Electrospun Phenolic Fibers with Tunable Post-Processing

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Solution Overview

Problem

Current electroprocessing techniques primarily focus on fiber fabrication and lack methods for subsequent processing steps to create materials with enhanced or tunable characteristics for specific applications, particularly in nano- or micro-scale dimensions.

Innovation Solution

The development of electroprocessed phenolic materials, including nanofibers, microfibers, beads, and films, through electrospinning and electrospraying, followed by curing and carbonization, to produce materials with tailored properties suitable for various applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electroprocessing is used as a terminal process for fiber fabrication, then fiber production is achieved, but subsequent processing capabilities and material tunability are limited

Engineering Contradiction:

Improvematerial tunabilityVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by performing electroprocessing as a precursor step to create electroprocessed phenolic materials that retain properties suitable for subsequent processing. The electroprocessed materials are prepared in advance with controlled morphology and structure, enabling them to undergo further treatments like curing, carbonization, and activation to achieve tailored final properties for specific applications

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the material fabrication process into distinct stages: electroprocessing to create base materials, followed by separate subsequent processing steps (curing, carbonization, activation). This segmentation allows each stage to be optimized independently and enables flexible combination of processing steps to achieve desired material characteristics

Inventive Principle:

Principle #1Segmentation

2Area of stationary object

If phenolic polymeric system is electrospun to create nanofibers, then high surface area is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvesurface areaVSAvoidmanufacturing ease

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The patent replaces conventional mechanical fiber fabrication methods with electrospinning, which uses electrical fields instead of mechanical forces to draw and deposit fibers. This substitution enables precise control over fiber diameter and morphology while achieving nanoscale dimensions and high surface area, overcoming limitations of traditional mechanical approaches

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If phenolic materials are carbonized to provide carbonized phenolic materials, then material stability is improved, but processing steps increase

Engineering Contradiction:

Improvematerial stabilityVSAvoidproduction efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent applies parameter changes by controlling the carbonization temperature and atmosphere to transform phenolic materials into carbonized forms with enhanced stability. By optimizing these parameters, the patent achieves improved material stability while minimizing processing time and energy consumption, balancing stability gains with production efficiency

Inventive Principle:

Principle #35Parameter changes

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 process enables the creation of materials with high surface area and uniform pore size distribution, suitable for applications such as filtration, catalysis, and smoking articles, by tuning properties through post-processing treatments like activation.

Implementation Method 1

electroprocessing the phenolic polymeric system to create electroprocessed phenolic materials. The electroprocessing may be performed by electrospinning or electrospraying the phenolic polymeric system

Methodology Applied

Scientific EffectElectrostatics: Electrostatics

Implementation Method 2

The process preferably further comprises curing the phenolic materials

Methodology Applied

Scientific EffectCuring:

Implementation Method 3

carbonizing the cured materials to provide carbonized phenolic materials

Methodology Applied

Scientific EffectCarbonization: Pyrolysis

Implementation Method 4

The process comprises activating an electroprocessed material under activating conditions

Methodology Applied

Scientific EffectActivation:

Data Source

PatentUS8012399B2Formation of nano-or micro-scale phenolic fibers via electrospinning

Publication Date: 2011.09.06 PHILIP MORRIS USA INC

AI summary

Electroprocessed phenolic nanofibers, microfibers, beads, and films and materials including these electroprocessed materials are prepared using a delivery means (10), a grounded collecting means (20) and a power supply (30) for generating an electric field.