Conductive Fiber Sol-Gel Composition for Bending Durability

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Solution Overview

Problem

Existing methods for producing conductive fibers, such as metal coating, result in carbon layers that are easily peeled off when the fibers are bent, leading to reduced conductivity.

Innovation Solution

A sol-gel composition comprising indium tin oxide and polyethylene oxide in a specific ratio, mixed with an organic solvent like ethanol or acetone, is used in an electrospinning process to create conductive fibers with improved conductivity by forming well-connected ITO particles within the PEO polymer matrix.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If carbon coating is applied to fiber surface to provide conductivity, then conductivity is achieved, but the coating peels off easily when fiber is bent

Engineering Contradiction:

Improveconductivity stabilityVSAvoidcoating adhesion

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines the conductive material (carbon or metal oxide) with the polymer matrix into a single composite fiber structure. The conductive particles are dispersed throughout the polymer during fiber formation, creating intimate contact and strong bonding between the conductive phase and polymer phase, eliminating the peeling issue of surface coatings.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a composite fiber where conductive particles (carbon black, graphite, metal oxides) are embedded within a polymer matrix (nylon, polyester, acrylic). This composite structure provides both mechanical strength from the polymer and electrical conductivity from the dispersed conductive particles, with the particles strongly bonded to the polymer throughout the fiber cross-section.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conductive particles are dispersed in polymer matrix, then conductivity and durability are improved, but manufacturing process complexity increases

Engineering Contradiction:

Improveconductivity durabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent performs preliminary mixing of conductive particles with polymer pellets or solution before fiber formation. The conductive particles are pre-dispersed uniformly in the polymer matrix during compounding or solution preparation, ensuring homogeneous distribution is achieved before the fiber spinning process begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex post-processing coating operations with a simpler bulk mixing and extrusion process. Instead of applying coatings after fiber formation, the conductive materials are incorporated during the primary fiber manufacturing process, reducing the number of processing steps and equipment required.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method produces conductive fibers with sheet resistance close to that of metal films, maintaining conductivity even when bent, due to well-connected ITO particles within the PEO polymer matrix, enhancing their durability and performance.

Implementation Method 1

electrospinning is the technology of making polymer fibers by applying electric field to a polymer solution. The electric field charged polymer solution may be solidified after the solvent is evaporated and thereby forming fibers

Methodology Applied

Scientific EffectElectrospinning: Electrohydrodynamics