Deflagration Channel Formation in Polymer Substrates

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Solution Overview

Problem

Vascular channel manufacturing in composite materials is challenging due to the difficulty in consistently removing sacrificial materials, with existing methods like melting and vaporization being slow and leaving residual material that restricts fluid flow.

Innovation Solution

A method involving molding a sacrificial component with a combustible material into a substrate, igniting it to cause deflagration, and cleaning the channel to remove byproducts, which is faster and minimizes thermal effects on the substrate, using a protective shell and specific combustible materials like black powder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If melting or vaporization is used to remove sacrificial material, then the sacrificial material can be removed from the substrate, but the process is slow and leaves residual material that restricts fluid flow

Engineering Contradiction:

Improvecomplete removal of sacrificial materialVSAvoidchannel formation speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the removal mechanism from thermal (melting/vaporization) to chemical (deflagration). By using a combustible sacrificial material that undergoes rapid chemical combustion, the removal process achieves both high speed and complete consumption of the material, eliminating residuals that would restrict fluid flow.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The sacrificial material undergoes a phase transition through deflagration (rapid combustion), transforming from solid to gas and energy release. This phase change enables complete consumption of the sacrificial material at high speed, resolving the contradiction between complete removal and processing speed.

Inventive Principle:

Principle #36Phase transitions

2Productivity

If deflagration is used to remove sacrificial material, then the channel formation is rapid with minimal residuals, but thermal effects on the substrate must be minimized

Engineering Contradiction:

Improvechannel formation speedVSAvoidthermal impact on substrate

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent segments the thermal impact by confining the deflagration to the sacrificial material itself. The sacrificial material is positioned within the substrate channels, so the thermal energy is localized to where it is needed (consuming the sacrificial material) rather than affecting the entire substrate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent converts the potentially harmful thermal effect of deflagration into a beneficial localized process. The heat generated is immediately consumed by the sacrificial material to drive the removal process, and the rapid completion of deflagration limits thermal exposure time to the substrate, turning a harmful thermal effect into an efficient removal mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the entire composite is heated for melting or vaporization, then sacrificial material can be removed, but the thermal effects on the polymer composite are excessive

Engineering Contradiction:

Improvesacrificial material removalVSAvoidoverall substrate temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent extracts the thermal process from the bulk substrate and confines it to the sacrificial material. By using deflagration of the sacrificial material itself, the thermal energy is generated and consumed locally within the sacrificial material, eliminating the need to heat the entire composite substrate to high temperatures.

Inventive Principle:

Principle #2Taking out (Extraction)

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 method efficiently forms channels with minimal residual material, ensuring rapid fluid flow and reduced thermal impact on the substrate, enabling cost-effective manufacturing of complex shapes and heat-sensitive electronics.

Implementation Method 1

igniting the sacrificial component to cause a deflagration of the sacrificial component, thereby forming a channel in the substrate

Methodology Applied

Scientific EffectDeflagration: Deflagration

Implementation Method 2

Heat generated through deflagration is rapidly dissipated to minimize thermal effects to the polymer composite (or another substrate)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10744682B2Vascular channel manufacture by deflagration

Publication Date: 2020.08.18 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method of forming channels within a substrate includes: (a) molding a sacrificial component directly into the substrate; (b) igniting the sacrificial component to cause a deflagration of the sacrificial component, thereby forming a channel in the substrate; and (c) cleaning the channel in the substrate to remove byproducts of the deflagration of the sacrificial component. The sacrificial component includes a combustible material with a protective shell, and the substrate includes a polymeric material.