Fibrous Joinery Interface for Dissimilar Polymer Medical Implants
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Solution Overview
Problem
Joining materials that are not readily bondable, such as silicone and polyurethane polymers, requires complex processing operations including surface treatment and adhesives, which can be time-consuming and increase production costs in medical device manufacturing.
Innovation Solution
A fiber matrix with a plurality of fibers is interpenetrated within one material and mechanically fixed to a first component, with a second portion of the fiber matrix connected to a second component, allowing for a strong joint without the need for additional adhesives or surface treatments, using methods like electro-spinning and heat bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex processing operations including surface treatment and adhesives are used to join silicone polymer and polyurethane polymer, then the joint strength is improved, but the production time increases and manufacturing complexity increases
Solution Approach 1:
The patent removes the intermediary adhesive layer from the joining process. Instead of using adhesive to bond silicone polymer to polyurethane polymer, the invention creates a direct mechanical interlocking joint where the polyurethane polymer is molded over the silicone polymer with embedded fibers that penetrate both materials, eliminating the need for surface treatment and adhesive application steps.
Solution Approach 2:
The patent employs a composite structure consisting of silicone polymer, polyurethane polymer, and embedded fibers (such as glass fibers or other reinforcement fibers). This composite approach creates a mechanically interlocked joint where the fibers penetrate both polymer materials, providing structural reinforcement and direct mechanical bonding without requiring chemical adhesives or surface treatments.
2Strength
If surface treatment and adhesives are used to join dissimilar polymers, then the joint strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent eliminates the adhesive layer and surface treatment steps from the manufacturing process. The joining mechanism relies solely on mechanical interlocking through fiber reinforcement and direct molding, removing the complexity associated with adhesive application, surface preparation, and curing processes.
Solution Approach 2:
The polyurethane polymer material itself performs the joining function through its mechanical interlocking with the silicone polymer via embedded fibers. The material structure is designed to create its own bonding mechanism through the molding process, without requiring external adhesives or surface treatments to facilitate the joint.
3Ease of manufacture
If polyurethane polymer surface is prepared through plasma treatment, then the bondability is improved, but the processing time must be completed quickly before surface deterioration
Solution Approach 1:
The patent removes the plasma treatment step entirely from the manufacturing process. Instead of relying on chemical surface activation that requires immediate subsequent bonding, the invention uses mechanical interlocking through fiber reinforcement that does not require surface modification, thereby eliminating the time-critical nature of the process.
Solution Approach 2:
The patent replaces chemical bonding mechanisms (plasma treatment and adhesive bonding) with a mechanical bonding mechanism. The fibers are embedded in the polyurethane polymer and mechanically interlock with the silicone polymer through direct physical contact and friction, providing a time-independent joining method that does not rely on surface chemistry.
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 simplifies the joining process, reduces production time, and enhances the strength of the joint between dissimilar materials, preventing surface deterioration and eliminating the need for complex processing steps.
Implementation Method 1
using methods like electro-spinning and heat bonding
Implementation Method 2
using methods like electro-spinning and heat bonding
Data Source
AI summary
An implantable medical device includes a first component including a first material, a second component including a second material, and a fiber matrix including a plurality of fibers. The fiber matrix joins the first component to the second component. The fiber matrix includes a first a first portion connected to the first component, and a second portion connected to the second component. The first portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the first material. The first portion of the fiber matrix directly contacts the first material.