Structured Nanoporous Materials via UV Interference and Solvent Crazing
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Solution Overview
Problem
The development of structured nanoporous materials with periodically stratified structures is limited by the need for phase-separated block copolymers, which are expensive and have a narrow compositional range, and the phase separation process is inefficient.
Innovation Solution
A method involving the creation of an interference pattern within a homogeneous precursor polymeric material using electromagnetic radiation to induce differential cross-linking, followed by solvent exposure to form structured polymeric materials with pores, eliminating the need for phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If phase-separated block copolymers are used to form heterogeneous morphology, then the characteristic periodically stratified porous structure can be formed, but the material cost increases and the compositional range is restricted
Solution Approach 1:
The patent uses homogeneous polymeric materials instead of phase-separated block copolymers. The homogeneous material is subjected to UV irradiation to create a heterogeneous crosslinked structure, eliminating the need for pre-phase-separated materials while achieving the desired periodically stratified porous structure.
Solution Approach 2:
The patent applies UV irradiation as a preliminary action to create a heterogeneous crosslinked structure within the homogeneous polymer matrix before solvent exposure. This pre-established heterogeneous structure guides subsequent solvent penetration and pore formation, enabling periodic stratification without requiring phase-separated starting materials.
2Manufacturing precision
If phase separation process is used to form heterogeneous morphology, then the periodically stratified structure can be achieved, but the manufacturing efficiency decreases due to additional processing steps
Solution Approach 1:
The patent combines multiple functions into a single step: UV irradiation simultaneously creates heterogeneous crosslinked regions and establishes the periodic structure pattern. This merged approach eliminates the need for separate phase separation and crosslinking steps, improving manufacturing efficiency while maintaining structural precision.
Solution Approach 2:
The patent extracts and eliminates the phase separation step from the conventional process. By using homogeneous materials that are structurally modified by UV irradiation rather than relying on thermal phase separation, the process is simplified and manufacturing efficiency is improved while still achieving the desired periodically stratified structure.
3Reliability
If block copolymers with specific compositional range are used, then the required phase separation behavior and differential crosslinking capability are achieved, but the material selection is restricted and cost increases
Solution Approach 1:
The patent changes the key parameter from material composition (requiring specific block copolymer ratios) to structural modification (UV-induced crosslinking patterns). This parameter change allows any homogeneous polymeric material to be used, as the heterogeneous structure is created by irradiation rather than inherent material phase separation, greatly expanding material selection while ensuring reliable structure formation.
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 approach allows for the formation of similar microstructures without the need for expensive block copolymers and phase separation, enhancing manufacturing efficiency and expanding the range of materials that can be used to create structured nanoporous materials with specific microstructures.
Implementation Method 1
setting up an interference pattern of electromagnetic radiation within the body comprising precursor polymeric material to form a partially cross-linked polymeric material
Implementation Method 2
the interference pattern thereby causing spatially differential cross linking of the precursor polymeric material
Implementation Method 3
contacting the partially cross-linked polymeric material with a solvent to cause expansion and crazing of at least some of the non-crosslinked regions to form a structured polymeric material containing pores
Data Source
AI summary
A method is disclosed for manufacturing a structured polymeric material. In the method, a body is provided comprising a substantially homogenous precursor polymeric material. An interference pattern of electromagnetic radiation is set up within the body to form a partially cross-linked polymeric material, the interference pattern comprising maxima and minima of intensity of the electromagnetic radiation, the interference pattern thereby causing spatially differential cross linking of the precursor polymeric material to form crosslinked regions having relatively high cross linking density and non-crosslinked regions having relatively low cross linking density, the crosslinked regions and non-crosslinked regions corresponding to the maxima and minima of intensity of the electromagnetic radiation, respectively. The partially cross-linked polymeric material is then contacted with a solvent to cause expansion and crazing of at least some of the non-crosslinked regions to form a structured polymeric material containing pores.