Monopolymer Cast Polyurethane Matrix for Multi-Layer Device Simplification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of complex stratified active-dispensing devices with multiple polymer layers is technically challenging due to compatibility issues and the need for multiple technological operations, which complicates the production process and can lead to energy consumption and environmental concerns, as well as potential deterioration of thermolabile active ingredients.
Innovation Solution
A multifunctional cast polyurethane matrix is created using a sequential casting process, where different phase solutions of isocyanate and polyol complexes are poured into a mold in a specific order to achieve copolymerization, allowing for a single matrix to function as support, reservoir, and adhesive, reducing the complexity of production and eliminating the need for multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple polymer layers are used to achieve different functions (support, reservoir, adhesive), then functional versatility is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple functional layers (support layer, reservoir layer, and adhesive layer) into a single monolithic polymer matrix. Different regions within this single matrix are formulated with different polymer compositions and properties to provide support functions, active ingredient reservoir capabilities, and adhesive properties, thereby eliminating the need for multiple separate layers while maintaining all required functions.
Solution Approach 2:
The single polymer matrix is designed to perform multiple functions simultaneously. By incorporating different polymer formulations and phases within the same matrix structure, it provides mechanical support, stores and releases active ingredients, and provides adhesive bonding to the skin, making one component serve multiple purposes that traditionally required separate layers.
2Adaptability or versatility
If multiple separate layers are used, then functional specialization is improved, but manufacturing operations and technological constraints increase
Solution Approach 1:
The manufacturing process combines what would traditionally be three separate layer fabrication processes into a single casting operation. Different polymer formulations are mixed with active ingredients and cast simultaneously or sequentially in a single mold to form the integrated matrix, eliminating the need for separate extrusion, lamination, or assembly operations for each functional layer.
3Manufacturing precision
If hot extrusion or melting processes are used for substrate preparation, then film formation is improved, but energy consumption increases and thermolabile active ingredients may deteriorate
Solution Approach 1:
The patent changes the processing temperature parameter from high-temperature hot extrusion or melting processes to room temperature or low-temperature casting. The polymer formulations are designed to be castable in liquid or semi-liquid state at low temperatures and then cured or solidified through chemical reaction (polymerization) rather than thermal processing, thereby avoiding energy-intensive heating while preserving thermolabile active ingredients.
4Ease of manufacture
If hot treatment is applied to polyurethane reservoir, then polymer processing is improved, but thermolabile active ingredients deteriorate
Solution Approach 1:
The patent replaces thermal processing (heat-based polymer processing) with chemical processing. The polyurethane reservoir is formed through chemical polymerization reactions that proceed at low temperatures, substituting the mechanical/thermal energy input with chemical reaction energy, thereby enabling polymer processing without subjecting thermolabile active ingredients to damaging high temperatures.
5Ease of operation
If adhesive layer is made by adding silicone or copolymer, then adhesive properties are improved, but dosage precision requirements increase
Solution Approach 1:
The adhesive functionality is merged into the polymer matrix formulation itself rather than being applied as a separate adhesive layer. The adhesive polymers or adhesion-promoting agents are incorporated during the matrix casting process, allowing the adhesive properties to be built-in to the structure and eliminating the need for separate adhesive application steps with stringent dosage control requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the production process, allows for controlled release of active ingredients, and preserves the quality of thermolabile substances by avoiding high-temperature treatments, while enabling a wide range of active ingredients to be used, including both lipophilic and hydrophilic substances.
Implementation Method 1
copolymerization at the interface of which ensures the structural uniqueness of said matrix
Implementation Method 2
allows for controlled release of active ingredients
Data Source
AI summary
The invention relates to a monopolymer multifunctional sequenced cast polyurethane matrix produced simply and efficiently, by sequentially pouring various isocyanate/polyol complex phase solutions successively into a mould with alternating solidification of said phase solutions according to a defined order and respecting the polymerisation stage (after the pot life and before the demoulding time) of the sequence preceding the one being cast, so as to end with the casting of the last phase solution that will go up to the demoulding time thereof and thereby finish the polymerisation of the whole of the matrix. It is loaded, in its "reservoir" sequences, with naturally originating or synthesised transdermally penetrating or volatile active substances. They are medicating and therapeutic, cosmetic, phytosanitary or wellness substances, repellents, attractants, pheromones, biocides, perfumes or deodorants. At least two active substances can be loaded into the same matrix in order to act unidirectionally or in opposite directions. Said matrix is used to form different devices that adhere to the skin or any other surface, in order to deliver at least one substance in a controlled manner. Said devices are patches, patches with a plurality of active substances, replaceable plasters stuck to a textile support, active heel pads and ball pads for shoes, pheromone cards for controlling insects, self-adhesive insecticide attractant cards, or other devices equivalent in terms of structure and function.