Fiber Assembly Oxide Coating for Moisture-Resistant Heat Insulation

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Solution Overview

Problem

Fiber assemblies, such as glass wool, exhibit moisture adsorption due to capillary phenomena, leading to issues like condensation, mold growth, and weight increase, and existing waterproof treatments lack durability.

Innovation Solution

A fiber assembly with a coating layer containing an oxide or nitride, where the carbon content in the surface layer is higher than inside, formed by intertwining fibers and using methods like atomic layer deposition to ensure a uniform and dense film that reduces moisture absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a fiber assembly is used as a heat insulation material, then excellent heat insulation performance is achieved, but the fiber assembly easily adsorbs moisture due to capillary phenomenon

Engineering Contradiction:

Improveheat insulation performanceVSAvoidmoisture adsorption

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

A coating layer comprising an oxide film or a nitride film is formed on the surface of each fiber to create a protective barrier that prevents moisture adsorption while maintaining the fiber assembly's heat insulation performance

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The fiber assembly combines heat insulation fibers with a protective coating layer of oxide or nitride, creating a composite structure that simultaneously provides thermal insulation and moisture resistance

Inventive Principle:

Principle #40Composite materials

2Reliability

If a water-repellent treatment is performed by forming a film on fiber surface using physical vapor deposition method, then waterproof properties are improved, but the treatment lacks durability

Engineering Contradiction:

Improvewaterproof propertiesVSAvoiddurability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent changes the deposition parameters by controlling the deposition temperature to be 100°C or higher, which enables the formation of a dense film structure with improved durability while maintaining waterproof properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Oxygen is introduced during the deposition process to accelerate oxidation reactions, forming a dense oxide or nitride film structure that enhances both waterproof properties and long-term durability

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

3Reliability

If the carbon content in the coating layer is increased, then the coating layer provides better waterproof properties, but the density and adhesion may be compromised

Engineering Contradiction:

Improvewaterproof propertiesVSAvoidcoating layer density and adhesion

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by creating a coating layer with non-uniform carbon distribution, where the carbon content is controlled to be 0.1-5.0 at% to locally enhance waterproof properties while maintaining overall coating density and adhesion

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses partial action by introducing carbon only in specific amounts and locations within the coating layer, rather than uniformly throughout, achieving sufficient waterproofing without compromising structural integrity

Inventive Principle:

Principle #16Partial or excessive action

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 coating layer provides excellent waterproof properties, maintaining the fiber assembly's shape and preventing moisture adsorption for long-term use, with improved durability and resistance to water penetration.

Implementation Method 1

a coating layer that contains an oxide or a nitride covering a surface of the fiber

Methodology Applied

Scientific EffectHydrophobe: Hydrophobe

Implementation Method 2

the technique disclosed in Japanese Patent Laid-Open No. 2002-121082 discloses a technique of performing a water-repellent treatment by forming a film on a surface of a fiber with gold (Au), platinum (Pt), or yttria (Y2O3) using a physical vapor deposition method

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Implementation Method 3

the fiber assembly has a property of easily adsorbing moisture due to a capillary phenomenon

Methodology Applied

Scientific EffectCapillary Action: Capillary Action

Data Source

PatentUS20250304493A1Fiber assembly, heat insulation material, and method of producing fiber assembly

Publication Date: 2025.10.02 CANON KK

AI summary

A fiber assembly according to the present disclosure includes a fiber, and a coating layer that contains an oxide or a nitride covering a surface of the fiber, in which a carbon content in a surface layer of the coating layer is greater than a carbon content inside the coating layer, the fiber assembly is formed by intertwining of the fiber, and the inside or the surface layer of the coating layer contains a hydrocarbon group.