Adhesion: How Plasma and Corona Treatment Guarantees strong adhesion of Plastic Medical Devices

Strong adhesion is imperative in the medical device industry. Whether it is a catheter, a syringe, or an ostomy bag, it is essential that inscriptions, tubes, vents, and other appliances adhere securely. However, achieving a proper adhesion level is not always easy, especially when dealing with soft plastics meant for containing fluids and safe for medical use.

Traditionally, the adhesive capabilities of plastics devices has been improved with either chemical primers or mechanical abrasion techniques. However, these methods pose significant HSE-issues, and may even harm the products, if it is made from i.e. polypropylene.

Fortunately, advances in technology have brought about new methods for improving adhesion and coating of medical devices. Corona and plasma treatments are emerging as highly effective and efficient ways to enhance surface energy and adhesion, even on difficult-to-treat materials like polypropylene.

In this article, we will explore how corona and plasma treatments can solve the adhesion challenges faced by the medical device industry. We will also provide examples of how these treatments are used in various medical devices, such as syringes, catheters, ostomy bags, and ophthalmic lenses.

Let’s dive in.

Why You Need to Faze Out Chemical Primers

Chemical primers have been widely used across industries, including the medical device industry. The primers improve adhesion properties of polymers for medical devices, they present several challenges and limitations.

Firstly, chemical primers pose a threat to worker safety and health because of their potential toxicity and hazardous nature. The proper handling and disposal of these chemicals requires that workers adhere to stringent protocols. This increases production expenses and delays.

Secondly, areas with complex geometries or tight spaces, both of which are common in medical devices, can make it challenging to apply chemical primers uniformly. Adhesion failures caused by an inadequate coating can compromise the device’s safety and usefulness.

Thirdly, chemical primers can have limited shelf life and require careful storage conditions, which adds to the complexity and costs of the manufacturing process.

Finally, there is a growing concern about the environmental impact of using chemical primers in medical device manufacturing. Many primers contain volatile organic compounds (VOCs) which can contribute to air pollution and have potential health effects on workers and the surrounding community.

Given these challenges, there is a need for alternative methods to improve adhesion properties of medical device plastics.

Corona and Plasma Surface Treatment for the Medical Device Industry

The adhesion issues of the medical device sector seems solved by using corona and plasma surface treatments. Unlike chemical primers, these methods ensure effective adhesion without any negative impact on the environment or the health of workers.

Corona and plasma treatments utilize high-voltage electrical discharge to modify the surface properties of materials. They improve the surface energy, which in turn enhances the wettability of the material, making it easier for adhesives to bond to the surface. By doing so, corona and plasma treatments do away with the need for chemical primers and solvents altogether.

In contrast to chemical primers, corona and plasma treatments can be applied to various materials, including plastics, metals, and glass, regardless of the shape and size of the part.

The uniformity of the treatment across the entire surface is guaranteed by the high degree of repeatability and consistency offered by both corona and plasma treatments. In the medical device field, this means better bonding strength, adhesion, and coating. Moreover, corona and plasma treatments are FDA-approved, making them a safe and reliable option for medical device manufacturers.

Overall, corona and plasma treatments offer an efficient and practical solution for achieving proper adhesion and coating of medical devices. They eliminate the health and environmental hazards posed by chemical primers while providing uniform, consistent, and repeatable results.

5 Examples of How the Medical Device Industry Benefits from Plasma and Corona Treatment

Corona and plasma surface treatments have been used in various medical device applications to improve adhesion and coating properties. The ability of these treatments to modify the surface energy of different materials has made them an ideal solution for overcoming challenges in the medical device industry.

Let’s go through some use cases

1. Needle Hubs: One area that has benefited greatly from corona and plasma surface treatments is needle hubs. Assembling needle hubs can be a challenging process, particularly when dealing with polypropylene materials. Improving the wettability and adhesion properties of the hub is necessary to ensure a strong bond when cannulas are inserted, and glue is put in place. By using corona or atmospheric plasma treatments to create wettability and adhesion improvement, the cannula can be easily inserted, and the glue can wet and adhere properly.
2. Syringes are another example of medical device that requires proper surface treatment. Printing on the outside of the syringe is crucial for ensuring that the graduations on the syringe last for the life of the syringe. The print quality is important to ensure that the doctor can accurately read the dosage information. Treating the inside of the syringe can also be necessary for coating processes. This can be achieved through the use of high voltage electrodes, gas pumping, or vacuum chamber plasma treatments – all of which are types of corona or plasma technologies.
3. Catheter tubing is third example of a medical device that benefit from corona and plasma treatments. Printing on the catheter to indicate length or placement inside the body is critical for proper use. By ensuring that the print adheres well, doctors can avoid placing the catheter too far or not far enough, which can be detrimental to the patient. Coating the catheter with a lubricious coating that wets out uniformly is also essential to reduce discomfort during placement. Both can be achieved with plasma and corona technologies that raises the surface energy of the tubes and allows for strong adhesion and uniform coating.
4. Ostomy Bags: A fourth example of a medical device that benefit from corona treatment is ostomy bags. They too require proper adhesion and printing for tracking and traceability purposes. By exposing the Velcro attachment to corona treatment, the Velcro tape can be adequately glued to prevent peeling. The date code print on the bag must also adhere well to ensure proper tracking and traceability.
5. Finally, ophthalmic lenses require proper adhesion and coating to improve their quality. Applying anti-fog, anti-scratch, and transitions coloring coatings on the lenses is critical to enhancing their value. Polycarbonate materials are notoriously difficult to treat, but plasma and corona treatments can ensure that each layer of coating adheres properly and does not flake off or scratch easily.

Overall, corona and plasma treatments have been applied to different medical devices to improve adhesion and coating properties. From needle hubs to ophthalmic lenses, these treatments have been successful in enhancing the quality and value of medical devices.

A Simple Solution to a Complex Medical Device Problem

In conclusion, plasma and corona surface treatment provide an effective solution to the challenge of achieving proper adhesion and coating of medical devices. The use of chemical primers – though popular in the past – pose several problems that can be eliminated with plasma and corona treatment.

With these new methods, hard-to-reach areas and oddly shaped instruments can be treated uniformly and efficiently. And with FDA-approved technologies, such as those provided by Tantec, medical device manufacturers can be confident in their processes and products.

In the medical device industry, proper adhesion is not just a matter of aesthetics, but a critical factor in ensuring patient safety and product efficacy. With the plasma and corona technologies available today, the medical device industry may solve both the quality, financial and environmental challenge – all at once.