Expandable Cell Matrix Using Recyclable Thin-Film Sealing
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Solution Overview
Problem
Existing expandable cell matrices, commonly used in applications like mattresses and airbags, are costly and often made from PVC, which is not suitable for healthcare settings due to contamination concerns, and there is a need for recyclable and disposable alternatives that can expand in response to fluid introduction.
Innovation Solution
A method for manufacturing expandable cell matrices using recyclable thin films, involving the creation of interconnected cells through folding and sealing processes, allowing the structures to be stored flat and expandable upon fluid introduction, with options including cross-web, gusset, and vertical sealing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dip molding, vacuum forming, or cast molding of PVC vinyls and polyurethanes is used to manufacture cell matrices, then the structures can be made with durable materials, but the manufacturing cost increases and the materials become non-recyclable and unsuitable for healthcare settings
Solution Approach 1:
The patent changes the material parameters from traditional PVC vinyls and polyurethanes to thin film materials that are recyclable and suitable for healthcare settings. This parameter change maintains structural integrity while reducing manufacturing cost and improving environmental compatibility.
Solution Approach 2:
The patent employs disposable thin film cell matrices that can be manufactured at lower cost and disposed of after use in healthcare settings. This approach eliminates contamination concerns associated with durable materials like PVC while maintaining functional reliability during the service period.
2Shape
If traditional molding methods are used for cell matrices, then the structures can be manufactured with complex shapes, but the manufacturing speed decreases and production costs increase
Solution Approach 1:
The patent segments the cell matrix into modular units formed from thin films that can be quickly assembled. This segmentation allows for rapid manufacturing of complex structures by combining standardized components rather than molding entire complex shapes in one process.
Solution Approach 2:
The patent uses flexible thin films to create complex cell matrix structures that can be rapidly formed and assembled. The thin film material allows for quick shaping and configuration changes without requiring slow, expensive molding processes for each structural variation.
3Strength
If PVC materials are used for cell matrices in healthcare settings, then the structures can provide durable support, but contamination from bodily fluids requires disposal after each use, increasing costs
Solution Approach 1:
The patent implements disposable thin film cell matrices that provide sufficient support capability for healthcare applications during each use. After use, these matrices can be disposed of, eliminating contamination risks associated with reusable PVC materials while keeping costs manageable through lower material and manufacturing costs.
Solution Approach 2:
The patent employs composite or specialized thin film materials that combine adequate mechanical strength for support with properties suitable for single-use healthcare applications. These materials provide the necessary strength during use while being compatible with disposal protocols to prevent contamination spread.
Data Source
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AI summary
A cell matrix expandable structure includes of a plurality of interconnected cells normally in flat form but readily expandable into the form of a container upon the introduction of fluid. The structures may be made out of recyclable films. Methods of manufacturing the cell matrix in a continuous manufacturing process are also disclosed.