Polycarbonate Copolymer Thin-Walled Medical Articles

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Solution Overview

Problem

There is a need for polycarbonate materials that can be easily processed to form thin-walled molded articles without brittleness, cracking, or poor flowability, while maintaining strength and being suitable for medical applications, including biocompatibility and non-toxicity.

Innovation Solution

The development of high flow ductile polycarbonate copolymer compositions comprising at least one poly(aliphatic ester)-polycarbonate copolymer, a mold release agent, and a radiation stabilizer, which exhibit superior processing properties, including a melt flow rate of 25 g/10 minutes or higher, light transmittance of 80% or higher, and haze of 1% or less, allowing for the creation of thin-walled medical articles with enhanced impact strength and thermal stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If standard polycarbonate materials are used, then structural strength is maintained, but flowability deteriorates and thin-walled formation becomes difficult

Engineering Contradiction:

Improvethin-walled formationVSAvoidflowability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent modifies the molecular structure parameters of polycarbonate by introducing aliphatic ester units (adipic acid, sebacic acid, dodecanedioic acid) into the polymer chain, changing the material's flow characteristics and enabling thin-walled formation while maintaining strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite polycarbonate material combining aromatic polycarbonate segments (for strength) with aliphatic ester segments (for flowability), achieving both high flow rate and structural integrity in thin-walled articles

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If wall thickness is reduced to create thin-walled articles, then material usage is decreased, but brittleness and cracking increase

Engineering Contradiction:

Improvematerial usageVSAvoidbrittleness

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent changes the polymer's molecular weight distribution and chain flexibility parameters through copolymerization, enabling the material to maintain ductility and impact strength even at wall thicknesses of 0.5mm or less

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates localized flexibility within the polymer chain through aliphatic ester segments, allowing the material to absorb stress and prevent crack propagation in thin-walled structures

Inventive Principle:

Principle #3Local quality

3Shape

If surface quality is improved to eliminate unsightly surfaces, then aesthetic appearance is enhanced, but processing complexity increases

Engineering Contradiction:

Improvesurface qualityVSAvoidprocessing complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent adjusts the polymer's viscosity and flow parameters through copolymer composition control, enabling the material to self-level and fill mold cavities smoothly, producing unsightly-free surfaces through optimized processing rather than complex post-treatment

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9872939B2Polycarbonate copolymer compositions for forming molded medical articles with thin walls

Publication Date: 2018.01.23 SHPP GLOBAL TECH BV

AI summary

Disclosed is a thin-walled article that can be used for medical applications. The medical article is molded from a thermoplastic composition. The composition comprises a poly(aliphatic ester)-polycarbonate copolymer, a mold release agent, and a gamma radiation stabilizer. The composition exhibits excellent melt flow rate, is amenable to thin wall injection molding, and has good transparency.