Electrospun Microconduit Networks With Low Porosity and High Interconnectivity

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Solution Overview

Problem

Current methods fail to efficiently produce microconduit networks with low porosity and high interconnectivity, which are essential for maintaining mechanical strength while enabling rapid fluid transport, as existing technologies either lack interconnection, result in non-optimal mechanical properties, or are unsuitable for high-speed mass production.

Innovation Solution

The process involves electrospinning polymer solutions into a fibrous web with branching connections, encapsulating the web in a matrix precursor, and then removing the polymer filaments to create an interconnected network of microconduits within a solid matrix, achieving a low porosity fraction while maintaining high interconnectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If conventional templating methods are used to create interconnected pore networks, then fluid transport capability is improved, but porosity increases and mechanical strength decreases

Engineering Contradiction:

Improvefluid transport capabilityVSAvoidmechanical strength

Core Design Contradiction:

SpeedVSStrength

Solution Approach 1:

The invention divides the continuous pore network into discrete microconduits formed by electrospun fiber templates. Each fiber becomes a discrete template that defines a specific conduit pathway, allowing for segmented yet interconnected fluid transport channels that maintain structural integrity better than continuous porous networks

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the porosity parameter by using electrospun fibers with controlled diameter and spacing to create microconduits that occupy minimal volume (low porosity) while maintaining connectivity. The fiber diameter, spacing, and orientation are controlled parameters that enable low porosity (below 20%) while preserving fluid transport capability through the interconnected conduit network

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high porosity is achieved to enable rapid fluid transport, then transport efficiency is improved, but mechanical properties deteriorate

Engineering Contradiction:

Improvetransport efficiencyVSAvoidmechanical properties

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention uses electrospun fiber mats as temporary porous templates that are subsequently removed. The fibers themselves form a porous-like interconnected structure during templating, but the final product has minimal porosity since the template voids are minimized while maintaining connectivity. The electrospun fibers create a scaffold that enables efficient transport pathways without requiring high overall porosity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention transitions from traditional three-dimensional porous networks to a more organized structure where fluid transport occurs through defined one-dimensional microconduit pathways. The electrospun fibers create linear conduit templates that guide fluid flow along specific paths, enabling efficient transport without the need for extensive three-dimensional porosity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If electrospun fiber templates are used to create microconduit networks, then mechanical strength is maintained through low porosity, but interconnectivity and fluid transport capability must be ensured

Engineering Contradiction:

Improvemechanical strengthVSAvoidinterconnectivity requirement

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The electrospun fiber mat serves multiple functions simultaneously: it provides mechanical support during processing, defines the microconduit pathways through its fiber network, ensures interconnectivity through the web-like structure of electrospun fibers, and acts as a removable template. This multi-functionality resolves the contradiction by using a single material system to address both structural and transport requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 allows for the efficient transport of functional molecules and nanostructures within the structure, enhancing mechanical properties and enabling adaptive functionality, while avoiding the trade-off between transport efficiency and mechanical strength found in other methods.

Implementation Method 1

electrospinning techniques... drawn within an electrostatic field obtaining fine fibers

Methodology Applied

Scientific EffectElectrostatic field: Electric Field

Implementation Method 2

The resulting composite is then vacuum extracted with a solvent for the polymer to dissolve the filaments and remove them from the encapsulant, leaving a network of interconnected microconduits

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS8354052B1Process for manufacturing microconduit networks formed by electrospinning techniques

Publication Date: 2013.01.15 THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY

AI summary

A microconduit network structure and methods for making the same. One aspect of the invention relates to a microconduit network structure, including: a solid or semi-solid matrix having at least one interconnected web of filaments formed within the matrix; and wherein at least one interconnected web of filaments having diameters of about 10 nm to about 1 mm.