Develop a Polyurethane Spray Coating Solution to produce a component of an arterial catheter for coronary applications.
The customer is a Fortune 500 company, and a major producer of coronary catheters. Their R&D group had developed a new catheter tip component that was formed via spray coating onto a mandrel. The critical issue for the customer was they were unsuccessful in developing a spray forming solution that was stable; the polymer would precipitate in a very short time yielding the process impractical.
Bay Materials developed a solvent system that maintains polyurethane in solution, and worked with the client to optimize the polymer properties for the application. We further completed a formal development including documentation that met the requirements of their stringent quality system.
Upon completion of the development, the customer needed a “small volume” source, so Bay Materials agreed to produce the spray-forming solution. This required a Quality System Audit that met the highest quality standards for invasive medical devices. “Bay Materials passed with pride.”
Develop a compound with exceptional heat transfer properties that can wet and flow into a matrix of carbon nano-tubes that are grown off a substrate.
The customer was a Silicon Valley Start Up addressing the issue of efficiently pulling thermal energy out of computer chips. Carbon nano-tubes have exceptional heat transfer properties, but to be effective in a heat transfer application, they must be wet by a heat transfer medium; and make good contact to the heat source and heat sink.
Bay Materials performed a materials screening to identify candidate materials that could be effective as a heat transfer medium that was also able wet and flow into a nano-tube matrix in a melt condition. Test methods were developed to screen candidate materials. Screening was completed and a few top candidates were selected for development. A matrix of formulations were produced and tried until a final candidate was selected.
The outcome of the project was a material formulation, a process for application, quality documentation, and related intellectual property were handed off to the customer.
Develop a sensor that can measure a property of saliva (Saliva Osmolality) that is a bio-marker for the state of Human Hydration.
The US Army recognized some leading physiology research that identified an association between saliva osmolality and human hydration. They initiated a Small Business Innovation Program to unlock practical approaches to measuring saliva osmolality in soldiers. Bay Materials conceptualized and proposed the use of a “sensing polymer” in combination with a MEMS Microcantilever, a base technology that was invented at Northern Arizona University by Tim Porter, PhD, and Michael Eastman, PhD. The development had two needs to prove the concept; we needed a polymer that would swell reversibly as a function of saliva osmolality, and a piezo-resistive microcantilever to measure volume changes of the polymer.
Hydrogel Polymers that are available commercially were screened and showed promise, but none could meet all the requirements. Dr. Stewart formulated a sensing polymer at the Bay Materials Facility that did meet all the requirements. In parallel, Jim Reed worked with Alisa Fitzgerald, Fitzgerald Associates, to develop a micro-cantilever MEMS die that met all the requirements of a sensor that would eventually reside in the oral cavity. After a few MEMS development cycles at Stanford Fab Lab, we eventually worked with a commercial MEMS Foundry to produce micro-cantilever MEMS die on 6” wafers (commercial scale). We did succeed at demonstrating “proof-of-concept” and went on to develop a hand held instrument.
Recognizing that a Medical Device Human Hydration Sensor did not fit the Bay Materials Business Model, Cantimer Incorporated was founded to commercialize the technology. (see “Cantimer.com”)
Our client is a leading aligner therapy company with an idea for a revolutionary orthodontic aligner material that has superior stress retention, chemical resistance and optical clarity properties.
Working closely with the client’s scientists and clinicians, we developed a comprehensive material needs and wants profile. After finalizing the material criteria, we identified multiple candidate polymeric materials and developed manufacturing processes to speed them into clinical tests. Along with the material selection, we designed an annealing process that further improved the performance of the materials without adding regulatory burden. Simultaneously, we developed rigorous laboratory test methods to predict product performance and lifetime.
Our polymer material was used as a custom fitted aligner to sequentially move teeth over a period of time. Today, the client is the worldwide leader in aligner therapy treatment with over 2 million patients treated.
Our documentation and quality system enables us to meet industrial needs, and allows us to deliver extruded and die cut product on a monthly basis with 100% on-time and 0% reject over the last two years.
Develop a metal foil that could be heat sealed to cyclic olefin co-polymer (COC) polymers.
Commercial materials were screened and found to be unsuitable for the client’s needs. A custom heat seal layer r was developed and coated onto a thin commercial metal foil. This modified foil was suitable for application in the automatic sealing equipment used by the client. Client was delivered production information for the film along with prototype quantities of working material.
Who doesn’t love a perfectly roasted turkey? Our client was an established company with a desire to improve on a reliable temperature indicating device. An organic material was desired to replace the existing metal based trigger component for pop-up roasting timers. A significant number of variables must be taken into account to deliver an indicator for a perfectly roasted product and a safe, convenient material that will rapidly melt at the target temperature is the solution to that need.
Bay Materials has developed a range of Precision Melting Organic Compounds (PMOC) with exact melting temperatures from 70-90 C for this industry. Materials are compounded at Bay Materials and their precise temperature properties are verified with each batch through our in house analytical systems. The material is shipped to the U.S. manufacturer for incorporation in the final device.
Today the pop-up timer market has expanded from consumer turkeys and industrial cooking to a much broader range of roasted products such as pork shoulder and tri-tip. If you go to the market on any given day you’ll see some of these timers with our enabling material just waiting to pop in your oven.
|8,263,017||Temperature-switching materials having improved strength and thermal properties|
|8,083,969||Thermally-responsive materials and devices comprising such materials|
|7,875,207||Thermally-responsive materials and devices comprising such materials|
|20090306327||Method of reducing stress relaxation in polymer articles and articles formed thereby|
|20090217864||Device with visual temperature indicator (APPLICATION SOLD)|
|20090108230||Thermally-responsive materials and devices comprising such materials|
|NA||Unpublished Application Dental products|
|NA||Unpublished Application Electrochemical devices|
Bay Materials is an inventor of a multiple patents owned by client companies whom Bay Materials provides consulting services to. Bay retains some patent right in specific fields.
Bay Materials currently only files patents in selected areas. The principal of Bay Materials holds a number of additional patents that are assigned to other companies including the following:
|5382909||Method for detecting and obtaining information about changes in variables|
|5101657||Sensors for detecting and locating fluid|
|5074988||Apparatus for monitoring an electrolyte|
|5049247||Method for detecting and locating an electrolyte|
|5045163||Electrochemical method for measuring chemical species employing ion exchange material|
|5019235||Method and articles employing ion exchange Material|
|5015958||Elongate sensors comprising conductive polymers, and methods and apparatus using such sensors|
|5007989||Method and articles employing ion exchange materials|
|4990231||Corrosion protection system|
|4957612||Electrodes for use in electrochemical processes|
|4926165||Devices for detecting and obtaining information about an event|
|4830855||Temperature-controlled active agent dispenser|
|5387450||Temperature-activated adhesive assemblies|
|5254354||Food package comprised of polymer with thermally responsive permeability|
|5156911||Skin-activated temperature-sensitive adhesive assemblies|
|5129180||Temperature sensitive seed germination control|
|5120349||Microcapsule having temperature-dependent permeability profile|
|6225367||Polymeric modifying agents|
|6199318||Aqueous emulsions of crystalline polymers for coating seeds|
|6540984||Aqueous Dispersions of Crystalline Polymers and Uses|
|6492462||Side Chain Crystalline Polymer as Rehology modifier|
|718295||Selection and treatment of seeds|