Coated substrate and method for forming coated substrate
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Solution Overview
Problem
Current prosthetic heart valves face durability issues due to thrombosis, calcification, and mechanical stiffness, and existing textile-based solutions lack a directional mechanical profile that mimics native heart valve functions, while thermoplastic polyurethanes are challenging to integrate with solvent-based coatings.
Innovation Solution
A coated substrate with a solvent-sensitive substrate and a polyester coating comprising a polyester copolymer of a polyol and a polyacid, applied using a spray nozzle to form a conformal coating that maintains or reduces porosity and enhances mechanical properties, including anisotropic textiles with varying elastic moduli for improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermoplastic polyurethanes are used as substrate for prosthetic heart valves, then flexibility and elastic properties are improved, but compatibility with solvent-based coatings deteriorates because thermoplastic polyurethanes are soluble in many solvents
Solution Approach 1:
The patent introduces a solvent barrier layer as an intermediary between the thermoplastic polyurethane substrate and the solvent-based coating. This barrier layer prevents solvent penetration and dissolution of the substrate while allowing the coating to be applied effectively, thus resolving the incompatibility issue.
Solution Approach 2:
The patent creates a composite structure combining thermoplastic polyurethane fibers with a solvent barrier coating. This composite material maintains the flexibility and elasticity of the polyurethane while adding solvent resistance through the barrier layer, enabling subsequent solvent-based coating processes.
2Duration of action of stationary object
If chemical treatment processes are applied to bioprosthetic heart valves, then shelf life and stability are improved, but mechanical properties deteriorate due to crosslinking making materials stiffer and more immunogenic
Solution Approach 1:
The patent extracts and removes the harmful crosslinking step from the traditional chemical treatment process. Instead of using crosslinking agents like glutaraldehyde or formaldehyde, the invention employs alternative treatments that preserve mechanical properties while still achieving the desired shelf life and stability.
Solution Approach 2:
The patent changes the chemical treatment parameters by using milder, non-crosslinking chemical processes. This allows the biopolymer tissue to be treated for stability and shelf life extension without undergoing crosslinking that would stiffen the material and compromise mechanical properties.
3Strength
If textile-based materials are used to improve tear strength and flexure properties, then mechanical durability is improved, but ability to achieve directional mechanical profile deteriorates because current textiles are typically isotropic
Solution Approach 1:
The patent introduces asymmetry into the textile structure by aligning fibers in specific directions to create anisotropic mechanical properties. This allows the textile to exhibit different mechanical characteristics in different directions, mimicking the directional profile of native heart valve tissue while maintaining high tear strength.
Solution Approach 2:
The patent applies local quality by varying fiber orientation, density, and composition in different regions of the textile. This creates zones with specific mechanical properties tailored to local functional requirements, enabling a directional mechanical profile that matches native valve tissue while maintaining overall durability.
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
The solution decreases production costs, extends service life, and provides practical customizability by creating a durable, anisotropic textile-based prosthetic heart valve with enhanced mechanical properties and reduced porosity, addressing the limitations of existing technologies.
Implementation Method 1
spraying solvated polyester material from a spray nozzle onto a solvent-sensitive substrate
Implementation Method 2
drying the solvated polyester material to form a polyester coating disposed on the solvent-sensitive substrate
Data Source
AI summary
A coated substrate is disclosed, including a solvent-sensitive substrate and a polyester coating disposed on the solvent-sensitive substrate, wherein the polyester coating includes a polyester copolymer of a polyol and a polyacid. A method for forming a coated substrate is disclosed including spraying solvated polyester material from a spray nozzle onto a solvent-sensitive substrate and drying the solvated polyester material to form a polyester disposed on the solvent-sensitive substrate, wherein the solvated polyester material and the polyester coating include a polyester copolymer of a polyol and a polyacid.