PVC-Non-PVC Multilayer Article for Sterilization-Resistant Adhesion
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Solution Overview
Problem
Existing container-closure systems for continuous ambulatory peritoneal dialysis (CAPD) face challenges in balancing cost and environmental concerns, with total PVC systems raising health and pollution issues, while total non-PVC systems are more expensive.
Innovation Solution
A hybrid system using non-PVC materials for components in contact with dialysis solution and PVC for other parts, employing a polymer blend with propylene and α-olefin copolymer and carbon monoxide-containing polyolefin-based copolymer for strong adhesion during steam sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If total non-PVC materials are used for all components, then health and environmental concerns are resolved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using non-PVC materials specifically for components that contact dialysis solution during steam sterilization (injection molded parts), while PVC is used for other components (tubing) that do not require steam sterilization. This targeted approach resolves health concerns for critical components while maintaining cost effectiveness for non-critical components.
Solution Approach 2:
The container-closure system is segmented into different material zones: non-PVC injection molded parts for sterilization contact and PVC tubing for fluid transport. This segmentation allows each component to be optimized for its specific function and exposure conditions, balancing health safety with manufacturing cost.
2Ease of manufacture
If non-PVC injection molded parts are connected to PVC tubing, then hybrid system cost benefits are achieved, but adhesion strength between different materials deteriorates
Solution Approach 1:
The patent uses composite materials by creating a multi-layer structure where a non-PVC polymer blend (containing polypropylene, elastomer, and adhesive promoter) is molded onto PVC tubing. This composite structure provides both the chemical resistance needed for sterilization and strong mechanical adhesion between the dissimilar materials.
Solution Approach 2:
The patent introduces an adhesive promoter as an intermediary layer in the polymer blend that facilitates bonding between the non-PVC injection molded part and the PVC tubing. This intermediary component enables strong adhesion despite the chemical incompatibility of the base materials.
3Object-affected harmful factors
If non-PVC materials are used for steam sterilization components, then health safety is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using non-PVC materials specifically for components that contact dialysis solution during steam sterilization (injection molded parts), while PVC is used for other components (tubing) that do not require steam sterilization. This targeted approach resolves health concerns for critical components while maintaining cost effectiveness for non-critical components.
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 hybrid system provides a cost-effective solution with improved adhesion between non-PVC and PVC components, ensuring robust connections without health risks from bisphenol A or acidic substances.
Implementation Method 1
the polymer blend layer may be attached to the polyolefin layer by overmolding
Implementation Method 2
non-PVC injection molded parts can be connected with non-PVC tubing by autoclave heat bonding during steam sterilization
Data Source
Figure 1
AI summary
A multi-layer article is described. The article comprises: a first layer comprising polyvinyl chloride; and a second layer attached to the first layer, wherein the second layer comprises a polymer blend including (1) a propylene and α-olefin copolymer in an amount of from 15% to 70% by weight of the polymer blend, and (2) an ethylene-n-butyl acrylate-carbon monoxide copolymer in an amount of from 25% to 85% by weight of the polymer blend.