Batch Surface Modification of Syringe Gaskets
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Solution Overview
Problem
Conventional methods for surface modification of three-dimensional objects, such as gaskets for syringes, are inefficient for mass production due to high costs and poor productivity, making them unsuitable for practical use.
Innovation Solution
A method involving immersion of multiple three-dimensional objects in a photopolymerizable monomer-containing liquid followed by photoirradiation while rotating the vessel at an inclined angle, allowing for simultaneous polymerization and growth of polymer chains on the surfaces, which enhances sliding and sealing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional individual surface modification methods are used, then surface modification quality is maintained, but productivity is poor and manufacturing cost is high
Solution Approach 1:
The patent merges multiple individual surface modification operations into a single batch processing operation. Multiple three-dimensional objects are simultaneously immersed in photopolymerizable monomer-containing liquid and modified together through photoirradiation, eliminating the need for sequential individual processing and thereby dramatically improving productivity while reducing manufacturing costs
Solution Approach 2:
The patent creates a universal surface modification system that can process multiple different three-dimensional objects simultaneously using the same photopolymerizable monomer-containing liquid and photoirradiation conditions, enabling mass production across various product types without requiring separate modification lines for each object
2Productivity
If multiple objects are processed simultaneously, then productivity improves, but uniformity of surface modification may deteriorate
Solution Approach 1:
The patent employs dynamic agitation during the photoirradiation process to continuously move and redistribute the multiple three-dimensional objects within the photopolymerizable monomer-containing liquid. This dynamic processing ensures uniform exposure and monomer distribution across all objects simultaneously, maintaining manufacturing precision while enabling batch processing for high productivity
Solution Approach 2:
The patent incorporates monitoring and control mechanisms to track the surface modification process in real-time, adjusting photoirradiation intensity, duration, and agitation parameters to ensure uniform modification across all objects in the batch, thereby maintaining manufacturing precision while processing multiple items simultaneously
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
This method enables the production of surface-modified gaskets with excellent sliding and sealing properties while improving productivity and economic efficiency by uniformly modifying a large number of objects simultaneously.
Implementation Method 1
a step 2 of polymerizing the photopolymerizable monomer by photoirradiation while rotating a vessel containing the plurality of three-dimensional objects and the photopolymerizable monomer-containing liquid
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
The present invention provides methods of modifying the surfaces of a plurality of three-dimensional objects at the same time to provide good sliding properties, good durability after repeated sliding, good sealing properties, and the like, and also provides gaskets for syringes obtained by such methods. The present invention relates to a method for modifying the surfaces of a plurality of three-dimensional objects including: a step 1 of immersing a plurality of three-dimensional objects in a photopolymerizable monomer-containing liquid; and a step 2 of polymerizing the photopolymerizable monomer by photoirradiation while rotating a vessel containing the plurality of three-dimensional objects and the photopolymerizable monomer-containing liquid, to grow polymer chains on the surfaces of the plurality of three-dimensional objects.