Multicellular Structure Manufacturing via Low-Viscosity Monomer Replication

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Solution Overview

Problem

Conventional extrusion replication processes for manufacturing multicellular structures with polymer melts are limited by high viscosity, restricting replication depth and preventing the production of structures with thin walls and fine features, such as cell wall heights greater than 20 mm with cell wall thicknesses less than 2.0 mm, and require high-pressure applications, increasing complexity and cost.

Innovation Solution

A process involving a reactive monomer mixture with viscosity no greater than 10,000 mPa-s is incorporated into precursor structures, allowing for the production of multicellular structures with improved mechanical performance and characteristics, such as increased stiffness and reduced density, without the need for external pressure, by utilizing a polymerizable precursor that effectively fills the mold at atmospheric pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional extrusion replication processes use high-viscosity polymer melts, then the process can manufacture multicellular structures, but the replication depth is limited and thin-walled structures cannot be produced

Engineering Contradiction:
Improvecell wall thicknessVSAvoidprocess complexity
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the viscosity parameter of the polymer material from high (conventional) to low (≤10,000 mPa·s), enabling the material to flow into fine precursor structures and achieve thin wall thicknesses (≤2.0 mm) without requiring complex high-pressure equipment

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional high-pressure mechanical extrusion system with a low-pressure or atmospheric pressure process, using the low-viscosity material's inherent flow characteristics to fill the mold cavities without complex pressure application equipment

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If high-pressure is applied to facilitate polymer melt incorporation into precursor structures, then replication can occur, but device complexity and costs increase

Engineering Contradiction:
Improvereplication depthVSAvoidpressure application system
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the viscosity parameter of the polymer material from high (conventional) to low (≤10,000 mPa·s), enabling the material to flow into fine precursor structures and achieve thin wall thicknesses (≤2.0 mm) without requiring complex high-pressure equipment

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional high-pressure mechanical extrusion system with a low-pressure or atmospheric pressure process, using the low-viscosity material's inherent flow characteristics to fill the mold cavities without complex pressure application equipment

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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

The process enables the manufacturing of multicellular structures with fine structures, achieving cell wall heights greater than 20 mm and thicknesses less than 2.0 mm, providing enhanced mechanical performance and reduced density, suitable for various industrial, home, and personal safety applications.

Implementation Method 1

the reactive monomer mixture has a viscosity of no greater than 10,000 mPa-s when incorporated into the precursor structures of the multicellular structure

Methodology Applied
Scientific EffectViscosity: Viscometer

Implementation Method 2

polymerizable precursor of a polymeric material into the precursor structures of the mold

Methodology Applied
Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP3486077B1Multicellular structure comprising interconnected cells
Publication Date: 2023.12.20 3M INNOVATIVE PROPERTIES CO

AI summary

The present disclosure relates to a process of manufacturing a multicellular structure comprising interconnected cells, wherein the process comprises: a) providing a polymerizable precursor of a polymeric material, wherein the polymerizable precursor comprises a reactive monomer mixture; b) providing a mold comprising precursor structures of the multicellular structure; c) optionally, heating at least one the reactive monomer mixture or the mold; d) incorporating the reactive monomer mixture into the precursor structures of the multicellular structure thereby substantially filling up the precursor structures of the mold, wherein the reactive monomer mixture has a viscosity of no greater than 10,000 mPa-s when incorporated into the precursor structures of the multicellular structure and when measured according to the viscosity test method defined in the experimental section; e) polymerizing the polymerizable precursor of the polymeric material into the precursor structures of the mold; and f) demolding the multicellular structure formed by polymerizing the polymerizable precursor of the polymeric material. According to another aspect, the present disclosure relates to a multicellular structure obtainable by the process as described above. In another aspect, the present disclosure relates to the use of a multicellular structure as described above for industrial applications.