Soluble Mold for Complex Polymer Shapes

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Solution Overview

Problem

Conventional methods for forming polymers into complex shapes require high viscosity materials with volatile solvents, which are difficult to handle and result in lower adhesion to substrates, necessitating a more efficient method for shaping curable polymers without the use of viscosity-increasing fillers.

Innovation Solution

The method involves using a mold with a soluble material to shape and cure curable polymers, allowing for the formation of complex geometries without the need for high viscosity polymers, and eliminating the use of volatile solvents by dissolving the mold after curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If high viscosity polymers with fillers are used to enable manual manipulation into complex shapes, then the polymer can be formed into desired geometries, but adhesion to substrates is reduced

Engineering Contradiction:

Improvecomplex geometryVSAvoidadhesion

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The process is segmented into distinct stages: applying low viscosity polymer to substrate, then forming the shape. This allows adhesion to occur first with the low viscosity material, then shaping follows without compromising the bond strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The polymer is applied to the substrate in its low viscosity state before shaping occurs. This preliminary application ensures strong adhesion is established before any manipulation or forming operations take place.

Inventive Principle:

Principle #10Preliminary action

2Shape

If high viscosity polymers are used to allow for manual manipulation, then complex shapes can be formed, but the manufacturing process becomes time-intensive requiring extensive hand-working

Engineering Contradiction:

Improvecomplex geometryVSAvoidmanufacturing time

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

Manual mechanical manipulation is replaced with a mold-based forming system. The mold cavity defines the complex geometry, eliminating the need for time-intensive hand-working while maintaining the ability to produce complex shapes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The desired complex shape is copied into the mold cavity, which then imparts this shape to the polymer material. This eliminates the need for skilled technicians to manually form each piece, significantly reducing manufacturing time.

Inventive Principle:

Principle #26Copying

3Ease of operation

If viscosity is increased to allow for manipulation of polymer into complex shapes, then the polymer can be handled manually, but adhesion onto substrates is lowered

Engineering Contradiction:

ImprovemanipulabilityVSAvoidadhesion

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mold acts as an intermediary tool that enables shaping of the polymer after it has been applied to the substrate. This intermediary device allows complex shape formation without requiring the polymer itself to have high viscosity for manipulability.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Shape

If conventional processes with volatile solvents are used for forming polymers, then complex geometries can be achieved, but unsafe work environments are created

Engineering Contradiction:

Improvecomplex geometryVSAvoidwork environment safety

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

Volatile solvents are completely extracted from the process. The new method achieves complex geometry formation without relying on solvents, eliminating the safety hazards associated with volatile chemical exposure while maintaining the ability to form complex shapes.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enables rapid formation of cured polymers with improved adhesion to substrates and reduced manufacturing time, avoiding the use of hazardous chemicals and volatile solvents, while allowing for the use of lower viscosity curable polymers.

Implementation Method 1

the mold comprising a soluble material... eliminating the use of volatile solvents by dissolving the mold after curing

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentUS10099403B2Soluble manufacturing aid

Publication Date: 2018.10.16 THE BOEING CO

AI summary

Provided is a method of forming a shaped structure. The method includes coupling a first section of a mold to a second section of the mold such that a mold cavity is defined, wherein a cross-sectional shape of the mold cavity corresponds to a cross-sectional shape of the shaped structure and wherein at least one of the first section of the mold and the second section of the mold comprise a soluble material; at least partially filling the mold cavity with a curable polymer; and curing the curable polymer in the mold cavity to make the shaped structure.