This product is a high-performance composite component manufactured using LSR (Liquid Silicone Rubber) overmolding on PSU (Polyphenylsulfone / Polysulfone).
It combines the exceptional high-temperature resistance and dimensional stability of PSU with the flexibility, sealing performance, and biocompatibility of medical-grade liquid silicone rubber.
The structure is widely used in medical, laboratory, and high-end fluid control systems where repeated sterilization, chemical resistance, and long-term reliability are required.
Through precision injection overmolding, the LSR layer is permanently bonded to the PSU substrate, forming a stable soft-hard integrated structure that eliminates traditional sealing assemblies.
Key Advantages of LSR Over PSU
Excellent High Temperature Resistance
PSU is a high-performance thermoplastic engineered for extreme thermal environments.
- Continuous use temperature up to 160°C
- Excellent dimensional stability under heat
- Suitable for repeated sterilization cycles
Medical Grade Silicone Performance
The LSR overmold provides biocompatible sealing and flexible interface functionality.
- ISO 10993 compliant
- USP Class VI certified material
- Non-toxic, odorless, and chemically stable
- Suitable for direct and indirect medical contact
Superior Sterilization Resistance
Designed for demanding medical and laboratory environments.
- Resistant to autoclave sterilization (121°C–134°C)
- Compatible with EO and gamma sterilization
- No cracking, deformation, or yellowing
Excellent Chemical Resistance
PSU combined with LSR provides strong resistance to aggressive media.
- Resistant to disinfectants and cleaning agents
- Stable in acidic and alkaline environments
- Suitable for repeated chemical exposure
Integrated Sealing and Structural Design
LSR overmolding eliminates traditional assembly components.
- No O-rings or secondary seals required
- Reduced leakage risk
- Improved system reliability and assembly efficiency
Manufacturing Process
The product is manufactured using precision overmolding technology:
- PSU Injection Molding
High-performance polysulfone is molded into the structural base. - Surface Preparation
Surface activation improves bonding performance. - LSR Overmolding
Liquid silicone rubber is injected onto PSU substrate. - Thermal Curing
Silicone is cured to form a permanent bonded interface. - Quality Inspection
Sealing performance, adhesion strength, and dimensional accuracy are verified.
Technical Specifications
| Item | Description |
|---|---|
| Product Name | LSR Overmolded PSU Component |
| Base Material | PSU (Polysulfone / Polyphenylsulfone) |
| Overmold Material | Liquid Silicone Rubber (LSR) |
| Process | Injection Overmolding |
| Continuous Temperature | Up to 160°C |
| Sterilization Methods | Autoclave, EO, Gamma |
| Chemical Resistance | High (detergents, disinfectants) |
| Biocompatibility | ISO 10993 / USP Class VI |
| Structure Type | Rigid PSU + flexible silicone sealing |
Applications
- Medical sterilization equipment components
- Surgical and diagnostic device housings
- Laboratory fluid handling systems
- Pharmaceutical processing equipment
- High-temperature fluid control systems
- Reusable medical device assemblies
- Precision medical connectors and seals
Engineering Considerations
Bonding Between LSR and PSU
PSU has high chemical stability and low surface energy, requiring:
- Plasma surface treatment
- Specialized medical-grade primer systems
- Controlled molding temperature for adhesion stability
Thermal Compatibility
Both materials are selected for high-temperature environments:
- PSU provides structural rigidity at elevated temperatures
- LSR maintains elasticity after repeated sterilization cycles
Sterilization Performance Design
The system is optimized for:
- Repeated autoclave cycles
- Long-term chemical exposure
- Dimensional stability after thermal cycling
Frequently Asked Questions
Why choose PSU instead of PC or PA?
PSU offers significantly higher heat resistance and better long-term stability under sterilization conditions.
Is LSR suitable for medical applications?
Yes, medical-grade LSR is widely used in ISO 10993 and USP Class VI certified applications.
Can this product withstand repeated sterilization?
Yes, it is designed for repeated autoclave, EO, and gamma sterilization processes.
Is customization available?
Yes, PSU grade, silicone hardness, structure design, and sealing geometry can be customized.
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