Packaging and de-packaging methods using shape memory polymers

Abstract

Packaging and de-packaging methods using shape memory polymers are disclosed herein. An embodiment of the packaging method involves placing a part adjacent to shape memory polymer in its permanent shape, heating the shape memory polymer to a temperature above its switching temperature, and applying a force to the heated shape memory polymer such that the polymer switches from its permanent shape into a temporary shape. The temporary shape of the shape memory polymer conforms to at least one of i) a shape of the part, or ii) a desired shape for packaging the part. The method further includes cooling the shape memory polymer to a temperature below its switching temperature to set the temporary shape.

1 . A packaging method, comprising:
 placing a part adjacent to a shape memory polymer in its permanent shape;   heating the shape memory polymer in the permanent shape to a temperature above the switching temperature of the shape memory polymer;   applying a force to the heated shape memory polymer such that it conforms to at least one of i) a shape of the part, or ii) a desired shape for packaging the part, thereby changing the shape memory polymer from the permanent shape into the temporary shape; and   cooling the shape memory polymer to a temperature below the switching temperature to set the shape memory polymer into the temporary shape.   
     
     
         2 . The method as defined in  claim 1 , further comprising de-packaging the part by:
 heating the shape memory polymer to a temperature above the switching temperature, thereby reverting the shape memory polymer from the temporary shape into a permanent shape, and releasing the part; and   removing the part from the shape memory polymer in the permanent shape.   
     
     
         3 . The method as defined in  claim 2  wherein the shape memory polymer is integrated with a non-shape memory material such that the shape memory polymer in the temporary shape and the non-shape memory material together conform to the part shape, and wherein the non-shape memory material is separable from the part when the shape memory polymer is reverted from the temporary shape into the permanent shape. 
     
     
         4 . The method as defined in  claim 1  wherein the applying of the force is accomplished by pressurizing the shape memory polymer, vacuum forming the shape memory polymer around the part, or combinations thereof. 
     
     
         5 . The method as defined in  claim 1  wherein the permanent shape is more open than the temporary shape. 
     
     
         6 . The method as defined in  claim 1  wherein the switching temperature ranges from freezing temperature up to about 100° C. 
     
     
         7 . The method as defined in  claim 1  wherein the switching temperature is at least one of: i) below a lowest melting temperature of the part, or ii) below a degradation temperature of the part, or iii) below a melting temperature of a component of the part having a lowest melting temperature of all components of the part, or iv) below a degradation temperature of a component of the part having a lowest degradation temperature of all components of the part. 
     
     
         8 . The method as defined in  claim 1 , further comprising:
 thermoforming a non-shape memory material to conform to a first portion of the part; and   wherein the applying of the force to the heated shape memory polymer is accomplished such that the polymer conforms to a second portion of the part.   
     
     
         9 . The method as defined in  claim 1  wherein the shape memory polymer is integrated with a non-shape memory material such that shape memory polymers are present at each opposed end of the non-shape memory material, and wherein the method further comprises:
 deforming an other separate non-shape memory material to conform to a first portion of the part;   deforming the non-shape memory material that is integrated with the shape memory polymers such that the non-shape memory material conforms to a second portion of the part; and   wherein the applying of the force to the heated shape memory polymers is accomplished such that each forms a crimp at the opposed end of the other separate non-shape memory material.   
     
     
         10 . A de-packaging method, comprising:
 providing a part at least partially surrounded by a shape memory polymer in its temporary shape;   heating the shape memory polymer to a temperature above a switching temperature of the shape memory polymer, thereby reverting the shape memory polymer from the temporary shape into a permanent shape and releasing the part; and   removing the part from the shape memory polymer in the permanent shape.   
     
     
         11 . The method as defined in  claim 10  wherein the shape memory polymer is integrated with a non-shape memory material such that the shape memory polymer in the temporary shape and the non-shape memory material together conform to the part shape, and wherein the non-shape memory material renders the part separable therefrom when the shape memory polymer is reverted from the temporary shape into the permanent shape. 
     
     
         12 . The method as defined in  claim 10  wherein the reverting of the shape memory polymer from its temporary shape into its permanent shape opens up the shape memory polymer surrounding the part, thereby enabling the removing of the part. 
     
     
         13 . The method as defined in  claim 10  wherein the switching temperature ranges from freezing temperature up to about 100° C. 
     
     
         14 . The method as defined in  claim 10  wherein the switching temperature is at least one of: i) below a lowest melting temperature of the part, or ii) below a degradation temperature of the part, or iii) below a melting temperature of a component of the part having a lowest melting temperature of all components of the par, or iv) below a degradation temperature of a component of the part having a lowest degradation temperature of all components of the part. 
     
     
         15 . A packaging method, comprising:
 heating a shape memory polymer in its permanent shape above its switching temperature, the permanent shape corresponding to a predetermined part shape;   applying a force to the heated shape memory polymer such that it changes from the permanent shape into a temporary shape, the temporary shape being more open than the permanent shape;   cooling the shape memory polymer in its temporary shape to set the temporary shape;   placing a part at a predetermined position adjacent to the shape memory polymer in its temporary shape;   heating the shape memory polymer above its switching temperature, thereby causing the shape memory polymer to spontaneously revert to its permanent shape and surround the part; and   cooling the shape memory polymer to a temperature below the switching temperature to set the shape memory polymer into the permanent shape.   
     
     
         16 . The method as defined in  claim 15 , further comprising de-packaging the part by:
 heating the shape memory polymer to a temperature above the switching temperature;   applying a force to the heated shape memory polymer such that it changes from the permanent shape into the temporary shape; and   removing the part from the shape memory polymer in the temporary shape.   
     
     
         17 . The method as defined in  claim 15  wherein the switching temperature is at least one of: i) below a lowest melting temperature of the part, or ii) below a degradation temperature of the part, or iii) below a melting temperature of a component of the part having a lowest melting temperature of all components of the part, or iv) below a degradation temperature of a component of the part having a lowest degradation temperature of all components of the part.