Laser Markable Polypropylene Medical Devices

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Polypropylene and polypropylene-based materials are non-polar and lack reactive functional groups, making them difficult to laser mark, as they do not absorb laser light effectively, which is a challenge in medical device manufacturing where clear, legible, and durable markings are essential.

Innovation Solution

The use of amphiphilic graft copolymers with a polypropylene backbone and hybrid micromolecule side-chains based on organo-functional silanes, combined with inorganic fillers, enhances the laser markability of polypropylene-based materials by improving their absorption of laser energy and thermal degradation, allowing for precise and permanent markings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polypropylene-based materials are used for medical devices, then chemical resistance and heat resistance are improved, but laser markability deteriorates due to non-polar nature and absence of reactive functional groups

Engineering Contradiction:

Improvechemical resistanceVSAvoidlaser markability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by introducing polar functional groups at the surface level of polypropylene through graft copolymers and inorganic fillers. The bulk polypropylene maintains its non-polar properties for chemical resistance, while the surface layer contains polar groups that enable laser marking, thus resolving the contradiction between bulk material properties and surface functionality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates composite materials by combining polypropylene with graft copolymers containing polar functional groups and inorganic fillers. This composite structure allows the material to simultaneously exhibit the chemical resistance of polypropylene and the laser markability of polar components, effectively resolving the technical contradiction.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional surface-printing methods are used for device markings, then manufacturing simplicity is maintained, but marking durability deteriorates due to mechanical damage and abrasion

Engineering Contradiction:

Improvemarking simplicityVSAvoidmarking durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces mechanical surface-printing methods with laser marking technology. The laser marking process creates permanent markings by modifying the material structure at the surface level through thermal degradation and carbonization, eliminating the durability issues associated with mechanical printing methods while maintaining manufacturing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If polar additives are dispersed in polypropylene, then laser markability is improved, but dispersion uniformity deteriorates due to non-polar matrix and polar additive incompatibility

Engineering Contradiction:

Improvelaser markabilityVSAvoiddispersion uniformity

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent uses graft copolymers as intermediary substances between the non-polar polypropylene matrix and polar additives. The graft copolymers contain both non-polar polypropylene chains that are compatible with the matrix and polar functional groups that attract and uniformly distribute polar additives, thus resolving the dispersion uniformity issue while maintaining laser markability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enables the creation of medical devices with clear, durable, and legible laser markings, even on complex surfaces, improving safety and reducing errors in high-stress environments by providing a robust and environmentally friendly marking method.

Implementation Method 1

PPs and PPBMs are non-polar (absence of hydrophilic groups) and do not contain reactive functional groups that limits there applications in the fields where adhesion, solvent bondability, surface paintability, laser marking or dispersion of the polar additives

Methodology Applied

Scientific EffectLaser absorption: Absorption (EM radiation)

Implementation Method 2

allowing for precise and permanent markings

Methodology Applied

Scientific EffectThermal degradation: Pyrolysis

Data Source

PatentUS10814040B2Laser markable medical devices

Publication Date: 2020.10.27 BECTON DICKINSON & CO

AI summary

Medical devices comprise a polymeric body comprising: a base polymeric formulation comprising at least a polymer or co-polymer of propylene; and an additive comprising a copolymer having a polypropylene backbone and hybrid micromolecule side-chains based on organo-functional silanes (PP-g-XSiOA) in the presence of a co-agent, for example, difunctional metallic diacrylate monomers, where “X” is an organic group or an organo-functional group, and “A” is a metal, an inorganic oxide, an inorganic hydroxide, or any other inorganic material. X may be derived from a compound selected from the group consisting of epoxy, amino, acrylate, methacryloxy, and vinyl; and A is selected from the group consisting of: silicon, (Si), aluminum (Al), iron (Fe), titanium (Ti), silver (Ag), zinc (Zn), nickel (Ni), calcium (Ca), copper (Cu), tin (Sn); oxides thereof; hydroxides thereof; and mixtures of the foregoing. Optionally, inorganic fillers may be included. The medical devices are laser markable.