Polymer Nanofiber Sheet Crosslinked with Low-Molecular Weight Epoxy

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Solution Overview

Problem

Existing polymer nanofiber structural bodies have low mechanical strength and are weak against tensile forces and friction due to physical entanglement, with previous methods like heating and partial bonding or crosslinking facing challenges in controlling fiber diameter and achieving sufficient strength.

Innovation Solution

A polymer nanofiber sheet with crosslinked regions containing a low-molecular weight epoxy compound (100-3,000 molecular weight) for chemical or physical crosslinking, enhancing mechanical strength and delamination resistance while maintaining a high specific surface area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If heating treatment is applied to perform partial bonding, then mechanical strength is improved, but fiber diameter increases and specific surface area reduces

Engineering Contradiction:

Improvemechanical strengthVSAvoidspecific surface area

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The invention changes the bonding mechanism from thermal bonding (heating) to chemical bonding using a crosslinking agent. This parameter change allows achieving mechanical strength improvement without the harmful side effect of fiber diameter increase, thereby preserving specific surface area.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical/thermal bonding system with a chemical bonding system. Instead of using heat and pressure to bond fibers (mechanical system), a crosslinking agent is used to create chemical bonds between fibers, achieving the same strength improvement without compromising fiber dimensions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If crosslinking material is used to join nanofibers, then mechanical strength is improved, but sufficient strength cannot be achieved depending on the crosslinking material

Engineering Contradiction:

Improvemechanical strengthVSAvoidstrength sufficiency

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention optimizes the molecular weight parameter of the crosslinking agent, selecting compounds with molecular weights between 100 and 3,000. This parameter optimization ensures sufficient penetration into nanofibers and adequate crosslinking density, reliably achieving the required mechanical strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses low-molecular weight crosslinking agents that can effectively copy and replicate the bonding function at the nanoscale level, ensuring uniform distribution and consistent crosslinking throughout the nanofiber mat, thereby achieving reliable and sufficient strength.

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If physical entanglement is used to form nanofiber structural body, then manufacturing is simple, but mechanical strength is low and resistance to tensile force and friction is weak

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The invention introduces a crosslinking agent as an intermediary substance that mediates between the simple physical entanglement structure and the required mechanical strength. The crosslinking agent forms chemical bonds between fibers, bridging the gap between manufacturing simplicity and structural strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite structure combining physically entangled nanofibers with chemically crosslinked bonds. This composite approach maintains the manufacturing simplicity of physical entanglement while adding the strength characteristics of chemical bonding through the crosslinking agent.

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

The polymer nanofiber sheet exhibits high delamination resistance, mechanical strength, and retains a high specific surface area, making it suitable for long-term use without fiber fraying, with the crosslinked structure effectively resisting external factors like rubbing.

Implementation Method 1

at least part of the polymer nanofibers are crosslinked at a crosslinked part having crosslinking portions and a non-crosslinking portion; and the crosslinked part contains a low-molecular weight epoxy compound having a molecular weight of from 100 to 3,000

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Data Source

PatentUS10968315B2Method of producing a polymer nanofiber sheet

Publication Date: 2021.04.06 CANON KK

AI summary

Provided is a polymer nanofiber sheet having high delamination resistance, a high mechanical strength, and a high specific surface area. Specifically, provided is a polymer nanofiber sheet, including polymer nanofibers, the polymer nanofibers being laminated and three-dimensionally entangled with each other, in which: at least part of the polymer nanofibers are crosslinked at a crosslinked part having crosslinking portions and a non-crosslinking portion; and the crosslinked part contains a low-molecular weight epoxy compound having a molecular weight of from 100 to 3,000.