Two-Ply Sterilization Liner Flame Lamination Moisture Management
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Solution Overview
Problem
Existing tray liners fail to efficiently absorb residual moisture after sterilization, leading to potential contamination and damage to surgical instruments, and the use of adhesives in multi-layered liners can deteriorate under sterilization conditions.
Innovation Solution
A two-ply liner construction combining a hydrophilic polyurethane foam layer with medical grade paper, joined through flame lamination, to absorb and evaporate moisture effectively, eliminating the need for separate adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single material tray liner (foam or cellulose) is used, then the structure is simple and easy to manufacture, but the evaporation rate and moisture absorption efficiency are insufficient
Solution Approach 1:
The patent applies composite materials by combining foam and paper layers to create a two-ply liner. The foam layer provides cushioning and initial moisture contact, while the paper layer offers superior absorbency and evaporation. This composite structure resolves the contradiction by achieving both manufacturing feasibility and enhanced moisture management performance.
Solution Approach 2:
The patent segments the liner into two distinct functional layers: a foam layer for structural support and initial moisture interaction, and a paper layer for active absorption and evaporation. This segmentation allows each layer to optimize its specific function, thereby improving overall moisture absorption efficiency while maintaining reasonable manufacturing complexity.
2Stability of the object's composition
If adhesive is used to join foam and paper layers, then the liner structure is stable, but the adhesive deteriorates under high heat and steam exposure during sterilization
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive) with a mechanical/thermal bonding method (flame lamination). The flame lamination process creates a direct bond between the foam and paper layers through controlled thermal exposure, eliminating the need for separate adhesive materials that would deteriorate during sterilization. This substitution resolves the contradiction by achieving structural stability through a sterilization-compatible bonding mechanism.
Solution Approach 2:
The patent changes the bonding parameter from chemical (adhesive composition) to thermal (flame lamination temperature and duration). This parameter change enables the bonding process to be compatible with subsequent sterilization conditions, as the thermal bond withstands high heat and steam exposure without deteriorating, unlike chemical adhesives.
3Ease of manufacture
If adhesive is used to bond layers, then the liner can be manufactured as a multi-layer structure, but adhesive residue is sticky and difficult to eliminate, potentially contaminating sterile instruments
Solution Approach 1:
The patent replaces chemical bonding (adhesive) with thermal bonding (flame lamination) to eliminate adhesive residue contamination. The flame lamination process creates a clean bond between layers without introducing foreign adhesive materials that could flake off or transfer to sterile instruments, thus resolving the contamination issue while maintaining multi-layer construction capability.
Solution Approach 2:
The patent employs a disposable liner where the bonding method (flame lamination) creates a sufficiently durable bond for single-use applications without requiring long-term durability. This approach eliminates the need for adhesive materials that would need to withstand prolonged use, allowing the use of a bonding method that is simple, residue-free, and appropriate for disposable medical applications.
4Strength
If foam liner is used alone, then the cushioning property is good, but the evaporation rate and moisture dispersing properties are insufficient
Solution Approach 1:
The patent creates a composite structure where the foam layer provides cushioning strength and the paper layer provides evaporation capability. The foam's closed-cell structure offers mechanical support and initial moisture wicking, while the paper's fibrous structure provides high surface area for evaporation. This composite material approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers: the foam layer is optimized for cushioning and structural support, while the paper layer is optimized for moisture absorption and evaporation. This functional differentiation allows each layer to excel at its specific task, resolving the contradiction between cushioning strength and evaporation rate.
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 two-ply liner effectively traps and evaporates moisture, protecting instruments and trays from residual moisture, while maintaining integrity under sterilization conditions, ensuring dryness and preventing contamination.
Implementation Method 1
A foam layer, such as hydrophilic polyurethane foam, is flame laminated to a paper layer
Implementation Method 2
The paper layer is capable of absorbing moisture from the foam layer and evaporating the moisture to the atmosphere
Implementation Method 3
the paper layer is capable of absorbing moisture from the foam layer and evaporating the moisture to the atmosphere
Implementation Method 4
A foam layer, such as hydrophilic polyurethane foam, is flame laminated to a paper layer
Data Source
AI summary
The present invention is directed to a two-ply absorbent liner for use in a sterilization process and, more particularly, to an absorbent liner having a foam layer and a paper layer for cushioning sterilization trays and surgical instruments in a sterilization pack and providing advantageous moisture absorption functionality during and after completion of a sterilization process. The absorbent liner functions advantageously with steam or ethylene oxide gas as the sterilization agent. The absorbent liner is fabricated from a foam material, preferably a hydrophilic polymeric foam material, e.g., a hydrophilic polyurethane foam flame laminated to paper, preferably medical grade paper. The disclosed liner may be advantageously utilized in sterilizing surgical instruments and in conjunction with sterilizing trays such that potential residual moisture is eliminated from the surface of the instruments or trays and metal surfaces are cushioned.