Shape Memory Polymer Preform Drawing for Complex Geometries
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Solution Overview
Problem
Existing methods for forming devices from shape memory polymers are costly and time-consuming, particularly when intricate geometries or small features are required, and often necessitate complex post-processing techniques.
Innovation Solution
A method involving the drawing of shape memory polymer preforms into fibers using a draw apparatus, which allows for the creation of fibers with precise structural features and geometries, enabling efficient device manufacturing by maintaining the preform's characteristics at a reduced scale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to form devices from shape memory polymers, then device functionality can be achieved, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent changes the physical state parameters of the shape memory polymer by controlling temperature during manufacturing. By heating the polymer above its glass transition temperature, it becomes soft and moldable, allowing direct formation of complex device geometries without expensive post-processing. This parameter change enables high productivity while maintaining ease of manufacture.
Solution Approach 2:
The patent performs preliminary shaping of the device geometry directly during the manufacturing process by molding the soft polymer into the desired final shape before cooling. This preliminary action eliminates the need for subsequent complex post-processing steps, thereby improving manufacturing efficiency and reducing costs.
2Manufacturing precision
If intricate geometries and small features are required in shape memory polymer devices, then device functionality improves, but manufacturing cost and time increase
Solution Approach 1:
The patent utilizes temperature parameter changes to achieve high feature resolution. By maintaining the polymer in a soft state above its glass transition temperature during molding, intricate geometries and small features can be precisely formed. The high viscosity of the soft polymer then locks these precise features in place during cooling, achieving high manufacturing precision without sacrificing productivity.
3Manufacturing precision
If complex post-processing techniques are used to achieve desired geometries, then manufacturing precision improves, but manufacturing time and cost increase
Solution Approach 1:
The patent performs the geometric shaping action preliminarily during the main manufacturing process by molding the soft polymer into the final desired geometry before cooling. This preliminary formation of precise geometries eliminates the need for subsequent complex post-processing techniques, thereby reducing post-processing time while maintaining high geometric accuracy.
Solution Approach 2:
The patent extracts or removes the need for complex post-processing techniques entirely by achieving the desired geometric precision directly during the primary manufacturing step through temperature-controlled molding of the soft polymer.
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 approach reduces manufacturing costs and time, enables the formation of complex geometries like helical channels, and allows for scalable production of devices with improved feature resolution, particularly suitable for medical and MRI applications where quick shape recovery and non-magnetic materials are beneficial.
Implementation Method 1
heating a first portion of the first preform... a draw temperature, which corresponds to a temperature at which the shape memory polymer is soft
Implementation Method 2
During the drawing of a fibre from a preform, the structure shrinks in the transverse direction of the preform and is elongated in the longitudinal direction
Data Source
AI summary
There is provided herein a method of manufacturing a device comprising at least a first fibre using a draw apparatus, the method comprising: providing a first preform comprising a shape memory polymer to the draw apparatus; heating a first portion of the first preform; and drawing, using the draw apparatus, the heated first portion in order to form the first fibre.