Polysiloxane Coating for Injection Needle Adhesive Blockage
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Solution Overview
Problem
Injection needles used for applying adhesive often become blocked due to adhesive buildup, leading to short service life and increased replacement frequency, which decreases productivity and increases costs.
Innovation Solution
A polysiloxane coating is applied to the inner surface of stainless steel injection needles, comprising specific monomer units that form a chemical bond, providing a non-reactive surface with adhesive and enhancing the needle's service life. The coating is manufactured through a process involving hydroxylation treatment, immersion in a silane and silicate ester slurry, and curing, resulting in a stable and non-stick surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied through an injection needle, then the adhesive bonding function is achieved, but the injection needle becomes blocked by adhesive buildup
Solution Approach 1:
A coating layer comprising polysiloxane is applied as an intermediary between the injection needle surface and the adhesive. This coating layer prevents direct contact between the adhesive and the needle surface, eliminating adhesive buildup while maintaining the needle's adhesive application function. The coating acts as a non-reactive barrier that allows adhesive flow without bonding to the needle.
2Productivity
If the injection needle is replaced frequently due to blockage, then adhesive application can resume, but productivity decreases and costs increase
Solution Approach 1:
The coating layer is applied in advance to the injection needle before adhesive application begins. This preliminary protective measure ensures that the needle remains blockage-free throughout the adhesive application process, eliminating the need for frequent replacements and maintaining continuous productivity without requiring interruptions for needle maintenance.
3Duration of action of stationary object
If a coating is applied to prevent adhesive buildup, then the service life of the needle is extended, but the manufacturing process becomes more complex
Solution Approach 1:
The coating composition parameters are optimized to achieve effective protection with a simple dip-coating process. By controlling the polysiloxane concentration, molecular weight, and crosslinking density, the coating forms an effective barrier at very thin thicknesses (1-10 μm), minimizing process complexity while maximizing service life extension.
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 polysiloxane coating significantly extends the service life of injection needles by preventing adhesive buildup, reducing the need for frequent replacements, and lowering production costs while maintaining equipment compatibility and allowing for mass production.
Implementation Method 1
the coating is bonded to the tube through a chemical bond of —O—
Implementation Method 2
applying a hydroxylation treatment on the tube to form hydroxyl groups on an inner surface of the tube
Implementation Method 3
the slurry comprises a first monomer and a second monomer, the first monomer is selected from a silane containing at least one alkoxy and at least one alkyl, and the second monomer is selected from a silicate ester
Data Source
AI summary
A non-stick, durable, and long-serving coating in an inner surface of a tube that transports adhesive, a material of the coating includes polysiloxane. The polysiloxane includes a first monomer unit and a second monomer unit. The first monomer unit is at least one group selected from the group consisting of —O—Si—(R1)(R2)(R3), Si—(R1)(R2)(—O—)2, and Si—(R1)(—O—)3, the R1, R2 and R3 being independently selected from the group consisting of substituted alkyl and unsubstituted alkyl. The second monomer unit includes Si(—O—)4. An injection needle and a method for manufacturing the coating on an injection needle is also provided.