Recycled Resin Compositions And Disposable Medical Devices Made Therefrom

Abstract

Compositions including recycled resin components and medical devices and components made form such compositions are disclosed. The compositions and medical devices are characterized as biocompatible and sterilization stable. In one or more embodiments, the compositions include a recycled resin component and may include one or more of an anti-oxidant component, slip additive component, anti-static component, impact modifier component, colorant component, acid scavenger component, X-ray fluorescence agent component, radio opaque filler component, surface modifier component, melt stabilizer component, clarifier component, processing aid component and reinforcing agent component. Methods of forming medical articles and components are also disclosed.

What is claimed is: 
     
         1 . A method of forming a medical device comprising:
 providing a melt blend composition including a 50% to 99% recycled resin component, the melt blend composition having a cytotoxicity score of zero;   stabilizing the composition to withstand exposure to gamma rays, electron beams, X-ray radiations, ethylene oxide gas, autoclave, plasma sterilization; and   solidifying the composition in a pre-selected shape.   
     
     
         2 . The method of  claim 1 , wherein providing a melt blend composition comprises feeding a recycled resin component and one or more of an antioxidant component, slip additive component, anti-static component, impact modifier component, colorant component, acid scavenger component, nucleating agents, clarifiers, x-ray fluorescence agent component, radio opaque filler component, surface modifier component, processing aid component and reinforcing agent component into a melt compounding extruder. 
     
     
         3 . The method of  claim 1 , wherein solidifying the composition comprises one of injection molding the composition, extruding the composition, blow molding the composition and rotational molding the composition. 
     
     
         4 . The method of  claim 1 , wherein the pre-selected shape comprises one of a plunger rod, a syringe barrel, a catheter, a blood collection device, a surgical blade handle, a needle shield, safety shield, catheter wings, catheter flow control plugs and a needle hub, sharps containers, body fluid collection devices, tubing, adapters and drainage tubes. 
     
     
         5 . The method of  claim 1 , further comprising stabilizing the composition to withstand exposure to gamma rays in the range from about 5 kGys to about 75 kGys. 
     
     
         6 . The method of  claim 1 , wherein the recycled resin component is biocompatible. 
     
     
         7 . The method of  claim 1 , wherein the recycled resin component comprises from about 0.1% to about 100% by weight recycled resin selected from one of post-industrial recycled resin, post-consumer recycled resin and combinations thereof. 
     
     
         8 . The method of  claim 1 , wherein the melt blend composition further comprises one or more of a virgin resin component and/or a biobased resin component. 
     
     
         9 . The method of  claim 8 , wherein the composition of recycled resin composition mechanically mixed with virgin polypropylene resin comprises 60% by weight of recycled resin composition and 40% by weight of the virgin polypropylene resin. 
     
     
         10 . The method of  claim 8 , wherein the composition of recycled resin composition mechanically mixed with virgin polypropylene resin comprises 70% by weight of recycled resin composition and 30% by weight of the virgin polypropylene resin. 
     
     
         11 . The method of  claim 8 , wherein the composition of recycled resin composition mechanically mixed with virgin polypropylene resin comprises 50% by weight of recycled resin composition and 50% by weight of the virgin polypropylene resin. 
     
     
         12 . A composition for molding a medical device comprising:
 a recycled resin sourced from a traceable source; and   one or more of an antioxidant component, slip additive component, anti-static component, impact modifier component, colorant component, acid scavenger component, x-ray fluorescence agent component, radio opaque filler component, surface modifier component, processing aid component, melt stabilizer component, clarifier component, nucleating agents and reinforcing agent component,   wherein the composition is biocompatible and has a cytotoxicity score of zero.   
     
     
         13 . The composition of  claim 12 , wherein the composition is capable of withstanding exposure to gamma rays in the range from about 5 kGys to about 75 kGys. 
     
     
         14 . The composition of  claim 12 , wherein the composition is capable of withstanding exposure to electron beams in the range from about 30 kGys to about 100 kGys. 
     
     
         15 . The composition of  claim 12 , wherein the composition is capable of withstanding exposure to one of X-ray radiation, ethylene oxide gas, autoclaving and plasma sterilization. 
     
     
         16 . The composition of  claim 12 , comprising a flexural modulus in the range from about 70 kpsi to about 350 kpsi. 
     
     
         17 . The composition of  claim 12 , comprising a melt flow range in the range from about 3 dg/minute to about 80 dg/minute. 
     
     
         18 . The composition of  claim 12 , comprising a heat deflection temperature from about 60° C. to 260° C. 
     
     
         19 . The composition of  claim 12 , comprising notched izod impact strength in the range from about 0.1 ft-lb/in to about 4.0 ft-lb/in. 
     
     
         20 . The composition of  claim 12 , further comprising one or more of a virgin resin component and a biobased resin component.