Block Copolymer Electret via Self-Assembly and Selective Etching
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Solution Overview
Problem
Existing polymer electrets lack high porosity and polarizability, limiting their performance in applications such as acoustic devices, and have limited flexibility and moisture tolerance.
Innovation Solution
A method of manufacturing a polymer electret involving the formation of a block copolymer thin film with self-assembled nano-structures, where one block is selectively removed to create pores, and the film is charged using an electron beam or corona discharge, resulting in a polymer electret with improved porosity, polarizability, and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If mechanical stretching is used to form porous electrets from PTFE, then porosity is improved, but polarizability and elasticity deteriorate
Solution Approach 1:
The invention divides the polymer structure into block copolymer segments with distinct phases (crystalline and amorphous blocks), where each block serves different functions. The crystalline blocks provide structural integrity and polarizability, while the amorphous blocks create porous structures, thus resolving the contradiction between porosity and polarizability through structural segmentation.
Solution Approach 2:
The invention uses block copolymer composite structures combining different polymer blocks with complementary properties. The crystalline blocks contribute to polarizability and elasticity, while the amorphous blocks provide porosity, creating a composite material that simultaneously achieves high porosity and maintained polarizability.
2Quantity of substance
If mechanical stretching is used to form porous electrets, then porosity is improved, but moisture tolerance deteriorates
Solution Approach 1:
The invention applies local quality by creating distinct regions within the electret structure: hydrophobic crystalline blocks that resist moisture penetration and amorphous blocks that provide porosity. This localized differentiation allows the material to simultaneously achieve high porosity while maintaining moisture tolerance through the protective crystalline regions.
3Ease of manufacture
If conventional polymer materials are used, then ease of manufacture is maintained, but polarizability and elasticity are limited
Solution Approach 1:
The invention changes the fundamental parameter of polymer structure from conventional homopolymers to block copolymers with controlled microphase separation. This parameter change enables simultaneous achievement of high polarizability, elasticity, and porosity while maintaining compatibility with existing manufacturing processes through appropriate processing conditions.
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
The approach enhances the porosity and polarizability of polymer electrets, allowing for improved performance in acoustic devices and increased moisture tolerance, while enabling the creation of electrets with varied properties through blending or polymerizing with elastomers.
Implementation Method 1
forming a nano-structure of the BCP in which a first block formed by first polymer chains that self-assemble together and a second block formed by second polymer chains that self-assemble together are micro-phase-separated
Implementation Method 2
a first block formed by first polymer chains that self-assemble together and a second block formed by second polymer chains that self-assemble together are micro-phase-separated
Implementation Method 3
by performing an annealing process on the polymer thin film
Implementation Method 4
The charging the polymer thin film may include injecting positive charge or negative charge into the polymer thin film with the use of an electron beam, corona discharge, an ion gun or an electron beam
Implementation Method 5
The charging the polymer thin film may include injecting positive charge or negative charge into the polymer thin film with the use of an electron beam, corona discharge, an ion gun or an electron beam
Data Source
AI summary
Provided is a method of manufacturing a polymer electret. The method of manufacturing a polymer electrets includes forming a polymer thin film, which includes a block copolymer (BCP) having two or more polymer chains covalently bonded together; forming a nano-structure of the BCP in which a first block formed by first polymer chains that self-assemble together and a second block formed by second polymer chains that self-assemble together are micro-phase-separated, by performing an annealing process on the polymer thin film; forming a porous polymer film with a nano-pore by selectively removing one of the first block and the second block; and charging the porous polymer film.