Polymeric Cutting Edge Structures via 2-Photon Polymerization
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Solution Overview
Problem
Existing methods for manufacturing cutting edge structures, particularly razor blades, using polymeric materials are not cost-effective for mass production and struggle to achieve a tip radius less than 1 micrometer, and high-resolution additive manufacturing techniques face challenges with internal stresses and time inefficiencies in producing larger objects.
Innovation Solution
A method utilizing 2-photon polymerization to cure liquid precursor materials with electromagnetic radiation, forming cutting edge structures with sub-micrometer precision and reducing internal stresses by creating closely spaced cutting edge elements, allowing for the production of polymeric razor blades with a tip radius less than 1 micrometer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If melt flow processing techniques are used to inject molten polymer into a mold cavity, then mass production can be achieved, but the polymer viscosity is too high to penetrate sub-micrometer dimensioned spaces required for razor blade edges
Solution Approach 1:
The patent changes the physical state of the polymeric material from molten (high viscosity) to a solubilized state in supercritical carbon dioxide (low viscosity). This parameter change in the material's physical state enables penetration into sub-micrometer mold cavities while maintaining mass production capability through the injection molding process.
Solution Approach 2:
The patent utilizes phase transitions of carbon dioxide between supercritical and gaseous states. The polymeric material is solubilized in supercritical CO2 during injection, then precipitates as the CO2 returns to gaseous state, enabling precise formation of cutting edges with tip radii less than 1 micrometer.
2Manufacturing precision
If injection pressure is increased to improve penetration into sub-micrometer dimensioned spaces, then cutting edge precision improves, but polymeric material penetrates between mating surfaces of the mold tool causing flashing
Solution Approach 1:
The patent changes the viscosity parameter of the polymeric material by solubilizing it in supercritical carbon dioxide. This reduces the material viscosity dramatically, allowing penetration into sub-micrometer spaces at moderate injection pressures without causing flashing between mold surfaces.
3Ease of manufacture
If polymeric raw material is heated above glass transition temperature to decrease viscosity, then material flow improves, but cooling causes shrinkage and rounding of the edge
Solution Approach 1:
The patent uses the phase transition of carbon dioxide from supercritical to gaseous state to drive material ejection instead of thermal cooling. The polymeric material precipitates out of the supercritical CO2 as it returns to gaseous state, maintaining the sharp cutting edge geometry without thermal shrinkage or rounding.
4Adaptability or versatility
If conventional additive manufacturing techniques are used to fabricate polymeric structures, then complex shapes can be created, but spatial resolution is limited to tens of micrometers which is greater than the ultimate tip radius required
Solution Approach 1:
The patent replaces mechanical additive manufacturing processes with a chemical/supercritical fluid-based injection molding process. The solubilized polymeric material in supercritical CO2 can flow into and precisely fill sub-micrometer mold cavities, achieving tip radii less than 1 micrometer while maintaining the ability to create complex three-dimensional blade shapes.
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 cost-effective mass production of polymeric razor blades with precise cutting edges and reduces internal stresses, facilitating faster fabrication of larger objects with improved shaving performance.
Implementation Method 1
curing portions of the liquid precursor material in a focal point of an electromagnetic radiation
Implementation Method 2
A method utilizing 2-photon polymerization to cure liquid precursor materials with electromagnetic radiation
Data Source
AI summary
A functional polymeric cutting edge structure and methods for the manufacturing of cutting edge structures comprised of polymeric materials are provided. The cutting edge structures may be produced on a substrate having a blade body or blade support type. The polymeric material is produced by curing a precursor material by electromagnetic radiation wherein a wavelength of said radiation is about double a wavelength required to cure the precursor material. A razor blade for use in a razor cartridge or a blade box may be formed using the present invention.