Smart thermoplastic composites

Abstract

A smart thermoplastic composite material includes: at least one thermoplastic component (12) having a first cross-sectional profile; at least one thermal component (14) having a second cross-sectional profile and in contact with the thermoplastic component (12); wherein the cross-sectional arrangement is such that the thermal component (14) changes the thermal properties of the thermoplastic component in its thermally activated or cold-activated state, ensuring the existence of a flexible deformation region within the thermoplastic component (12) by: raising the local temperature of the thermoplastic component (12) above its softening point but below its viscosity temperature; and maintaining the ambient temperature above its softening point and maintaining the local temperature below its softening point.

Description

Technical Field

[0001] This invention relates to the fields of materials and electromechanical engineering.

[0002] Specifically, the present invention relates to the field of functional materials comprising composite components, the composite components comprising thermoplastic and non-thermoplastic components.

[0003] More specifically, the present invention relates to a variable stiffness composite material.

[0004] Specifically, the present invention relates to intelligent thermoplastic composite materials. Background Technology

[0005] In engineering, "deformation" refers to a change in the size or shape of an object. Depending on the type of material, the size and geometry of the object, and the applied force, various types of deformation can occur.

[0006] Figure 1 A typical stress-strain diagram is shown, which indicates the various stages of deformation, including the elastic zone, the plastic zone, and the fracture zone.

[0007] In elastic deformation, the deformation is temporary and can be recovered simply by removing the applied force. This is an inherent self-healing property of materials.

[0008] In plastic deformation, the deformation cannot be easily recovered by removing the applied force. Thermoplastic materials with high chain mobility exhibit a considerable range of plastic deformation. This invention utilizes temperature-induced chain mobility to achieve a viscoelastic state, thereby allowing for a higher degree of deformation.

[0009] In a "cooler" environment setting, internal heating elements are used to increase the temperature to achieve the desired deformation; conversely, in a "hotter" environment setting, internal heating elements are used to cause the thermoplastic material to move out of the viscoelastic state and achieve the desired high stiffness state.

[0010] There is a need to invent materials with an expandable range of plastic deformation.

[0011] The purpose of this invention: One object of the present invention is to provide on-demand formable materials.

[0012] Another object of the present invention is to provide materials that are reformable and reusable on demand.

[0013] Another object of the present invention is to provide a breathable, small-footprint and reformable composite material. Summary of the Invention

[0014] According to the present invention, a smart thermoplastic composite material is provided, comprising: - At least one thermoplastic component having a first cross-sectional profile; - At least one thermal component having a second cross-sectional profile and being in contact with the thermoplastic component; in, The cross-sectional arrangement allows the thermal component to alter the thermal properties of the thermoplastic component in its thermally activated or cold-activated state. By generating a controlled thermal gradient within a region of interest or volume in the thermoplastic component, a flexible deformable region is ensured to exist within the thermoplastic component. This controlled thermal gradient is achieved through the following means: Raising the local temperature of the thermoplastic component to above its softening point but below its viscosity temperature; and Maintain the ambient temperature above its softening point and maintain the local temperature below its softening point.

[0015] In at least one embodiment, the composite material is bonded to: - An energy source configured to enable energy transfer between the thermal component and the thermoplastic component; and - Configured to enable energy sinks to absorb energy between the thermal component and the thermoplastic component; - A control mechanism configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region or volume of interest in the thermoplastic component, thereby realizing a flexible deformable region within the thermoplastic component, by: The energy transfer is controlled in a first selected unidirectional manner, and the energy absorption is controlled in a second selected unidirectional manner, wherein the directions of the first selected unidirectional manner and the second selected unidirectional manner are never the same. The energy transfer is controlled between the viscosity point and the softening point of the thermoplastic component.

[0016] In at least one embodiment, the connection is selected from the group of connection types: thermal connection, physical connection, partial connection, complete coverage connection where the thermoplastic component completely covers the thermal component, complete coverage connection where the thermal component completely covers the thermoplastic component, partial coverage connection where the thermoplastic component partially covers the thermal component, and partial coverage connection where the thermal component partially covers the thermoplastic component.

[0017] In at least one embodiment, the thermoplastic material is activated in its thermally activated operating mode, wherein: energy control from the energy source to the energy sink is performed by a control mechanism, such that the temperature (Tt) of the thermoplastic material is higher than the viscosity temperature (Tv / Tm) of the thermoplastic material but lower than the softening temperature (Tg) of the thermoplastic material.

[0018] In at least one embodiment, the thermoplastic material is activated in its thermally activated working mode, wherein: energy control from energy source to energy sink is performed by a control mechanism, such that the temperature of the energy source (Tsource) is greater than or equal to the temperature of the thermal component (Tth), the temperature of the thermal component (14) (Tth) is greater than or equal to the temperature of the thermoplastic component (Ttp), and the temperature of the thermoplastic component (Ttp) is greater than or equal to the temperature of the energy sink (Tsink).

[0019] In at least one embodiment, the thermoplastic material is activated in its cold-activated operating mode, wherein: energy control from energy sink to energy source is performed by a control mechanism, such that the temperature (Tt) of the thermoplastic material is higher than the softening temperature (Tg) of the thermoplastic material but lower than the viscosity temperature (Tv / Tm) of the thermoplastic material.

[0020] In at least one embodiment, the thermoplastic material is activated in its cold-activated operating mode, wherein: energy control from energy sink to energy source is performed by a control mechanism such that the temperature of the energy source (Tsource) is less than or equal to the temperature of the thermal component (Tth), the temperature of the thermal component (Tth) is less than or equal to the temperature of the thermoplastic component (Ttp), and the temperature of the thermoplastic component (Ttp) is less than or equal to the temperature of the energy sink (Tsink).

[0021] In at least one embodiment, the thermal component is a non-thermoplastic component used as an internal heat source.

[0022] In at least one embodiment, the thermal component is a non-thermoplastic component composed of a polar compound or dielectric material, which serves as a heat source when irradiated by electromagnetic radiation of a corresponding frequency.

[0023] In at least one embodiment, the thermal component is a non-thermoplastic component that is in thermal contact with an external heat source and the thermoplastic component.

[0024] In at least one embodiment, for the thermal component used as an energy source, the control mechanism is configured to achieve a flexible deformable region within the thermoplastic component by: upon receiving the transferred energy, generating a controlled thermal gradient within a region or volume of interest in the thermoplastic component, through: Maintain the ratio of loss modulus to storage modulus (V) of the thermoplastic component. E () is greater than or equal to 1.

[0025] In at least one embodiment, for the heat component used as an energy sink, the control mechanism is configured to achieve a flexible deformable region within the thermoplastic component by generating a controlled thermal gradient within a region or volume of interest in the thermoplastic component after receiving the transferred energy, through: Maintain the ratio of loss modulus to storage modulus (V) of the thermoplastic component. E () Less than 1.

[0026] According to the present invention, a smart thermoplastic composite material system is provided, comprising: - At least one thermoplastic component; - At least one thermal component in contact with the thermoplastic component; - An energy source configured to enable energy transfer between the thermal component and the thermoplastic component; and - Configured to enable energy sinks to absorb energy between the thermal component and the thermoplastic component; - A control mechanism configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region or volume of interest in the thermoplastic component, thereby realizing a flexible deformable region within the thermoplastic component, by: The energy transfer is controlled in a first selected unidirectional manner, and the energy absorption is controlled in a second selected unidirectional manner, wherein the directions of the first selected unidirectional manner and the second selected unidirectional manner are never the same. The energy transfer is controlled between the viscosity point and the softening point of the thermoplastic component.

[0027] In at least one embodiment, the control mechanism is configured to, upon receiving the transmitted energy, generate a controlled thermal gradient within a region or volume of interest in the thermoplastic component, thereby realizing a flexible deformable region within the thermoplastic component, by: Raising the local temperature of the thermoplastic component to above its softening point but below its viscosity temperature; and Maintain the ambient temperature above its softening point and maintain the local temperature below its softening point.

[0028] In at least one embodiment, the connection is selected from the group of connection types: thermal connection, physical connection, partial connection, complete coverage connection where the thermoplastic component completely covers the thermal component, complete coverage connection where the thermal component completely covers the thermoplastic component, partial coverage connection where the thermoplastic component partially covers the thermal component, and partial coverage connection where the thermal component partially covers the thermoplastic component.

[0029] In at least one embodiment, the energy transfer and the energy absorption take the form of conduction, convection, and / or radiation.

[0030] In at least one embodiment, the control may be selected from the following control group: electrical control, pressure control, volume control, chemical control, electromagnetic irradiation control, mechanical force control, magnetic field control, flow rate control, acoustic heating control, and acoustic cooling control.

[0031] In at least one embodiment, the thermoplastic material is activated in its thermally activated operating mode, wherein: energy control from the energy source to the energy sink is performed by the control mechanism, such that the temperature (Tt) of the thermoplastic material is higher than the viscosity temperature (Tv / Tm) of the thermoplastic material but lower than the softening temperature (Tg) of the thermoplastic material.

[0032] In at least one embodiment, the thermoplastic material is activated in its thermally activated operating mode, wherein: energy control from the energy source to the energy sink is performed by the control mechanism, such that the temperature of the energy source (Tsource) is greater than or equal to the temperature of the thermal component (Tth), the temperature of the thermal component (Tth) is greater than or equal to the temperature of the thermoplastic component (Ttp), and the temperature of the thermoplastic component (Ttp) is greater than or equal to the temperature of the energy sink (Tsink).

[0033] In at least one embodiment, the thermoplastic material is activated in its cold-activated operating mode, wherein: energy control from the energy sink to the energy source is performed by the control mechanism, such that the temperature (Tt) of the thermoplastic material is higher than the softening temperature (Tg) of the thermoplastic material but lower than the viscosity temperature (Tv / Tm) of the thermoplastic material.

[0034] In at least one embodiment, the thermoplastic material is activated in its cold-activated operating mode, wherein: energy control from the energy sink to the energy source is performed by the control mechanism such that the temperature of the energy source (Tsource) is less than or equal to the temperature of the thermal component (Tth), the temperature of the thermal component (Tth) is less than or equal to the temperature of the thermoplastic component (Ttp), and the temperature of the thermoplastic component (Ttp) is less than or equal to the temperature of the energy sink (Tsink).

[0035] In at least one embodiment, the thermal component is a non-thermoplastic component used as an internal heat source.

[0036] In at least one embodiment, the thermal component is a non-thermoplastic component composed of a polar compound or dielectric material, which serves as a heat source when irradiated by electromagnetic radiation of a corresponding frequency.

[0037] In at least one embodiment, the thermal component is a non-thermoplastic component that is in thermal contact with an external heat source and the thermoplastic component.

[0038] In at least one embodiment, for the thermal component used as an energy source, the control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region or volume of interest in the thermoplastic component, thereby realizing a flexible deformable region within the thermoplastic component, by: Maintain the ratio of loss modulus to storage modulus (V) of the thermoplastic component. E () is greater than or equal to 1.

[0039] In at least one embodiment, for the thermal component used as an energy sink, the control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region or volume of interest in the thermoplastic component, thereby realizing a flexible deformable region within the thermoplastic component, by: Maintain the ratio of loss modulus to storage modulus (V) of the thermoplastic component. E () Less than 1. Attached Figure Description

[0040] Figure 1 A typical stress-strain diagram is shown, which indicates the various stages of deformation, including the elastic zone, the plastic zone, and the fracture zone.

[0041] The present invention will now be described in conjunction with the accompanying drawings, wherein: Figure 2 This is a schematic block diagram of the intelligent thermoplastic composite material of the present invention; Figure 3 This is an illustration of an embodiment of the present invention, in which a thermal component is embedded inside a thermoplastic material, and an external energy source provides energy to the core, thereby causing a temperature change in the thermoplastic material; Figure 4 This is a block diagram for realizing the "intelligence" of intelligent thermoplastic composites; Figure 5 This is a flowchart illustrating the "intelligence" of intelligent thermoplastic composite materials based on their various working modes; Figure 6a , Figure 6b , Figure 6c and Figure 6d Various configurations of the smart thermoplastic composite material of the present invention are illustrated in cross-sectional views. Detailed Implementation

[0042] According to the present invention, a smart thermoplastic composite material is provided.

[0043] Figure 2 This is a schematic block diagram of the intelligent thermoplastic composite material of the present invention.

[0044] Figure 6a , Figure 6b , Figure 6c and Figure 6d Various configurations of the smart thermoplastic composite material of the present invention are illustrated in cross-sectional views.

[0045] In at least one embodiment, the present invention relates to a composite material or composite material comprising at least one thermoplastic component (12) and at least one thermal component (14) coupled to said thermoplastic component (12). Furthermore, the present invention relates to a composite material or composite material, particularly a smart composite material, comprising at least one energy source (16) and at least one energy sink (18).

[0046] The thermoplastic component (12) and the thermal component (14) are positioned relative to each other such that thermal energy can be transferred from one to the other in a bidirectional manner, but not simultaneously in both directions. The transfer can take the form of conduction, convection and / or radiation.

[0047] The interface between the thermoplastic component (12) and the thermal component (14) can be shown in the attached figure. Figure 5 One of the several configurations shown.

[0048] In at least one embodiment, as shown in the accompanying drawings Figure 6a As shown, the thermal component (14) completely covers the interior of the thermoplastic component (12).

[0049] In at least one embodiment, as shown in the accompanying drawings Figure 6b As shown, the thermal component (14) partially covers the interior of the thermoplastic component (12).

[0050] In at least one embodiment, as shown in the accompanying drawings Figure 6c As shown, the thermoplastic component (12) partially covers the interior of the thermal component (14).

[0051] In at least one embodiment, as shown in the accompanying drawings Figure 6d As shown, the thermoplastic component (12) completely covers the interior of the thermal component (14).

[0052] For the purposes of this invention, the viscosity point of a given thermoplastic material is defined as a temperature at which the loss modulus of the thermoplastic material allows the thermal element to displace due to the thermally induced viscosity of the thermoplastic material. The softening point of a given thermoplastic material is defined as the temperature at which the loss modulus equals the storage modulus, thus making it flexible. The ratio of loss modulus to storage modulus is defined as V. E .

[0053] In at least one embodiment, the thermal component (14) is a non-thermoplastic component, serving as an internal heat source operating based on ohmic heating (using resistance wire) or thermoelectric heating (using thermocouples). The current supplied to the thermal component (14) generates heat through eddy currents generated by electromagnetic induction or through current directly supplied to the conductor via conduction. This configuration favors "electric heating".

[0054] In at least one embodiment, the thermal component (14) is a non-thermoplastic component, which may be composed of a polar compound or a dielectric material, and serves as a heat source when irradiated by electromagnetic radiation of a corresponding frequency. One embodiment of this configuration may be a channel in the thermoplastic material volume filled with the thermal component (14). Another embodiment may be that the thermal component (14) is dispersed throughout the thermoplastic material volume as a suspended additive. This configuration is advantageous for "heating by electromagnetic radiation and / or induction (near field)".

[0055] In at least one embodiment, the thermal component (14) is a non-thermoplastic component that is in thermal contact with an external heat source and a thermoplastic material. In this configuration, the thermal component (14) acts as a conductor between heat sources by transferring heat from the “hotter” external heat source to the thermoplastic material in a “cooler” environment. Conversely, in a “hotter” environment, the thermal element can act as a conductor between heat sinks to increase the local stiffness of the thermoplastic component. This configuration facilitates “contact heat transfer.”

[0056] In at least one embodiment, the source (16) transfers energy to the thermal component.

[0057] In some embodiments, shape memory materials can be used as the thermal component (14), which can apply force to the thermoplastic component at a specific temperature and can even be trained at other temperatures. The properties and characteristics of such materials need to be considered: - Martensitic phase transformation temperature; - Austenite phase transformation temperature; - Degree of deformation; - Programmable temperature (shape memory polymer); - Restore temperature.

[0058] In addition, non-contact forces can also act on composite materials. These non-contact forces include: - Gravity: Gravity can be used to act on the volume of interest in the embodiments of the present invention; - Magnetic field: acting on the volume of interest in the embodiments of this invention; - Electrostatic force: acts on the volume of interest in the embodiments of the present invention.

[0059] In some embodiments, a combination of externally applied contact forces can be used to deform or maintain the shape of the composite material of the present invention.

[0060] In some embodiments, a combination of contact forces and non-contact forces can be used to deform or maintain the shape of the composite material of the present invention.

[0061] Figure 3 This is an illustration of an embodiment of the present invention, wherein the thermal component (14) is embedded inside the thermoplastic material, and an external energy source provides energy to the core, thereby causing the temperature of the thermoplastic material to change.

[0062] Figure 4 This shows the stiffness relationship of thermoplastic materials at different temperatures.

[0063] In its activated state, the thermal component (14) either acts as a thermodynamic / energy sink (absorbing heat / energy) (18) or a thermodynamic / energy source (emitting heat / energy) (16), while its surrounding environment (20) / entity is relatively opposite in direction or flow. The thermoplastic component (12) acts as a conductor / transmitter between them, facilitating the transfer / transmission of heat between them when there is a temperature difference between the thermal component (14) and the environment (20).

[0064] The activated state of the intelligent composite material of the present invention is characterized by the application of an external energy vector to the thermal component (14), thereby generating a controlled thermal gradient within the region of interest or volume of the thermoplastic component (12). This gradient leads to a local temperature change, thereby allowing a desired local change in the viscoelasticity of the thermoplastic material. The activated state of the composite material is defined as the state when an external energy vector applied to the thermal component (14) generates a controlled thermal gradient within the region of interest / volume of the thermoplastic component (12). This can be implemented in two ways: 1. The local temperature rises above the softening point of the thermoplastic material (12) but below its viscosity temperature.

[0065] 2. The ambient temperature is above the softening point, while the thermal component (14) lowers the local temperature below the softening point.

[0066] When energy is transferred from the source (16) to the non-thermoplastic component (14), the temperature of the non-thermoplastic component (14) rises above the threshold temperature. It then transfers heat to the thermoplastic component (12), enabling the thermoplastic component (12) to undergo controlled deformation under applied force or stress, forming the desired geometry.

[0067] Subsequently, when the energy supply to the thermal component (14) is interrupted, the embodiment of the composite material is cooled by active or passive means to maintain its geometry.

[0068] Conversely, the heat component (14) can be used to transfer heat from the thermoplastic material (12) using a heat sink (18) or a cooler to increase the stiffness of this embodiment. This composite material, together with the combined heat transfer method, enables controlled deformation for a variety of applications.

[0069] In at least one embodiment, the thermal component (14) is a non-thermoplastic component, serving as an energy source (16). Heat transfer from the thermal component (14) (the non-thermoplastic component) to the thermoplastic component (12) is facilitated by conduction and / or convection and / or radiation. The heat flux at the contact point or transfer point prevents the thermoplastic material from flowing. The net heat flow through the thermoplastic material ensures that the temperature of the surface furthest from the thermal component (14) is sufficient to reduce V... E Change to ≥1. Here, in its active state: - The thermal component (14) within the volume of the thermoplastic material (12): the temperature distribution diffuses from the thermal component (14) unit into the volume of interest of the thermoplastic material (12); - The thermal component (14) is outside the volume of the thermoplastic material (12), and the two are in contact; - The thermal component (14) and the thermoplastic material (12) have surface contact.

[0070] In at least one embodiment, the thermal component (14) is a non-thermoplastic component, serving as an energy sink (18). Heat transfer to the thermal component (non-thermoplastic component) (14) is facilitated from the thermoplastic component (12) via conduction and / or convection and / or radiation. The heat flux at the contact point or transfer point causes the thermoplastic material to remain rigid due to cooling by the thermal component (14). Here, in its activated state: - The thermal component (14) within the volume of the thermoplastic material (12): the temperature distribution converges to the thermal component (14) unit entering the volume of interest of the thermoplastic material (12); - The thermal component (14) is outside the volume of the thermoplastic material (12), and the two are in contact; - The thermal component (14) and the thermoplastic material (12) have surface contact.

[0071] There may be one or more methods for changing the temperature of the thermal component (14), which may be selected from: - Electrical power: The current and voltage applied to the non-thermoplastic component are controlled by resistance heating elements, thermoelectric equipment or other electric heating / cooling mechanisms (such as Peltier cooling).

[0072] - Pressure: Control system pressure to change the temperature of non-thermoplastic components through processes such as compression or expansion.

[0073] - Volume: While maintaining constant pressure, control the volume in the system to change the temperature of the non-thermoplastic component.

[0074] - Chemical reaction: In thermochemical thermal components, the rate and extent of chemical reactions in the thermal components are controlled to release or absorb heat.

[0075] - Electromagnetic irradiation: Controlling radiation exposure, intensity, and illuminance relative to thermal components.

[0076] - Mechanical force: Controlling mechanical work, which can be converted into heat energy through friction or other processes.

[0077] - Magnetic field: In magnetic refrigeration or induction heating systems, the magnetic field is controlled to regulate the temperature of the thermal components.

[0078] - Flow rate: Controlling the flow rate of the heat transfer fluid to change the heat exchange with the non-thermoplastic component.

[0079] - Acoustic heating / cooling: Controlling the amplitude and frequency of the thermoacoustic heat pump acting on the thermal components.

[0080] Figure 4 This is a block diagram for realizing the "intelligence" of intelligent thermoplastic composites.

[0081] like Figure 4 As shown, Tm = Melting temperature of thermoplastic material (12); Ts = Viscosity temperature of thermoplastic material (14); Tg = softening temperature; Tsource = Temperature of the source; Tsink = temperature of the sink; Tt = Temperature of thermoplastic component (12); Tc = Temperature of thermal component (14).

[0082] Figure 5 This is a flowchart illustrating the "intelligence" of intelligent thermoplastic composites based on their various working modes.

[0083] In order to use these smart composite materials efficiently, the following operating rules shall be followed according to the present invention.

[0084] In its thermally activated operating mode, the energy flow direction is from the source to the sink, such that: Tm <Tt<Tg; Tsource>= Tc>= Tt>= Tsink.

[0085] In its cold-activated operating mode, the energy flow direction is from the sink to the source, such that: Tm>Tt>Tg; Tsource <= Tc <= Tt <= Tsink.

[0086] The attached figure shows T1 as the crystallization temperature (the temperature at which maximum stiffness is achieved). The attached diagram shows T2 as the softening temperature. In the attached figure, T3 = glass transition temperature; The attached diagram shows T4 as the viscosity point / temperature. The attached figure shows T5 as the melting temperature (the temperature at which minimum stiffness / fluidity is achieved).

[0087] The region between T2 and T4 is the flexible region. Within this region, the intelligent composite material of the present invention can undergo high deformation with minimal force under the action of gravity and other forces.

[0088] To achieve this balance, consider the following parameters: A CT The contact area between the heating element and the thermoplastic material.

[0089] A CA The surface area of ​​a thermal element exposed to air.

[0090] A S The surface area of ​​a thermoplastic material exposed to its surrounding environment.

[0091] A C Cross-sectional area of ​​the thermal element.

[0092] A T The cross-sectional area of ​​a thermoplastic material in the heat flow region.

[0093] Thermoplastic material - contact area with heating element, ratio of thermoplastic material and heating element area exposed to the surrounding environment:

[0094] The temperature of thermoplastic materials must reach t T , so that: For "colder" surrounding environments, V E ≥ 1.0; For “hotter” surrounding environments, V E <1.

[0095] Regarding the operation of the intelligent composite material of the present invention, the material exhibits an embodiment of self-deformation, wherein the deformation force is inherently applied from within the composite material: Local density changes were observed: Thermal expansion: When thermoplastic materials are heated, they typically undergo thermal expansion, resulting in an increase in volume. Conversely, cooling tends to lead to thermal contraction and a decrease in volume. Localized swelling: Depending on the thermoplastic material, heating can cause localized swelling as the polymer chains separate and create void spaces. Conversely, cooling can lead to densification as the chains contract and move closer together.

[0096] Changes related to the polymer chain were observed: Crystallization: In some semi-crystalline thermoplastics, cooling can promote crystallization, leading to an increase in local density as the polymer becomes more ordered. Chain mobility: Local heating above the softening temperature increases chain mobility. The chain can move more freely and adopt a more disordered configuration; Chain entanglement: Cooling can lead to an increase in chain entanglement as polymer chains lose their mobility and become more ordered.

[0097] The composite material embodiments of the present invention may have thermal components, thermoplastic materials, conductors, thermal conductive paste, etc. in different physical states or combinations thereof.

[0098] Although this composite material specification describes various heat transfer methods from / through the thermal component, it will be apparent to those skilled in the art that the thermal component (14) can utilize any known heat transfer mechanism and combination thereof to achieve a controlled thermal gradient in the thermoplastic material, such that V in cold environments E ≥ 1.0, conversely, cooling thermoplastic materials in a thermal environment; thereby allowing the thermoplastic components to exhibit controlled deformation under applied force or stress, becoming the desired geometry.

[0099] Technical advantages: On-demand reformable materials solutions are limited; Thermoplastic castings, helmets, supports, splints, and braces, due to their high rigidity, provide greater rigidity than plaster-based supports, resulting in a relatively small volume footprint and lighter weight. Thermoplastic materials are unaffected by everyday liquids such as alcohol, oil, water, detergents, soap, milk, and carbonated water; therefore, patients can safely handle everyday liquid splashes and perform daily hygiene safely and comfortably. Using thermoplastic materials in the form of mesh / grid reduces material usage, thereby lowering costs and making them economically competitive with commonly used gypsum and glass fiber composites. The configuration of this invention results in a lower skin surface coverage than the relevant area to which it is applied, thus being very comfortable for the patient's skin—it exposes the skin to the air, greatly reducing the risk of skin complications and irritation; The smooth and inert inner layer eliminates the need for filler packaging; An internal heat source is implemented within the volume of a thermoplastic mesh or (thermoplastic mesh region), controlled by an external vector, to raise the temperature of the mesh / partial mesh to a range between the material's softening and viscosity points within an optimal timeframe. Once the desired temperature is reached, these areas with the heat source are essentially deformable. The thermal softening properties of this material collectively allow these specific regions to become flexible at the discretion of the person controlling the external vector, so that they can be wrapped, applied, and shaped as needed for orthopedic treatment. The mesh can be pre-formed and modified by medical personnel according to individual needs before being used as an orthosis; The internal heat source makes the device removable and even reusable; The thermal softening mechanism eliminates the need for rough tools during orthodontic application and removal; The adjustability and versatility of the deformable mesh area reduce the risk of pressure soft tissue injuries, pressure ulcers, etc. Easy to apply—pre-assembled and rapid polymer cooling reduces the long and complex applications common in all wrap-around bandages / fiber-based traditional orthopedic casting solutions and custom-fit orthotics such as corrective helmets.

[0100] Non-limiting exemplary use cases: Solution to skin problems: Completely covering the affected area with thick, hard materials (such as plasterboard, fiberglass, polymer helmets) can cause skin irritation and conditions such as dermatitis, bedsores, and ulcers. This invention solves these problems.

[0101] A solution to time-consuming application and molding processes: Plaster and fiberglass orthoses require significant effort and time. The application, molding, and complete curing of traditional fiberglass and plaster-based orthoses can take tens of minutes. Fabricating thermoplastic prosthetic attachments and orthotic calipers is also extremely labor-intensive. Devices such as deformity correction helmets require several days to custom-make for each patient. This invention solves these problems.

[0102] A solution to the problems of high volume and floor space requirements: Drywall panels have a large volume and weight, which makes daily life more difficult for patients who are already experiencing discomfort. This invention solves these problems.

[0103] Solution to Fragility: Plaster-based fracture molds are fragile and cannot maintain their integrity when in direct contact with everyday liquids such as alcohol, oil, water, detergents, soap, milk, and carbonated beverages. Fiberglass molds are also only partially resistant to water and other everyday liquids. This invention solves these problems.

[0104] High-cost solutions: Fiberglass plaster molds, offering a degree of water resistance and higher strength, are significantly more expensive than traditional plaster molds, making them unaffordable for many. There are also the costs of disposable equipment and repetitive use of equipment that cannot adapt to growth. This invention solves these problems.

[0105] Although this invention was developed for external orthopedic fixation, it can be readily applied to a variety of other applications, such as custom chairs, shoes, deformable wings in aircraft, etc. Constructive combinations of thermoplastic materials with a second material as a corresponding heat source to achieve on-demand thermal softening of the thermoplastic material can be readily used in various forms. This invention solves these problems.

[0106] The technological advancement of this invention lies in providing a smart composite material that intelligently provides a combined composite material comprising a thermoplastic component, a thermal component, a heat source, and a heat sink, thereby achieving intravolume heating / cooling for producing a desired geometry.

[0107] While certain specific embodiments have been disclosed in this detailed description for illustrative purposes, it will be apparent to those skilled in the art that various modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims, and it should be clearly understood that the foregoing description is for illustrative purposes only and not for limitation.

Claims

1. A smart thermoplastic composite material, comprising: At least one thermoplastic component (12) having a first cross-sectional profile; At least one thermal component (14) having a second cross-sectional profile and being in contact with the thermoplastic component (12); Its features are, The cross-sectional arrangement allows the thermal component (14) to change the thermal properties of the thermoplastic component in its thermally activated or cold-activated state, thereby generating a controlled thermal gradient within the region of interest or volume of the thermoplastic component (12) to ensure the existence of a flexible deformable region within the thermoplastic component (12): The local temperature of the thermoplastic component (12) is raised to above its softening point but below its viscosity temperature; and Maintain the ambient temperature above its softening point and maintain the local temperature below its softening point.

2. The smart thermoplastic composite material as described in claim 1, wherein, The composite material is bonded to the following: An energy source (16) configured to enable energy transfer between the thermal component (14) and the thermoplastic component (12); and An energy sink (18) is configured to enable energy absorption between the thermal component (14) and the thermoplastic component (12). The control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region of interest or volume of the thermoplastic component (12) in such a way as to achieve a flexible deformable region within the thermoplastic component (12): The energy transfer is controlled in a first selected unidirectional manner, and the energy absorption is controlled in a second selected unidirectional manner, wherein the directions of the first selected unidirectional manner and the second selected unidirectional manner are never the same. The energy transfer is controlled between the viscosity point and the softening point of the thermoplastic component (12).

3. The intelligent thermoplastic composite material as described in claim 1, wherein, The connection is selected from the following connection type group: thermal connection, physical connection, partial connection, complete coverage connection where the thermoplastic component (12) completely covers the thermal component (14), complete coverage connection where the thermal component (14) completely covers the thermoplastic component (12), partial coverage connection where the thermoplastic component (12) partially covers the thermal component (14), and partial coverage connection where the thermal component (14) partially covers the thermoplastic component (12).

4. The intelligent thermoplastic composite material as described in claim 1, wherein, The thermoplastic material is activated in its thermally activated working mode, wherein the energy from the energy source (16) to the energy sink (18) is controlled by the control mechanism, so that the temperature (Tt) of the thermoplastic material is higher than the viscosity temperature (Tv / Tm) of the thermoplastic material but lower than the softening temperature (Tg) of the thermoplastic material.

5. The smart thermoplastic composite material as described in claim 1, wherein, The thermoplastic material is activated in its thermally activated working mode, wherein energy is controlled from the energy source (16) to the energy sink (18) by a control mechanism, such that the temperature (Tsource) of the energy source (16) is greater than or equal to the temperature (Tth) of the thermal component (14), the temperature (Tth) of the thermal component (14) is greater than or equal to the temperature (Ttp) of the thermoplastic component (12), and the temperature (Ttp) of the thermoplastic component (12) is greater than or equal to the temperature (Tsink) of the energy sink (18).

6. The smart thermoplastic composite material as described in claim 1, wherein, The thermoplastic material is activated in its cold-activated working mode, wherein the energy from the energy sink (18) to the energy source (16) is controlled by the control mechanism, so that the temperature (Tt) of the thermoplastic material is higher than the softening temperature (Tg) of the thermoplastic material but lower than the viscosity temperature (Tv / Tm) of the thermoplastic material.

7. The smart thermoplastic composite material as described in claim 1, wherein, The thermoplastic material is activated in its cold-activated working mode, wherein energy control is performed from the energy sink (18) to the energy source (16) by a control mechanism, such that the temperature (Tsource) of the energy source (16) is less than or equal to the temperature (Tth) of the thermal component (14), the temperature (Tth) of the thermal component (14) is less than or equal to the temperature (Ttp) of the thermoplastic component (12), and the temperature (Ttp) of the thermoplastic component (12) is less than or equal to the temperature (Tsink) of the energy sink (18).

8. The smart thermoplastic composite material as described in claim 1, wherein, The thermal component (14) is a non-thermoplastic component and is used as an internal heat source.

9. The smart thermoplastic composite material as described in claim 1, wherein, The thermal component (14) is a non-thermoplastic component composed of polar compounds or dielectric materials, which serves as a heat source when irradiated by electromagnetic radiation of a corresponding frequency.

10. The smart thermoplastic composite material as described in claim 1, wherein, The thermal component (14) is a non-thermoplastic component that is in thermal contact with an external heat source and the thermoplastic component (12).

11. The smart thermoplastic composite material as described in claim 2, wherein, For the thermal component (14) used as an energy source (16), the control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region of interest or volume in the thermoplastic component (12) in such a way as to achieve a flexible deformable region within the thermoplastic component (12): Maintain the ratio (Vloss modulus to storage modulus) of the thermoplastic component (12). E () is greater than or equal to 1.

12. The smart thermoplastic composite material as described in claim 2, wherein, For the thermal component (14) used as an energy sink (18), the control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region of interest or volume in the thermoplastic component (12) in such a way as to achieve a flexible deformable region within the thermoplastic component (12): Maintain the ratio (Vloss modulus to storage modulus) of the thermoplastic component (12). E () Less than 1.

13. A smart thermoplastic composite material system, comprising: At least one thermoplastic component (12); At least one thermal component (14) is in contact with the thermoplastic component (12); An energy source (16) configured to enable energy transfer between the thermal component (14) and the thermoplastic component (12); and An energy sink (18) is configured to enable energy absorption between the thermal component (14) and the thermoplastic component (12). The control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region of interest or volume of the thermoplastic component (12) in such a way as to achieve a flexible deformable region within the thermoplastic component (12): The energy transfer is controlled in a first selected unidirectional manner, and the energy absorption is controlled in a second selected unidirectional manner, wherein the directions of the first selected unidirectional manner and the second selected unidirectional manner are never the same. The energy transfer is controlled between the viscosity point and the softening point of the thermoplastic component (12).

14. The intelligent thermoplastic composite material system of claim 13, wherein, The control mechanism is configured to, upon receiving the transmitted energy, generate a controlled thermal gradient within a region of interest or volume of the thermoplastic component (12) in such a manner as to achieve a flexible deformable region within the thermoplastic component (12): The local temperature of the thermoplastic component (12) is raised to above its softening point but below its viscosity temperature; and Maintain the ambient temperature above its softening point and maintain the local temperature below its softening point.

15. The intelligent thermoplastic composite material system as described in claim 13, wherein, The connection is selected from the following connection type group: thermal connection, physical connection, partial connection, complete coverage connection where the thermoplastic component (12) completely covers the thermal component (14), complete coverage connection where the thermal component (14) completely covers the thermoplastic component (12), partial coverage connection where the thermoplastic component (12) partially covers the thermal component (14), and partial coverage connection where the thermal component (14) partially covers the thermoplastic component (12).

16. The intelligent thermoplastic composite material system of claim 13, wherein, The energy is transferred and absorbed in the form of conduction, convection and / or radiation.

17. The intelligent thermoplastic composite material system of claim 13, wherein, The control can be selected from the following control groups: electrical control, pressure control, volume control, chemical control, electromagnetic irradiation control, mechanical force control, magnetic field control, flow rate control, acoustic heating control, and acoustic cooling control.

18. The intelligent thermoplastic composite material system of claim 13, wherein, The thermoplastic material is activated in its thermally activated working mode, wherein the energy from the energy source (16) to the energy sink (18) is controlled by the control mechanism, so that the temperature (Tt) of the thermoplastic material is higher than the viscosity temperature (Tv / Tm) of the thermoplastic material but lower than the softening temperature (Tg) of the thermoplastic material.

19. The intelligent thermoplastic composite material system of claim 13, wherein, The thermoplastic material is activated in its thermally activated working mode, wherein the energy from the energy source (16) to the energy sink (18) is controlled by the control mechanism, such that the temperature (Tsource) of the energy source (16) is greater than or equal to the temperature (Tth) of the thermal component (14), the temperature (Tth) of the thermal component (14) is greater than or equal to the temperature (Ttp) of the thermoplastic component (12), and the temperature (Ttp) of the thermoplastic component (12) is greater than or equal to the temperature (Tsink) of the energy sink (18).

20. The intelligent thermoplastic composite material system of claim 13, wherein, The thermoplastic material is activated in its cold-activated working mode, wherein the energy from the energy sink (18) to the energy source (16) is controlled by the control mechanism, so that the temperature (Tt) of the thermoplastic material is higher than the softening temperature (Tg) of the thermoplastic material but lower than the viscosity temperature (Tv / Tm) of the thermoplastic material.

21. The intelligent thermoplastic composite material system of claim 13, wherein, The thermoplastic material is activated in its cold-activated working mode, wherein the energy from the energy sink (18) to the energy source (16) is controlled by the control mechanism, such that the temperature (Tsource) of the energy source (16) is less than or equal to the temperature (Tth) of the thermal component (14), the temperature (Tth) of the thermal component (14) is less than or equal to the temperature (Ttp) of the thermoplastic component (12), and the temperature (Ttp) of the thermoplastic component (12) is less than or equal to the temperature (Tsink) of the energy sink (18).

22. The intelligent thermoplastic composite material system as described in claim 13, wherein, The thermal component (14) is a non-thermoplastic component and is used as an internal heat source.

23. The intelligent thermoplastic composite material system of claim 13, wherein, The thermal component (14) is a non-thermoplastic component composed of polar compounds or dielectric materials, which serves as a heat source when irradiated by electromagnetic radiation of a corresponding frequency.

24. The intelligent thermoplastic composite material system as described in claim 13, wherein, The thermal component (14) is a non-thermoplastic component that is in thermal contact with an external heat source and the thermoplastic component (12).

25. The intelligent thermoplastic composite material system as described in claim 13, wherein, For the thermal component (14) used as an energy source (16), the control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region of interest or volume in the thermoplastic component (12) in such a way as to achieve a flexible deformable region within the thermoplastic component (12): Maintain the ratio (Vloss modulus to storage modulus) of the thermoplastic component (12). E () is greater than or equal to 1.

26. The intelligent thermoplastic composite material system of claim 13, wherein, For the thermal component (14) used as an energy sink (18), the control mechanism is configured to, upon receiving the transferred energy, generate a controlled thermal gradient within a region of interest or volume in the thermoplastic component (12) in such a way as to achieve a flexible deformable region within the thermoplastic component (12): Maintain the ratio (Vloss modulus to storage modulus) of the thermoplastic component (12). E () Less than 1.

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