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Seamless membrane pressed thermoplastic sheet resists bacteria, harsh chemicals, abuse in healthcare environment
Versailles, OH — When it comes to infection control in a medical office, a lot depends on the cleanability of the work surfaces and equipment, which is why Midmark Corp., a supplier of healthcare products, switched from laminate tops on its medical carts and cabinets, to surfaces membrane pressed of a proprietary thermoplastic sheet. Employed in exam rooms, clinics, and multi-physician practices, the company's Midmark and Ritter series carts and cabinets, which include procedures carts, treatment cabinets, and mobile desks, help physicians access critical items at the point of care. "To eliminate the threat of bacterial growth and the transmission of viruses and other germs, our customers require work surfaces that will not absorb spilled fluids and chemicals and can be easily disinfected," explains Jon Wells, director of marketing for Ohio-based Midmark. "Membrane pressed Kydex® 150 sheet provides our carts and cabinets with seamless work surfaces that are very cleanable, durable, and aesthetically pleasing," he adds. "Extreme chemical resistance is also critical," says Scott Strait, Midmark's chief engineer. "Not only is there a potential for spills, but the surface is disinfected multiple times each day with harsh cleansers. Kydex 150 sheet exhibits greater chemical resistance than a typical laminate." Unlike many other plastics, Kydex sheet also resists exposure to lipids present in body fats and gamma radiation, making it particularly well suited for medical applications. "Our carts and cabinets must also be scratch and abrasion resistant and able to withstand a lot of abuse," says Wells. "The melamine and laminate surfaces we've used in the past would begin to show scratches and wear after only a brief time in the field, something we haven't experienced with our countertops membrane pressed with the Kydex product. They are considerably more durable." The proprietary sheet exhibits Notched Izod Impact Resistance of 18 ft-lbs/in (953 J/m) at 73°F (23°C), tensile strength of 6100 psi (42 N/mm²), flexural strength of 9300 psi (64 N/mm²), and Rockwell hardness of 94 (R scale). In addition, the color of Kydex sheet is integral, unlike that of high-pressure laminates, rendering gouges and scratches inconspicuous.
"With laminates, the requisite edge banding creates a seam that appears inconsequential until you consider the chemicals and bacteria these work surfaces might come in contact with during the course of a day," explains Strait. Membrane pressing, however, allows the thermoplastic sheet to conform to all top and side surfaces of the MDF substrate including compound curves, sharp edge profiles, rounded corners and undercut edges, encapsulating all but the bottom surface, which can be flat laminated beforehand with the same sheet, or prelaminated with melamine. Midmark outsources membrane pressing of its parts to R&R Fabrications, St. Henry, OH. Prior to membrane pressing, the MDF substrate is routed to create detailed edge profiles and compound curves. Machined components are then coated with a heat-activated adhesive and placed on a membrane-pressing table. Specified in Sand Gray, Pearl Gray, Pebble Gray, or a custom color, Kydex 150 thermoplastic sheet with a P-3 Velour texture is then placed over the components, and the table is slid into a chamber that heats the sheet and activates the adhesive. A vacuum from below and pressure from above forces the softened sheet onto all top and side surfaces of the MDF core, after which the parts are removed, cooled and trimmed, ready for assembly. A structural steel shell supports the wood top, which is membrane pressed with Kydex sheet, and the vacuum formed vinyl drawer and door fronts, creating a overall appearance that is "very warm and less institutional," says Wells. "We compete with local wood shops as well as manufacturers of heavy steel products," he adds. "With a steel structure and membrane pressed components we offer a solution that is both attractive and functional."
R&R Fabrications
Kleerdex Company, LLC
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