Filler-Resin Composite Distal End Exposure Method
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Solution Overview
Problem
Existing methods for producing filler-resin composites, such as those involving vertically-aligned carbon nanotubes and thermoplastic resin films, face challenges in controlling the exposure of the distal end of the carbon nanotube group, leading to damage and shortening of the nanotube length when the resin film is removed.
Innovation Solution
A method involving the preparation of a filler assembly, where at least one end is impregnated with a first polymer soluble in liquid to form a first polymer layer, and the rest with a second polymer insoluble in liquid to form a second polymer layer, allowing the first polymer layer to be dissolved and removed, thereby exposing the distal end of the filler assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the distal end portion of the carbon nanotube group is embedded or penetrated in the thermoplastic resin film, then the carbon nanotube group can be transferred to the resin film, but the distal end of the carbon nanotube group may be ripped off when the resin film is removed, shortening the length of the carbon nanotube group
Solution Approach 1:
The resin film is divided into two distinct layers: a first polymer layer (soluble in liquid) and a second polymer layer (insoluble in liquid). The carbon nanotube group is embedded in the first polymer layer, which can be selectively removed using the liquid solvent, thereby releasing the carbon nanotube group with its distal end intact while maintaining integration during the embedding process.
Solution Approach 2:
The first polymer layer acts as an intermediary that facilitates the embedding of the carbon nanotube group into the resin film. This intermediary layer can be selectively dissolved by the liquid solvent, serving as a temporary bonding medium that is removed to release the final product with intact carbon nanotubes.
2Ease of manufacture
If the distal end portion of the carbon nanotube group is embedded or penetrated in the thermoplastic resin film, then the composite material can be formed, but the exposure of the distal end of the carbon nanotube cannot be controlled when the resin film is removed
Solution Approach 1:
The resin film is segmented into two layers with different chemical properties. The first polymer layer (soluble) controls the embedding and release process, while the second polymer layer (insoluble) remains as the final matrix. By controlling the thickness and solubility of the first layer, the exposure of the carbon nanotube distal end can be precisely controlled after liquid treatment.
Solution Approach 2:
The solubility parameter of the resin film is changed by using a two-layer structure where the first polymer layer is soluble in the liquid solvent. By adjusting the thickness and solubility characteristics of the first layer, the degree of carbon nanotube exposure can be controlled through chemical dissolution rather than mechanical removal.
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 method allows for easy exposure and control of the distal end of the filler assembly, preventing damage and ensuring the integrity of the carbon nanotube length, while maintaining the reinforcement provided by the second polymer layer.
Implementation Method 1
dissolving the first polymer layer impregnated at at least an end in the thickness direction of the filler assembly in the liquid to remove the first polymer layer
Data Source
AI summary
The present invention includes a method for producing a filler-resin composite including (a) preparing a filler assembly in which a plurality of fillers are assembled, (b) impregnating at least one end in the thickness direction of the filler assembly with a first polymer soluble in liquid to produce a first polymer layer, (c) impregnating a portion of the filler assembly other than the one end in the thickness direction with a second polymer insoluble to the liquid to produce a second polymer layer, and (d) dissolving the first polymer layer impregnated at at least an end in the thickness direction of the filler assembly in the liquid to remove the first polymer layer.