Lattice Template for Controlled Porosity in Polymer Composites
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing techniques for creating micro-structured polymeric materials lack control over microstructure extent, pore formation, and connectivity, and are not well-suited for commercial production processes, particularly in producing branched and closed loop structures or internal networks of interconnected pores.
Innovation Solution
A method involving fluid flow and displacement in a lattice construction, allowing for the creation of branched or closed loop microstructures with controlled pore size and connectivity, using a polymeric material to invade and solidify within the lattice, which can be optionally removed to form a composite material with desired porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional techniques (micro-embossing, photolithography, etching, laser drilling) are used to create micro-structures on polymeric surfaces, then certain surface textures can be produced, but the ability to efficiently produce branched and closed loop structures or internal networks of interconnected pores is limited
Solution Approach 1:
A sacrificial lattice structure (intermediary object) is introduced into the polymer melt before solidification. This lattice serves as a template that enables the formation of complex branched and closed loop pore structures that cannot be achieved by direct conventional methods. After the polymer solidifies, the lattice is removed to leave the desired micro-structure.
Solution Approach 2:
The lattice structure is prepared and positioned within the polymer material before the final solidification step. This preliminary arrangement of the template allows the complex micro-structures to form naturally during solidification, eliminating the need for subsequent complex processing steps to create branched and closed loop configurations.
2Quantity of substance
If prior techniques are used to create porous structures throughout the entire polymer, then porosity is achieved, but control over the extent of micro-structure, pore formation, and connectivity is lacking
Solution Approach 1:
The lattice structure is designed with spatially varying properties - different regions of the lattice can have different pore sizes, connectivity, and densities. This allows different areas of the final polymer product to have tailored micro-structures optimized for specific local functions, such as varying porosity gradients or localized pore connectivity patterns.
Solution Approach 2:
The lattice parameters (pore size, spacing, geometry) can be systematically varied to control the resulting micro-structure. By changing lattice parameters in different regions or at different depths, precise control over pore formation extent, size distribution, and connectivity is achieved, enabling gradients and multi-modal pore structures.
3Shape
If existing methods are used to generate surface micro-structures, then texture can be created, but the production process is time consuming and not well suited to conventional commercial production processes
Solution Approach 1:
The micro-structure formation process is merged with the existing polymer solidification process. The lattice is embedded in the polymer melt during normal production, and the micro-structures form automatically as the polymer solidifies - eliminating the need for separate, time-consuming micro-structuring steps and enabling integration with conventional continuous production lines.
Solution Approach 2:
The lattice template is prepared and positioned before the polymer solidifies, allowing the micro-structure to form passively during the inevitable solidification process that occurs in all polymer production. This eliminates the need for additional time-consuming processing steps after production, enabling high-speed manufacturing.
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 provides flexibility in designing microstructures and controlling pore creation, enabling efficient production of composite materials with tailored properties, suitable for various applications including filtration and optical properties.
Implementation Method 1
A process for producing a composite and/or structured material includes the steps of: forming a lattice construction, fluidization of a polymeric material, invasion of the polymeric material into the lattice construction
Implementation Method 2
One embodiment disclosed herein relates to a novel method to create composite materials using the concept of fluid flow and fluid displacing in a lattice construction
Implementation Method 3
fluidization of a polymeric material, invasion of the polymeric material into the lattice construction and solidification of the resulting polymer composite
Data Source
AI summary
A method for making a composite and/or structured material includes: forming a lattice construction from a plurality of solid particles, the construction being formed so as to have one or more gaps between the particles; invading the lattice construction with a fluid material such that the fluid material at least partially penetrates the gaps; and, solidifying the material which invaded the lattice construction to form a composite material. In one suitable embodiment, the method further includes removing at least a portion of the lattice construction from the composite material thereby forming at the location of the removed portion one or more pores in the solidified material that invaded the construction.