Electrospun Polyethersulfone Fiber for Fine Microfiltration
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Solution Overview
Problem
Conventional polytetrafluoroethylene (PTFE) microfiltration membranes used in semiconductor production are expensive and difficult to produce into fine fibers, limiting their ability to trap fine particles effectively.
Innovation Solution
A method of producing polyethersulfone fibers with small diameters using electrostatic spinning, where a solution of polyethersulfone and solvent is discharged and drawn by electrical attraction in an electric field, forming thin, fine fibers suitable for microfiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTFE is used for microfiltration membranes, then chemical resistance and filtration performance are improved, but production cost increases
Solution Approach 1:
The patent replaces expensive PTFE with polyethersulfone, a more inexpensive polymer material that can be processed into fine fibers. This substitution maintains the necessary filtration performance while significantly reducing production costs, making the filter economically viable for semiconductor production applications.
Solution Approach 2:
The patent changes the material parameter from PTFE to polyethersulfone and optimizes the fiber diameter parameter to 0.01-5 μm through electrostatic spinning process control. This parameter optimization allows the cheaper material to achieve performance comparable to or exceeding PTFE membranes.
2Ease of manufacture
If polyethersulfone is used instead of PTFE, then production cost is reduced, but fiber diameter becomes larger
Solution Approach 1:
The patent replaces conventional mechanical spinning methods with electrostatic spinning technology. This substitution enables precise control over fiber formation through electrical fields, achieving ultra-fine fiber diameters of 0.01-5 μm that are difficult to obtain through traditional mechanical processes, thereby overcoming the limitation of larger fiber diameters with polyethersulfone.
Solution Approach 2:
The patent optimizes multiple process parameters including polymer solution concentration (3-30% by weight), electrostatic field strength (5-50 kV), and spinning distance (5-20 cm) to control fiber diameter. By systematically adjusting these parameters, the patent achieves the target fiber diameter range of 0.01-5 μm, resolving the issue of excessively large fiber diameters when using polyethersulfone.
3Device complexity
If conventional spinning methods are used for polyethersulfone, then production process is simple, but fiber diameter is too large for effective fine particle trapping
Solution Approach 1:
The patent replaces conventional mechanical spinning systems with an electrostatic spinning system that uses high-voltage electrical fields (5-50 kV) to control polymer jet formation and fiber deposition. This substitution provides precise control over fiber diameter and morphology, achieving 0.01-5 μm fiber sizes necessary for effective fine particle trapping in semiconductor filtration applications.
Solution Approach 2:
The patent introduces and optimizes electrical parameters (voltage 5-50 kV, distance 5-20 cm) and solution parameters (concentration 3-30%, viscosity 0.4-0.7 dL/g) to control fiber formation. This multi-parameter optimization enables precise control of fiber diameter within the 0.01-5 μm range, achieving the manufacturing precision required for fine particle filtration while maintaining process feasibility.
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 resulting polyethersulfone fibers have a small diameter and high glass transition temperature, providing excellent filtration properties and heat resistance, making them suitable for semiconductor production and other microfiltration applications.
Implementation Method 1
drawing the charged solution by electrical attraction in an electrical field generated between the solution and an electrically charged collecting means having the opposite charge of the solution
Implementation Method 2
evaporating at least a portion of the solvent to form a polyethersulfone fiber
Data Source
AI summary
The present invention provides a method for producing a polyethersulfone fiber, the method comprising the steps of discharging an electrically charged solution comprising a polyethersulfone and a solvent from a container; and drawing the charged solution by electrical attraction in an electrical field generated between the solution and an electrically charged collecting means having the opposite charge of the solution, while evaporating at least a portion of the solvent to form a polyethersulfone fiber. The fiber obtained in the present invention has a small average fiber diameter and can be made into a thin fiber cloth.