Reusable Medical Container Composite for Autoclave Sterilization
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Solution Overview
Problem
Existing medical containers made from polycarbonate and polyolefin resins suffer from low compatibility, leading to delamination and inadequate mechanical properties, chemical resistance, and heat resistance, making them unsuitable for reusable medical boxes that withstand autoclave sterilization and prevent needle penetration.
Innovation Solution
A polycarbonate resin composition comprising a polycarbonate-based resin, a polyolefin-based resin, and a styrene-based thermoplastic elastomer, with specific ratios and additives, enhances mechanical, chemical, and heat resistance, enabling a reusable medical box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyolefin-based resin is added to polycarbonate resin to improve workability and chemical resistance, then chemical resistance and processability are improved, but compatibility between resins deteriorates causing delamination and poor mechanical properties
Solution Approach 1:
A compatibilizer comprising a graft copolymer of an olefin and a carboxylic acid or its anhydride is introduced as an intermediary substance between polycarbonate and polyolefin resins. This compatibilizer has a molecular structure containing both polyolefin-derived segments and carboxylic acid groups that interact with polycarbonate, thereby mediating the interface between the two incompatible resins and preventing delamination.
Solution Approach 2:
The invention creates a multi-component composite resin system consisting of polycarbonate, polyolefin, and compatibilizer. This composite material combines the advantages of both resins (heat resistance from polycarbonate, chemical resistance and workability from polyolefin) while using the compatibilizer to ensure homogeneous mixing and prevent phase separation.
2Ease of manufacture
If conventional materials like cardboard and polypropylene are used for medical boxes, then ease of manufacture is improved, but heat resistance and reliability under autoclave sterilization deteriorate
Solution Approach 1:
The invention develops a composite resin system combining polycarbonate (providing heat resistance) with polyolefin and compatibilizer (providing chemical resistance and processability). This composite material achieves both high heat resistance for autoclave sterilization and ease of manufacture through good moldability, overcoming the limitations of conventional single-material containers.
3Temperature
If polycarbonate resin is used alone to achieve heat resistance, then heat resistance is improved, but chemical resistance and mechanical properties deteriorate
Solution Approach 1:
The invention creates a composite resin system where polycarbonate provides the heat-resistant matrix, while polyolefin components enhance chemical resistance. The compatibilizer ensures homogeneous distribution and strong interfacial adhesion, resulting in a material that simultaneously achieves both heat resistance and chemical resistance without the delamination problems of simple blends.
Data Source
Figure 1
AI summary
The present invention provides a reusable medical box which has excellent mechanical properties, chemical resistance, heat resistance, and needle-penetration resistance. The medical box of the present invention is a reusable medical box consisting of a polycarbonate resin composition comprising, based on a total of 100 parts by weight of (A) a polycarbonate-based resin (component A) and (B) a polyolefin-based resin (component B), 1 to 30 parts by weight of (C) a styrene-based thermoplastic elastomer (component C).