Polyurethane Valve Leaflet Integral Molding
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Solution Overview
Problem
Existing polymer valve leaflets suffer from uneven thickness, weak points, easy tearing, creep, low overall strength, and poor tear resistance, which affect their durability and fluid dynamic performance.
Innovation Solution
A method for preparing a polymer valve leaflet material by integral molding, involving electrospinning a first polyurethane solution to create a prefabricated film, and then compositing a second polyurethane with the film to achieve a three-dimensional structure with improved strength and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional impregnation process is used to prepare polymer valve leaflets, then the leaflets can be manufactured, but they exhibit uneven thickness, weak points, and easy tearing
Solution Approach 1:
The patent applies preliminary action by first electrospinning a polyurethane scaffold structure before impregnating with the second polyurethane solution. This pre-formed three-dimensional scaffold provides a uniform base structure that prevents uneven thickness and weak points during the subsequent impregnation process, thereby improving both manufacturing precision and tear resistance
Solution Approach 2:
The patent uses composite materials by combining two different polyurethane materials with different properties. The first polyurethane forms the electrospun scaffold providing structural integrity, while the second polyurethane is impregnated to provide flexibility and biocompatibility. This composite structure addresses both thickness uniformity and tear resistance issues
2Ease of manufacture
If polymer materials are used for valve leaflets, then good biocompatibility and ease of processing are achieved, but creep and deformation occur during use
Solution Approach 1:
The patent employs composite materials where the electrospun first polyurethane scaffold provides structural stability and creep resistance, while the second polyurethane impregnation maintains biocompatibility and ease of processing. The synergistic combination allows the valve leaflet to resist deformation during use while remaining manufacturable
Solution Approach 2:
The patent applies local quality by creating a hierarchical structure where the electrospun scaffold provides localized structural support at the micro-level to prevent creep, while the bulk impregnated material provides the necessary biocompatibility and processing characteristics. This localized differentiation of material functions resolves the contradiction between stability and ease of manufacture
3Strength
If multilayer compositing is used to improve mechanical properties, then durability is enhanced, but interlayer bonding is poor and the valve becomes flat
Solution Approach 1:
The patent applies preliminary action by electrospinning a three-dimensional scaffold structure before impregnation. This pre-formed structure provides inherent three-dimensionality and surface area for bonding, eliminating the need for separate bonding processes and ensuring strong interlayer adhesion while maintaining valve curvature
Solution Approach 2:
The patent replaces traditional mechanical layering approaches with an electrospinning-based structural formation method. The electrospun scaffold creates a three-dimensional network that inherently provides both structural integrity and bonding surfaces, substituting mechanical assembly with a more integrated formation process that improves both strength and interlayer bonding
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 method results in a leaflet with reduced stress during the cardiac cycle, improved creep resistance, enhanced edge tear resistance, extended service life, and improved fluid dynamics, addressing the limitations of existing polymer valve leaflets.
Implementation Method 1
a spinning step, electrospinning a first polyurethane solution onto a receiving device to obtain a prefabricated film on the receiving device
Data Source
AI summary
Disclosed are a polymer valve leaflet material, a preparation method for integrally molding the same, and use thereof. The preparation method includes: a spinning step, electrospinning a first polyurethane solution to a receiving device to obtain a prefabricated film on the receiving device; and a compositing step, compositing second polyurethane with the prefabricated film to obtain the polymer valve leaflet material. The present disclosure solves the problems of uneven thickness of various parts of the leaflets, weak points inside the leaflets, and easy tearing of the leaflets at weak points in the existing impregnation process, thereby addressing the issues of easy creep, relatively low overall strength and poor tear resistance of the existing leaflets.