Highly Branched Non-Crosslinked Polyimide Aerogels for Recycling

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Solution Overview

Problem

Conventional cross-linked polyimide aerogels face challenges in manufacturability and recyclability, making them difficult to produce commercially and limiting their application in large-scale manufacturing and dynamic conditions.

Innovation Solution

Aerogels with a highly branched polyimide matrix and minimal cross-linking are developed, incorporating a large amount of multifunctional monomers to enhance manufacturability and recyclability, using a novel production method that avoids simultaneous cross-linking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cross-linked polyimide aerogels are used to improve thermal properties and mechanical strength, then reliability is improved, but ease of manufacture and recyclability deteriorate

Engineering Contradiction:

Improvethermal properties and mechanical strengthVSAvoidmanufacturability and recyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the polyimide structure into modular units by using diamine and dianhydride monomers that form repeat units with controlled branching. This segmentation allows the polymer to achieve desired mechanical properties through hierarchical structure rather than extensive crosslinking, improving manufacturability while maintaining reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the crosslinking parameter from high to low by controlling the ratio and functionality of monomers used. Specifically, it uses a combination of diamine and dianhydride with controlled functionality to achieve low crosslink density, which dramatically improves ease of manufacture and recyclability while maintaining adequate thermal and mechanical properties through alternative structural design

Inventive Principle:

Principle #35Parameter changes

2Strength

If cross-linking is increased to improve mechanical properties, then strength is improved, but device complexity and difficulty of reprocessing increase

Engineering Contradiction:

Improvemechanical propertiesVSAvoidcomplexity of crosslinked network

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent incorporates branching functionality directly into the monomer structure before polymerization, rather than attempting to crosslink after polymer formation. This preliminary incorporation of branching units simplifies the overall process and reduces the complexity of achieving the desired three-dimensional network structure

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a dynamic balance in the polymer structure by controlling the functionality distribution among monomers. The use of diamine and dianhydride with specific functionality ratios creates a controlled branching architecture that achieves mechanical strength without the rigidity and complexity of highly crosslinked networks

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12404382B2Highly branched non-crosslinked aerogel, methods of making, and uses thereof

Publication Date: 2025.09.02 BLUESHIFT MATERIALS INC

AI summary

An aerogel that includes an open-cell structure and a polymer matrix is disclosed. The polymer matrix can include a branched polyimide polymer having a degree of branching of at least 0.5. The polymer matrix can contain less than 5% by weight of crosslinked polymers.