increases to more than 4 hours
Solution Approach 1:
The patent changes the solvent system from organic solvents to water-based or alcohol-based solvents. This parameter change maintains the ability to achieve uniform antimicrobial distribution through the glove material while dramatically reducing drying time, as water and alcohol evaporate much faster than organic solvents, eliminating the 4+ hour drying requirement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a significant antimicrobial effect with small amounts of antimicrobial agents, ensuring consistent distribution and reducing manufacturing costs and environmental impact, while maintaining the tactile characteristics of the articles.
Implementation Method 1
a coagulant formulation that includes a powder free mold release agent and an antimicrobial agent that imparts an antimicrobial effect on the molded product
Implementation Method 2
a coagulant formulation that includes a powder free mold release agent
Data Source
AI summary
According to one embodiment, a coagulant comprising calcium nitrate and an antimicrobial agent is disclosed. The coagulant may be used in the molding process to releasably bond the substrate material to the mold and to bond to the antimicrobial to the substrate material.