Thermosetting Elastomer Composition for Antimicrobial Additive Stability
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Solution Overview
Problem
Existing thermosetting elastomers lack effective antimicrobial capabilities, particularly in applications requiring hygiene, such as teatcup liners for milking systems, food production, and pharmaceutical products, due to degradation or inactivation of antimicrobial additives during vulcanization and post-vulcanization processes.
Innovation Solution
A composition comprising elastomers like EPDM, VMQ, NBR, HNBR, NR, FKM, FFKM, BR, with zinc pyrithione and silver phosphate glass as antimicrobial additives, processed through compression or injection moulding, ensuring the additives remain incorporated in the polymer matrix and maintain antimicrobial effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimicrobial additives are incorporated into thermosetting elastomers during vulcanization, then antimicrobial protection is achieved, but the additives degrade or become inactivated during the vulcanization and post-vulcanization processes
Solution Approach 1:
The patent modifies the chemical composition parameters by using zinc pyrithione combined with silver phosphate glass in specific ratios (1:4 to 1:10 by weight). This compositional parameter change allows the antimicrobial additives to withstand the high temperatures and chemical environment of vulcanization and post-vulcanization processes without degrading or becoming inactivated, thus maintaining both antimicrobial protection and additive stability.
2Ease of manufacture
If compression moulding is used for production, then ease of manufacture is improved, but production time increases
Solution Approach 1:
The patent incorporates all antimicrobial additives and other components into the elastomer composition before the vulcanization process. This preliminary action allows the composition to be directly moulded without requiring separate steps for additive application or surface treatment after moulding, thereby simplifying the manufacturing process while maintaining efficient production timelines.
3Productivity
If injection moulding is used for production, then production time is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent formulates the elastomer composition with specific rheological and processing parameters optimized for injection moulding. The composition includes plasticizers and processing aids that enable smooth flow and filling of complex mould cavities at high speeds, allowing injection moulding to be performed efficiently without excessive complexity in the moulding process itself.
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 resulting thermosetting elastomers exhibit high-speed, long-lasting antimicrobial activity that withstands cleaning processes, suitable for applications requiring hygiene, including teatcup liners, food packaging, and medical devices, with versatility in production methods.
Implementation Method 1
zinc pyrithione and silver phosphate glass in a 1:1 ratio by weight... exhibit high-speed, long-lasting antimicrobial activity
Implementation Method 2
The resulting thermosetting elastomers exhibit high-speed, long-lasting antimicrobial activity that withstands cleaning processes
Implementation Method 3
polymers which, in appropriate temperature and pressure conditions and/or in the presence of particular compounds, are transformed into rigid, insoluble and infusible materials in a process generally called vulcanization... following cross-linking reactions that take place between the polymer chains with the formation of strong bonds (covalent or ionic)
Implementation Method 4
The press on which the mould is fixed is provided with electrically heated and thermocontrolled beds which maintain the mould at the right temperature for moulding of the elastomer being processed, generally between 150°C and 170°C
Implementation Method 5
The actual compression moulding step consists in positioning the prepared rubber, having appropriate shape and weight, inside the heated mould, which is then closed under pressure for a time sufficient to allow vulcanization of the rubber
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a
AI summary
The present invention refers to a composition suitable for the production of a thermosetting elastomer with antimicrobial capabilities by means of vulcanization by moulding, the relative thermosetting elastomers and the use thereof.