Resorbable Glass Fiber Polymer Composite Without Melt Degradation
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Solution Overview
Problem
Existing methods for producing polymer-based medical implants using glass fibers and thermoplastic polymers require high processing temperatures, leading to polymer degradation and reduced mechanical performance, and necessitate a second surgery for implant removal due to non-resorbable materials.
Innovation Solution
A method involving the use of a solvent-based process to embed biocompatible and resorbable glass fibers in a matrix polymer, eliminating the need for high-temperature melt-processing by applying a mixture of matrix polymer in a solvent and removing the solvent with an anti-solvent to form a solid composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high processing temperatures are used to process thermoplastic polymer matrix, then the polymer viscosity decreases enabling extrusion processing, but the polymer undergoes thermo-oxidative degradation reducing mechanical performance
Solution Approach 1:
The invention changes the fundamental processing parameter from temperature-based melting to solvent-based dissolution. Instead of heating the polymer to melt state for extrusion, the patent uses solvents to dissolve the polymer at lower temperatures, creating a workable solution that can be applied to fibers without thermal degradation. This parameter change resolves the contradiction by enabling processing without the harmful high temperatures that cause polymer degradation.
Solution Approach 2:
The invention introduces a solvent as an intermediary substance to enable polymer processing. The solvent acts as a mediator that dissolves the polymer, allowing it to be applied to glass fibers in a workable state without requiring high temperatures. This intermediary approach replaces the direct thermal processing route with a chemical dissolution route, avoiding thermo-oxidative degradation while maintaining processing capability.
2Ease of manufacture
If thermoplastic polymers are used as matrix material, then the material can be processed by melt extrusion, but the high processing temperatures cause polymer degradation and reduced molecular weight
Solution Approach 1:
The invention fundamentally changes the processing parameter from thermal energy to chemical energy. Instead of using heat to melt and process the polymer, the patent employs solvents to dissolve the polymer at lower temperatures. This parameter change preserves the polymer's molecular weight and chemical structure, avoiding the degradation that occurs during high-temperature melt extrusion while still enabling effective processing.
3Strength
If non-resorbable metal alloys are used for implants, then the mechanical strength is sufficient to carry external loads, but a second surgery is required for implant removal
Solution Approach 1:
The invention employs composite materials combining glass fibers with polymer matrix to achieve both mechanical strength and resorbability. The glass fiber reinforcement provides the necessary load-bearing capacity, while the polymer matrix enables resorbability. This composite approach resolves the contradiction by allowing the implant to fulfill its mechanical function during the healing period and then be naturally resorbed, eliminating the need for removal surgery.
4Strength
If multiple layers of matrix polymer are applied to glass fibers, then the composite structure is enhanced, but the processing complexity increases
Solution Approach 1:
The invention enables continuous processing where glass fibers are continuously coated with polymer solution and then continuously passed through anti-solvent zones for precipitation. This continuous multi-layer coating process maintains the useful action of building composite structure without interruption, avoiding the batch processing complexity that would arise from applying multiple layers separately. The process flows continuously, enhancing structure while maintaining simplicity.
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 reduces polymer degradation, allows better control over composite composition, and enables the production of implants with improved mechanical properties and lower monomer content, eliminating the need for a second surgery.
Implementation Method 1
removing the solvent from the mixture using an anti-solvent to obtain the solid composite material
Data Source
AI summary
The invention pertains to a composite material, comprising a plurality of compatible glass fibers in a thermoplastic polymer matrix, wherein the glass fibers and the polymer matrix are biocompatible and resorbable. The invention further pertains to a method for obtaining a solid polymer composite material comprising a plurality of biocompatible and resorbable glass fibers, which are embedded in a biocompatible and resorbable matrix polymer, wherein the matrix polymer is applied from solution and the solvent of said solution is at least partially removed using an anti-solvent.