Corrugated Deflection Diaphragm Fabrication via Removable Scaffold
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Solution Overview
Problem
Existing fabrication schemes for corrugated membranes in electrolytic pumps face limitations in height tolerance control and uniformity, and are costly, particularly for small-scale implantable pumps, due to the need for deep reactive ion etching and subsequent oxidation and wet etching steps.
Innovation Solution
A method using a chemically removable layer applied to a substrate as a positive mold scaffold, allowing for the deposition and curing of a polymer layer, followed by removal to form a corrugated membrane, eliminating the need for costly etching processes and enabling easier design changes and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If deep reactive ion etching and oxidation and wet etching steps are used to fabricate corrugated membranes, then the membrane can be formed with corrugations, but the manufacturing cost increases and the process complexity increases
Solution Approach 1:
Instead of using etching to remove material and form corrugations (negative molding), the patent applies a photosensitive polymer layer that is selectively removed to form corrugations (positive molding). This inversion of the traditional approach eliminates costly etching steps while achieving the same corrugated structure.
Solution Approach 2:
The patent uses a disposable photosensitive polymer layer as a sacrificial mold that is applied, patterned, and then removed after transferring the corrugation pattern to the membrane. This temporary mold is cheaper than permanent etched molds and can be easily discarded after use.
2Shape
If deep reactive ion etching and oxidation and wet etching steps are used to fabricate corrugated membranes, then the membrane can be formed with corrugations, but the manufacturing time increases
Solution Approach 1:
The patent inverts the traditional fabrication sequence by building corrugations through selective deposition and removal of a photosensitive layer rather than through sequential etching steps. This reduces manufacturing time by eliminating multiple lengthy etching and oxidation processes.
Solution Approach 2:
The corrugation pattern is prepared in advance on a photosensitive polymer layer before the membrane material is deposited. This preliminary patterning allows for faster subsequent processing compared to performing etching steps after membrane formation.
3Shape
If etching processes are used to fabricate corrugated membranes, then the membrane can be formed with corrugations, but the height tolerance control and height uniformity deteriorate
Solution Approach 1:
The photosensitive polymer layer serves as a sacrificial mold with precisely controlled thickness that defines the corrugation height. This disposable mold provides superior height tolerance control compared to etching processes, as the polymer layer thickness can be uniformly controlled during application.
Solution Approach 2:
The patent changes the fabrication parameter from etching depth control to polymer layer thickness control. The latter provides better precision and uniformity because the polymer layer can be applied with controlled thickness across the entire substrate surface before patterning.
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 manufacturing process, reduces costs, and allows for reproducibility by using a removable material as a scaffold, facilitating the production of corrugated diaphragms with varying depths and lengths for efficient drug delivery in implantable and non-implantable drug-delivery systems.
Implementation Method 1
coating a membrane-forming layer comprising a hardenable polymer onto the patterned removable layer in a liquid phase; and following hardening of the hardenable polymer
Data Source
AI summary
A removable material is deposited or otherwise applied to a flat substrate surface in a pattern corresponding to desired corrugations in a membrane, e.g., a deflection diaphragm. The applied material serves as a scaffold for a polymeric material, which is applied thereover, and following cure or hardening, the polymeric material is removed to form a finished corrugated membrane.