Flame-Resistant Nanofiber Electrospinning With Blended and Coaxial Structures

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Solution Overview

Problem

Current fiber fabrication methods fail to efficiently produce fibers with tailored properties such as optimal textures, surface areas, and flame retardancy, limiting their effectiveness for specific applications.

Innovation Solution

A method involving electrospinning a polymer and a flame-retardant polymeric additive onto a surface, either as a single intertwined blend or coaxial composition, using controlled electrospinning conditions and apparatuses to form fibers with enhanced properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fiber fabrication methods are used, then production cost is reduced, but flame retardancy and surface area are insufficient

Engineering Contradiction:

Improveflame retardancyVSAvoidproduction complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the polymer matrix and flame-retardant additive into a single integrated electrospinning process, creating blended fibers where both components are uniformly distributed throughout the fiber structure. This merging approach achieves superior flame retardancy while maintaining manufacturing efficiency through a single-step process rather than requiring separate coating or treatment steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention creates composite nanofibers by integrating flame-retardant polymeric additives within the polymer matrix through electrospinning. The composite structure provides enhanced flame retardancy and tailored properties while the nanofiber morphology increases surface area, resolving the contradiction between performance improvement and manufacturing complexity.

Inventive Principle:

Principle #40Composite materials

2Area of stationary object

If fiber diameter is reduced to increase surface area, then flame retardancy improves, but mechanical strength decreases

Engineering Contradiction:

Improvesurface areaVSAvoidmechanical strength

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The patent incorporates flame-retardant additives within the nanofiber structure to create composite materials that maintain mechanical integrity despite reduced diameter. The integrated composite structure provides both the high surface area needed for flame retardancy and the structural reinforcement required for mechanical strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The electrospinning process creates nanofibers with localized distribution of flame-retardant additives within the polymer matrix, allowing different regions of the fiber to have optimized properties. The high surface area nanofiber structure provides flame retardancy while the polymer matrix maintains mechanical strength throughout the fiber structure.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If multiple electrospinning steps are used to create coaxial fibers, then property tailoring improves, but manufacturing complexity increases

Engineering Contradiction:

Improveproperty tailoringVSAvoidapparatus complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the polymer and flame-retardant additive into a single blended fiber matrix through one electrospinning process. This approach achieves effective property tailoring for flame retardancy without requiring multiple electrospinning steps or complex coaxial apparatus, thus improving adaptability while reducing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If flame-retardant additives are incorporated into fibers, then flame retardancy improves, but manufacturing efficiency decreases

Engineering Contradiction:

Improveflame retardancyVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines flame-retardant additives with the polymer matrix in a single electrospinning process, creating blended fibers that achieve superior flame retardancy without requiring separate processing steps. This integrated approach maintains high manufacturing efficiency while incorporating flame protection, resolving the contradiction between improved reliability and preserved productivity.

Inventive Principle:

Principle #5Merging (Combining)

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 method enables the production of fibers with smaller diameters, increased surface area, and improved flame retardancy, suitable for applications like children's clothing, personal protective gear, and lithium ion battery separators, at reduced costs and enhanced performance.

Implementation Method 1

electrospinning a polymer onto the surface; and electrospinning a flame-retardant polymeric additive onto the surface

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS20250270738A1Process for making pure, blended, and coaxial fire-resistant nanofibers

Publication Date: 2025.08.28 D J IRVIN CO LLC

AI summary

Embodiments of the present disclosure pertain to methods of making a flame-retardant fiber on a surface through (a) electrospinning a polymer onto the surface; and (b) electrospinning a flame-retardant polymeric additive onto the surface. Additional embodiments of the present disclosure pertain to flame-retardant fiber that include: (a) a polymer; and (b) a flame-retardant polymeric additive associated with the polymer.