Self-Molding Thermoplastic Support Structure with Embedded Heating
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Solution Overview
Problem
Existing thermoplastic materials for medical fixation applications require external heating for softening, have limited operational time, and are susceptible to degradation from ultraviolet light and organic solvents, making them impractical for flexible and durable use.
Innovation Solution
An electronically-activated, self-molding and re-shapeable load-bearing support structure system comprising multiple layers of thermally-responsive polymers with integrated heating elements and a temperature control system, allowing for precise control over the material's stiffness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external heating is used to soften thermoplastic materials, then the material becomes moldable and flexible, but the operational time is limited and the process becomes complex
Solution Approach 1:
The patent incorporates heating elements directly into the thermoplastic material during manufacturing, so the material is pre-equipped with heating capability. This eliminates the need for external heating devices and extends operational time, as the material can be reheated and remolded multiple times as needed.
Solution Approach 2:
The thermoplastic material contains embedded heating elements that allow it to heat itself without external intervention. This self-heating capability enables the material to maintain moldability for extended periods and eliminates dependency on external heating equipment, thereby extending operational time.
2Ease of manufacture
If traditional thermoplastic materials are used, then the material is easy to mold, but the material degrades under ultraviolet light and organic solvents
Solution Approach 1:
The patent uses composite thermoplastic materials that combine base polymer matrices with UV stabilizers, antioxidants, and solvent-resistant additives. This composite structure maintains the moldability of thermoplastics while significantly improving resistance to ultraviolet light and organic solvents, thereby enhancing reliability in environmental conditions.
3Ease of operation
If thermoplastic materials are heated for softening, then the material becomes flexible for molding, but the hardening time cannot be controlled according to patient's actual need
Solution Approach 1:
The patent incorporates controllable heating elements with variable power settings and timing controls, allowing the hardening process to be dynamically adjusted according to patient needs. The system can maintain the material in a flexible state longer or accelerate hardening as required, providing adaptability in hardening time control.
Solution Approach 2:
The patent uses controllable heating parameters (temperature, time, power level) to regulate the softening and hardening process. By adjusting these parameters, the material's flexibility duration and hardening rate can be precisely controlled to match patient-specific requirements, enhancing adaptability.
4Ease of manufacture
If low-quality thermoplastic compositions are used, then the material is easier to process, but the material melts when exposed to ultraviolet light for extended times
Solution Approach 1:
The patent employs high-quality composite thermoplastic formulations that integrate UV stabilizers and structural reinforcement agents within the polymer matrix. These additives protect the material composition from UV-induced degradation while maintaining ease of processing, thereby achieving both processability and structural stability.
Solution Approach 2:
The patent optimizes the chemical composition parameters of the thermoplastic material, including polymer molecular weight, cross-linking density, and stabilizer concentration. These parameter adjustments enhance UV resistance and structural stability without significantly compromising processability, resolving the contradiction between ease of manufacture and composition stability.
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 easy operation, convenient adjustment on the human body, low power consumption, and compatible mass production, with improved durability and resistance to environmental factors.
Implementation Method 1
one or more first heating elements positioned adjacent to the first layer on a first heating element side, the one or more first heating elements selected from one or more of carbon fibers, carbon fabric, conductive inks, metal mesh, metal film, metal wires, or flexible printed circuits
Implementation Method 2
a first layer of a first thermally-responsive polymer having a first elastic modulus at a temperature below a glass transition temperature or a melting temperature and a second elastic modulus at a temperature greater than the glass transition temperature or the melting temperature
Implementation Method 3
a first layer of a first thermally-responsive polymer having a first elastic modulus at a temperature below a glass transition temperature or a melting temperature and a second elastic modulus at a temperature greater than the glass transition temperature or the melting temperature
Data Source
AI summary
An electronically-activated, self-molding and re-shapeable load-bearing support structure system is provided that includes a first composite structure. The first composite structure includes a first layer of a first thermally-responsive polymer; one or more first heating elements positioned adjacent to the first layer on a first heating element side; a second layer of the first thermally-responsive polymer positioned adjacent to the first heating elements on a second heating element side; a temperature sensor communicating with at least the first layer or the second layer of the first thermally-responsive polymer; one or more electrical connectors electrically communicating with the heating elements; and an electrical controller detachably connectable to at least one of the electrical connectors of the composite for providing an electrical current to the heating elements. A method of molding the load-bearing support structure system is also provided.