Graphenic Yarns Hollow Core Structure for Low Density High Strength
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Solution Overview
Problem
Carbon fibers used in aerospace and automotive applications are heavy due to high density, leading to increased payload and propulsion requirements, and have low failure strain, making them unsuitable for many applications.
Innovation Solution
Development of graphenic yarns with bundled graphenic filaments that have lower densities (≤1.5 g/cc) and higher tensile strengths (≥0.5 GPa), offering improved strength-to-weight ratios compared to carbon fibers, achieved through electrospinning and thermal treatment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fibers are used to achieve high tensile strength, then strength is improved, but density increases leading to higher weight
Solution Approach 1:
The patent changes the material composition parameters by incorporating hollow cores and void spaces within the fiber structure, reducing density from typical carbon fiber values (1.8-2.0 g/cc) to below 1.0 g/cc while maintaining tensile strength through strategic placement of reinforcing elements and controlled wall thickness in the hollow structure
Solution Approach 2:
The patent creates a composite structure combining solid and hollow regions, where the outer shell provides structural integrity and tensile strength while the hollow interior reduces mass. This composite approach allows the fiber to achieve strength-to-weight ratios superior to both solid carbon fibers and conventional lightweight materials
2Strength
If carbon fibers are used to achieve high tensile strength, then strength is improved, but failure strain decreases making them more brittle
Solution Approach 1:
The patent divides the fiber into segmented regions including hollow cores, solid walls, and intermediate zones. This segmentation allows stress to be distributed across multiple pathways, preventing catastrophic failure and enabling progressive deformation that increases failure strain while maintaining overall tensile strength
Solution Approach 2:
The patent employs thin-walled hollow structures that provide flexibility and ductility. The thin walls can deform elastically under stress, increasing the material's ability to withstand strain before failure, thereby improving reliability without sacrificing the strength provided by the overall fiber architecture
3Weight of moving object
If preliminary attempts are made to manufacture graphene fibers with low density, then density is reduced, but tensile strength decreases significantly
Solution Approach 1:
The patent implements a nested structure where hollow cores are positioned within the fiber cross-section, and reinforcing elements are embedded within the wall structure. This nesting allows maximum material utilization where every element contributes to strength, achieving tensile strength comparable to solid fibers while maintaining low density through the hollow architecture
Solution Approach 2:
The patent transitions from two-dimensional planar graphene sheets to three-dimensional hollow fiber structures. By creating vertical walls and hollow chambers, the structure gains volumetric efficiency, providing strength in multiple directions while the hollow configuration reduces mass, effectively decoupling the strength-density relationship
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 graphenic yarns provide a lightweight alternative with enhanced strength and reduced brittleness, suitable for applications where high strength and low mass are critical, such as in aerospace and automotive industries.
Implementation Method 1
achieved through electrospinning and thermal treatment processes
Implementation Method 2
achieved through electrospinning and thermal treatment processes
Data Source
AI summary
Provided in certain embodiments are high performance graphene fibers and yarns, including components and precursors thereof, and composites comprising the same. Also provided herein are methods of manufacturing such fibers, yarns, composites, and components/precursors thereof.