Multimaterial Fiber Fabrication via Thermal Drawing

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Solution Overview

Problem

The high cost and difficulty in controlling the concentration, orientation, and composition of multimaterial fibers, particularly in thermal drawing processes, result in fibers with limited physical, chemical, and mechanical properties, making them expensive and less useful for applications like additive manufacturing.

Innovation Solution

A method involving the combination of low dimensional materials with thermoplastic materials to form a composite, which is then aligned and drawn into fibers using a thermal drawing process, where the composite is preformed with a defined structure to enhance control and alignment, utilizing materials like metal nanoparticles, semiconductor nanoparticles, or carbon nanoparticles with thermoplastics such as ABS or PLA.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional thermal drawing processes are used to form multimaterial fibers, then fiber production is achieved, but the cost is high and control over concentration, orientation, and composition is difficult

Engineering Contradiction:

Improvecontrol over concentration, orientation, and compositionVSAvoiddifficulty in controlling fiber properties

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming the composite material with a defined structure before the thermal drawing process. This pre-structuring allows the concentration, orientation, and composition of materials to be controlled in advance, making the subsequent drawing process more predictable and controllable, thereby resolving the difficulty in controlling fiber properties during traditional thermal drawing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by modifying the physical state of the composite material through heating during thermal drawing. By controlling temperature parameters and drawing conditions, the patent achieves precise control over the final fiber properties including concentration, orientation, and composition, while maintaining ease of manufacture through a standardized process

Inventive Principle:

Principle #35Parameter changes

2Productivity

If traditional thermal drawing processes are used to form multimaterial fibers, then fiber production is achieved, but the production cost is prohibitively high

Engineering Contradiction:

Improvefiber production efficiencyVSAvoidproduction cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent employs composite materials by combining low dimensional materials with thermoplastic materials to form a composite that can be processed through thermal drawing. This composite approach allows for cost-effective production while maintaining high productivity, as the thermoplastic matrix provides structural integrity and the low dimensional materials add functional properties, enabling scalable fiber production at lower costs

Inventive Principle:

Principle #40Composite materials

3Reliability

If traditional thermal drawing processes are used to form multimaterial fibers, then fibers are produced, but the physical, chemical, and mechanical properties are limited

Engineering Contradiction:

Improvephysical, chemical, and mechanical propertiesVSAvoidfunctionality of produced fibers

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent uses composite materials combining low dimensional materials (such as nanoparticles or nanofibers) with thermoplastic materials to create multimaterial fibers with enhanced and tunable properties. The low dimensional materials provide improved physical, chemical, and mechanical properties, while the thermoplastic matrix ensures processability and structural integrity, thereby increasing both reliability and adaptability of the produced fibers for various applications

Inventive Principle:

Principle #40Composite materials

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 produces fibers with improved physical, chemical, and mechanical properties, enabling better control over the composition and alignment, making them suitable for additive manufacturing and other applications with enhanced performance.

Implementation Method 1

heating the low dimensional material and thermoplastic composite to soften the composite

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a force is applied on one end of the composite to pull the end in a direction away from an opposing end of the composite, thereby lengthening the composite to form a fiber

Methodology Applied

Scientific EffectTensile force: Tension

Data Source

PatentUS11390028B1Method of fabricating multimaterial fibers from low dimensional materials

Publication Date: 2022.07.19 FLORIDA A&M UNIVERSITY

AI summary

Methods of forming multimaterial fibers via a thermal drawing process used to produce fibers with controlled compositions and alignments. The multimaterial fibers are usable as feedstock for additive manufacturing printing, as well as other applications that require elongated fibers with improved physical characteristics. The multimaterial fibers are formed from a mixture of low dimensional materials (LDM's), such as metal nanoparticles, and thermoplastic matrices. During fabrication of the fibers, a composite of LDM's and thermoplastics is heated and experiences a pulling force on one end in a direction away from an opposing end, thereby drawing the composite into an elongated fiber. The fiber includes a set of physical properties determined by the LDM's, and is usable as a filament across various applications.