Thermoplastic Soft Robot Fabrication via Thermal Bonding
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Solution Overview
Problem
The existing manufacturing processes for soft robotics are batch-based and time-consuming due to the curing of plastic materials, limiting throughput and efficiency.
Innovation Solution
A scalable method using thermoplastic resins for fabricating soft robots through thermal bonding of extensible and inextensible thermoplastic layers, with a pneumatic network configured for pressurization, allowing for faster production and continuous manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molding is used to make soft robotic actuators, then the device structure is integrated and complete, but the manufacturing throughput is low due to batch processing and curing time
Solution Approach 1:
The soft robotic actuator is divided into multiple thermoplastic layers that can be manufactured separately and then thermally bonded together. This segmentation allows each layer to be produced independently in a continuous process, eliminating the batch curing limitation while maintaining the integrated structure through thermal bonding.
Solution Approach 2:
The patent changes the material parameter from curing plastics to thermoplastic resins. Thermoplastics can be melted and bonded through heating and cooling cycles without requiring chemical curing, enabling continuous manufacturing processes while maintaining structural integrity through controlled thermal bonding parameters.
2Ease of manufacture
If batch processing with curing is used, then complete device fabrication is achieved, but the manufacturing time is lengthy and process efficiency is reduced
Solution Approach 1:
The manufacturing process transitions from batch processing to continuous production. Multiple thermoplastic layers are continuously fed, heated, bonded, and cooled in an uninterrupted sequence, eliminating idle curing time and maintaining continuous useful action throughout the manufacturing process.
Solution Approach 2:
The chemical curing process is replaced with a thermal bonding process. Instead of relying on chemical reactions that require extended curing time, the patent uses controlled heating and cooling to melt and bond thermoplastic layers, significantly reducing manufacturing time while achieving complete device fabrication.
3Productivity
If thermoplastic layers are thermally bonded, then high throughput continuous manufacturing is enabled, but the bonding process requires precise temperature and pressure control
Solution Approach 1:
The thermal bonding process serves multiple functions simultaneously: it melts the thermoplastic material, bonds the layers together, and seals the pneumatic network. This multi-functionality reduces the need for separate processing steps and simplifies overall process control despite the precision requirements.
Solution Approach 2:
The patent optimizes thermoplastic material selection and bonding parameters to achieve effective bonding within controlled temperature and pressure ranges. By selecting thermoplastics with appropriate melting points and bonding characteristics, the process maintains high throughput while managing the complexity of temperature and pressure control.
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 low-cost, high-throughput production of soft robotics by eliminating the need for lengthy curing times and allowing for rapid assembly of complex shapes and functionalities, such as quadrupedal designs and actuatable devices.
Implementation Method 1
The first and second thermoplastic layers are thermally bonded to each other
Implementation Method 2
pressurizing the pneumatic network to cause the extensible layer to expand and soft device to move
Data Source
AI summary
A soft robot device includes at least a first thermoplastic layer and a second thermoplastic layer, wherein at least one layer is comprised of an extensible thermoplastic material; at least one layer is an inextensible layer; and at least one layer comprises a pneumatic network, wherein the pneumatic network is configured to be in fluidic contact with a pressurizing source, wherein the first and second thermoplastic layers are thermally bonded to each other.