Synthetic Metal System Cellular Frame Polymeric Matrix

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Solution Overview

Problem

Traditional metal components face issues such as corrosion, metal-on-metal wear, allergic reactions, and environmental hazards, with existing corrosion control methods providing no structural benefits and being costly or environmentally harmful.

Innovation Solution

A synthetic metal system comprising a frame member with a cellular structure and a polymeric matrix material, allowing for tailored properties and reduced reliance on traditional metals, with the matrix material penetrating the frame member to encase it and provide enhanced conductivity, strength, and corrosion control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metal components are used, then strength and rigidity are provided, but corrosion and metal-on-metal wear occur

Engineering Contradiction:

Improvestructural strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies composite materials by combining a metal frame member with a polymeric matrix material to create a synthetic metal system. The metal frame provides strength and rigidity, while the polymeric matrix provides corrosion resistance and eliminates metal-on-metal wear. This composite structure resolves the contradiction by integrating the advantages of both materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by having the polymeric matrix material selectively penetrate and encase specific portions of the metal frame member. The matrix material fills the cellular structure and encases the metal framework, providing localized corrosion protection where needed while maintaining the metal's structural integrity in load-bearing regions.

Inventive Principle:

Principle #3Local quality

2Reliability

If galvanic anodes are used for corrosion control, then corrosion protection is provided, but no structural benefit is gained

Engineering Contradiction:

Improvecorrosion protectionVSAvoidstructural benefit

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges corrosion protection functionality with structural support by integrating the polymeric matrix material into the metal frame's cellular structure. Unlike separate galvanic anodes, the matrix material is structurally incorporated, providing both corrosion protection and contributing to the overall structural integrity of the component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The synthetic metal system creates a composite structure where the polymeric matrix and metal frame work together to provide both corrosion resistance and structural strength simultaneously, eliminating the need for separate corrosion control measures that provide no structural benefit.

Inventive Principle:

Principle #40Composite materials

3Speed

If metal is used for projectiles to retain velocity, then velocity retention is improved, but metal-on-metal wear and environmental pollution occur

Engineering Contradiction:

Improvevelocity retentionVSAvoidmetal particles and environmental pollution

Core Design Contradiction:

SpeedVSObject-generated harmful factors

Solution Approach 1:

The patent applies composite materials in projectile design by combining a metal frame member with a polymeric matrix. The metal frame maintains velocity retention properties, while the polymeric matrix eliminates metal-on-metal wear and prevents metal particle contamination, resolving the contradiction between performance and environmental harm.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent converts the harmful effect of metal-on-metal wear into a benefit by using the polymeric matrix to eliminate wear particles. The matrix material provides a non-wearing surface that maintains velocity retention while preventing the generation of harmful metal particles and environmental pollution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Strength

If titanium implants are used, then biocompatibility and strength are provided, but metal hypersensitivity reactions may occur

Engineering Contradiction:

Improveimplant strengthVSAvoidmetal hypersensitivity reactions

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials in implant design by combining a titanium frame member with a polymeric matrix material. The titanium frame provides biocompatibility and structural strength, while the polymeric matrix eliminates metal hypersensitivity reactions by preventing direct contact between metal and biological tissues.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by having the polymeric matrix material encase the titanium frame member at the interface with biological tissues. This localized encasement provides hypoallergenic properties where it is most needed (at the tissue interface) while maintaining titanium's structural advantages in load-bearing regions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20230323044A1Synthetic metal system

Publication Date: 2023.10.12 ENSEN PTY LTD

AI summary

A synthetic metal system comprising a frame member comprising a cellular structure including a plurality of openings; and a matrix material comprising a polymeric material, wherein the matrix material is configured to at least partially penetrate one or more of the plurality of openings in the frame member such that the frame member is at least partially encased within the matrix material.