Coextruded Composite Shape Memory Materials
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Solution Overview
Problem
Current shape memory polymers (SMPs) require complex, solvent-heavy synthesis processes, involving costly and toxic organic solvents, and are often not commercially available on a large scale, limiting their production and application due to the need for specialized copolymers and extensive processing.
Innovation Solution
A multilayered composite shape memory material is developed using coextruded polymer layers with different melt and glass transition temperatures, allowing for temperature-induced shape transitions from temporary to permanent shapes without the need for solvents, utilizing commercially available polymers and a solventless process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent-heavy synthesis processes are used to produce shape memory polymers, then the polymers can achieve desired shape memory behavior, but production costs increase and environmental harm increases due to costly and toxic organic solvents
Solution Approach 1:
The patent removes the harmful solvent component from the synthesis process entirely. By using a solventless polymerization method where monomers polymerize directly without requiring organic solvents, the harmful factor is extracted and eliminated from the system while maintaining the desired shape memory behavior through controlled monomer selection and reaction conditions.
Solution Approach 2:
The patent changes the fundamental parameter of the synthesis process from solvent-based to solventless. This parameter change transforms the chemical reaction environment, eliminating toxic organic solvents while achieving the same polymerization outcome through alternative reaction mechanisms and conditions that do not require solvent mediation.
2Reliability
If complex synthesis processes are used to produce shape memory polymers, then the polymers can achieve desired properties, but manufacturing complexity and time increase
Solution Approach 1:
The patent segments the synthesis process into simple, sequential steps: selecting compatible monomers with appropriate functional groups, mixing them in desired ratios, and allowing spontaneous polymerization. This segmentation breaks down the complex process into manageable, simple stages that eliminate the need for sophisticated equipment and procedures while maintaining product quality.
Solution Approach 2:
The patent employs self-service polymerization where the monomers themselves provide the necessary reaction components and conditions. The functional groups on the monomers automatically catalyze and drive the polymerization process without requiring external catalysts, solvents, or complex processing equipment, thereby simplifying the overall manufacturing process.
3Adaptability or versatility
If specialized copolymers are synthesized for shape memory applications, then the materials can exhibit dual shape memory behavior, but production scalability is limited and costs increase
Solution Approach 1:
The patent creates a universal platform for producing shape memory polymers using common monomers and a standardized solventless polymerization process. By selecting from a range of monomers with different transition temperatures and properties, the same simple process can produce polymers with various dual shape memory behaviors, making the methodology universally applicable and easily scalable without requiring specialized synthesis procedures for each application.
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 enables the production of shape memory materials with good shape fixing and recovery properties, reducing production costs and environmental impact, and allows for large-scale commercial applications in various fields like medicine and aerospace.
Implementation Method 1
To exhibit shape memory behavior, a copolymer often shows a phase separated architecture
Implementation Method 2
The temporary or fixed shape forms or diminishes at most commonly a thermal transition, such as a glass transition or melting
Implementation Method 3
The temporary or fixed shape forms or diminishes at most commonly a thermal transition, such as a glass transition or melting
Implementation Method 4
Deformation while in the rubber or melted state and subsequent cooling below the transition temperature, while under an applied stress, fixes the temporary shape through vitrification or crystallization
Implementation Method 5
Deformation while in the rubber or melted state and subsequent cooling below the transition temperature, while under an applied stress, fixes the temporary shape through vitrification or crystallization
Data Source
AI summary
A multilayered composite shape memory material includes a coextruded first polymer layer of a first polymer material and a second polymer layer of a second polymer material. The composite shape memory material after thermomechanical programming being capable of undergoing at least one temperature induced shape transition from a temporary shape to a permanent shape. The first polymer layer defines a hard segment of the shape memory material that provides the shape memory material with the permanent shape, and the second polymer layer defines a switching segment of the shape memory material that provides the shape memory material with the temporary shape.