3D Polymer Objects with Surface Micro-nanostructures
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Solution Overview
Problem
Existing methods for preparing 3D polymer objects with surface micro-nanostructures are limited in creating complex structures, especially with small thickness, as they struggle to maintain shape changes and produce stable, permanent micro-nanostructures.
Innovation Solution
A method involving the synthesis of 2D thermoset polymer objects with reversible exchangeable bonds, deformed above the reshaping temperature under external force, and thermally annealed to achieve a permanent 3D shape with surface micro-nanostructures, utilizing polymers like polyurethane, epoxy, and silicone with specific bonds such as ester, urethane, and siloxane bonds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional methods (photolithography, etching, compression molding) are used to prepare microstructures on polymer surfaces, then manufacturing precision and ease of manufacture are achieved for simple 2D structures, but the ability to create complex 3D objects with surface micro-nanostructures is limited
Solution Approach 1:
The invention separates the microstructure formation process from the 3D shaping process. First, 2D polymer objects with precise surface microstructures are fabricated using conventional methods. Then, these objects are cut into strips and assembled into 3D configurations. This segmentation allows each step to optimize for its specific requirement: precision for microstructures, versatility for 3D shapes.
Solution Approach 2:
The invention embeds 2D polymer objects with surface microstructures into a 3D configuration by cutting them into strips and assembling multiple layers. The 2D microstructured surfaces are nested within the 3D structure, maintaining their precision while achieving complex three-dimensional forms.
2Length of moving object
If polymer thickness is reduced to achieve thin 3D objects, then adaptability and ease of manufacture improve, but the stability and ability to maintain shape changes deteriorate
Solution Approach 1:
The invention cuts thin polymer sheets into strips and assembles them into 3D structures. This segmentation allows thin materials to be used while maintaining structural stability through the assembled configuration, rather than relying on the thickness of a single continuous piece.
Solution Approach 2:
The invention utilizes thin polymer sheets with surface microstructures as flexible components. These thin films are cut and assembled into 3D structures that maintain shape stability through their configuration rather than material thickness, enabling thin yet stable objects.
3Stability of the object's composition
If permanent 3D shapes with surface micro-nanostructures are required, then product stability improves, but the complexity of the manufacturing process increases
Solution Approach 1:
The manufacturing process is segmented into independent steps: fabricating 2D objects with microstructures using conventional methods, cutting them into strips, and assembling into 3D configurations. This segmentation maintains permanent shapes while avoiding the need for complex single-step processes.
Solution Approach 2:
The surface microstructures are formed on the polymer surfaces in advance before the 3D shaping process. This preliminary action allows conventional precise methods to create the microstructures, which are then preserved during the subsequent cutting and assembly into 3D forms.
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
Enables the creation of stable, complex 3D polymer objects with surface micro-nanostructures, overcoming the limitations of conventional methods by maintaining the deformed shape permanently and allowing for multiple reshaping cycles, thus achieving consistent and efficient production of intricate structures.
Implementation Method 1
the polymer network contains reversible exchangeable bonds
Implementation Method 2
Above the reshaping temperature, the reversible exchangeable bonds are activated. The reshaping temperature is above the glass transformation temperature or crystalline melting temperature of the polymer
Implementation Method 3
deformed above the reshaping temperature with an external force applied... after cooling, a permanent 3D polymer object with surface micro-nanostructure is obtained
Implementation Method 4
When an external stress is applied, the macroscopic deformation corresponds to changes in the molecular chain conformation and entropy
Implementation Method 5
When an external stress is applied, the macroscopic deformation corresponds to changes in the molecular chain conformation and entropy
Data Source
AI summary
The present invention discloses a method for preparing stable 3D polymer objects with surface micro-nanostructures. The method includes the following steps: Step (1): Synthesizing a thermoset 2D polymer object with surface microstructures. The polymer network contains reversible exchangeable bonds. Step (2): deforming synthesized polymer to an arbitrary desired shape above the reshaping temperature with an external force applied. The permanent reshaping temperature falls in the range of 50-130° C. and external stress is held for 5 min-24 hours Step (3): after cooling, a permanent 3D polymer object with surface microstructure is obtained. Step (2-3) can be repeated for many cycles and the 2D polymer object can be arbitrarily and cumulatively deformed to get a complex 3D structures. The polymer networks contain reversible exchangeable bonds and bond exchange catalysts in the present invention. The method disclosed in present invention is simple and efficient for preparing complex 3D polymer objects with surface micro-nanostructures.