Sacrificial Component Deflagration for Composite Vascular Channels
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Solution Overview
Problem
Vascular channel manufacturing in composite materials is challenging due to the slow and incomplete removal of sacrificial materials using existing methods like melting and vaporization, which often leave residual material restricting fluid flow.
Innovation Solution
A method involving the molding of a sacrificial component with oxidizing agents and metal powders into a substrate, followed by deflagration to create channels, allowing for rapid removal of byproducts and minimizing thermal damage to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If melting or vaporization methods are used to remove sacrificial material, then the sacrificial material can be removed from the substrate, but the process is slow and leaves residual material in the channels
Solution Approach 1:
The patent changes the chemical parameters of the sacrificial material by incorporating oxidizing agents (such as potassium permanganate, potassium chlorate, ammonium perchlorate) into the polymer matrix. This chemical modification enables rapid deflagration and complete combustion of the sacrificial material, resolving the contradiction between complete removal and removal speed by transforming the removal mechanism from slow thermal processes to rapid chemical reactions.
Solution Approach 2:
The patent directly applies strong oxidants within the sacrificial material composition to accelerate the removal process. The oxidizing agents enable rapid oxidation and combustion of the polymer matrix, achieving complete material removal at high speed without leaving residues, thus simultaneously improving both reliability and productivity of the removal process.
2Reliability
If rapid deflagration is used to remove sacrificial material, then complete removal is achieved, but thermal effects may damage the substrate
Solution Approach 1:
The patent applies local quality by confining the deflagration process to the sacrificial material itself through its specific composition (oxidizing agents embedded in polymer matrix). The rapid combustion is localized to where the sacrificial material resides, allowing complete removal while the heat does not propagate extensively to damage the surrounding substrate, thus resolving the contradiction between complete removal and thermal damage prevention.
Solution Approach 2:
The patent employs the skipping principle by making the deflagration process extremely rapid, completing the material removal before significant heat can transfer to the substrate. The quick combustion 'rushes through' the sacrificial material and completes the removal task before thermal effects can cause harmful damage to adjacent components, simultaneously achieving complete removal and minimizing thermal damage.
3Reliability
If the entire composite is heated for melting or vaporization, then sacrificial material can be removed, but the process is slow and affects the entire substrate
Solution Approach 1:
The patent extracts the removal capability from the entire substrate heating process and concentrates it within the sacrificial material itself by incorporating oxidizing agents. This allows the removal reaction to occur locally and rapidly within the sacrificial material without requiring slow heating of the entire composite, thus resolving the contradiction between reliable removal and processing time by isolating the removal action to only where needed.
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 enables efficient formation of channels with rapid deflagration and easy removal of byproducts, preventing residual material buildup and ensuring minimal thermal impact on heat-sensitive substrates.
Implementation Method 1
igniting the sacrificial component to cause deflagration of the sacrificial component, thereby forming a channel in the substrate
Implementation Method 2
The sacrificial component can include one or more oxidizing agents imbedded in a polymeric matrix
Implementation Method 3
Heat generated through deflagration is rapidly dissipated to minimize thermal effects to the polymer composite (or another substrate)
Data Source
AI summary
Methods for forming channels within a substrate include molding a sacrificial component directly into the substrate and igniting the sacrificial component to deflagrate of the sacrificial component and form a channel in the substrate. The sacrificial component can include oxidizing agents such as chlorates, perchlorates, nitrates, dichromates, nitramides, and/or sulfates imbedded in a polymeric matrix, and the oxidizing agents can be 30 wt. % to 80 wt. % of the sacrificial component. The sacrificial component can further include one or more of unoxidized metal powder fuels, flammable gas-filled polymeric bubbles, one or more metallocenes and/or one or more metal oxide particles, one or more polymers with nitroester, nitro, azido, and/or nitramine functional groups, one or more burn rate suppressants such as oxamide, ammonium sulphate, calcium carbonate, calcium phosphate, and ammonium chloride, and non-combustible hollow bubbles and/or inert particles. The polymeric matrix can have a limiting oxygen index of less than about 30.