Nanoporous Metal-Polymer Composite for Strength and Mass Transfer

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Solution Overview

Problem

Nanoporous metals face limitations such as poor mechanical properties, brittle nature, cumbersome production processes, and nanopore sizes that hinder commercialization and application effectiveness.

Innovation Solution

A composite material comprising a porous polymer substrate with a nanoporous metal within its micropores, featuring a hierarchical structure and unimodal, right-skewed nanopore size distribution, enhancing mechanical properties and supporting tissue integration while maintaining electrical conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If traditional nanoporous metals are used, then high metal surface area and electrical conductivity are achieved, but mechanical properties deteriorate (brittle and tear easily)

Engineering Contradiction:

Improvemetal surface areaVSAvoidmechanical properties

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The patent combines nanoporous metal with a porous polymer substrate to form a composite structure. The polymer substrate provides mechanical strength and flexibility while the nanoporous metal maintains high surface area and electrical conductivity, resolving the contradiction between mechanical properties and electrochemical performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The porous polymer substrate acts as a flexible support film that reinforces the brittle nanoporous metal. This allows the metal to be made thinner without compromising mechanical integrity, while the flexible substrate prevents tearing and handling issues.

Inventive Principle:

Principle #30Flexible shells and thin films

2Area of stationary object

If de-alloying process is used to produce nanoporous metals, then nanoporous structure with high surface area is achieved, but manufacturing complexity and waste increase

Engineering Contradiction:

Improvesurface areaVSAvoidmanufacturing process

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The patent forms a metal layer on the porous polymer substrate before creating the nanoporous structure. This preliminary deposition step allows subsequent nanopore formation through simpler processes like electrochemical etching or templating, avoiding the complex de-alloying process while maintaining high surface area.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The porous polymer substrate serves as an intermediary template that guides nanopore formation. By using the substrate's pore structure as a template, the patent avoids direct de-alloying of metal foils, simplifying the manufacturing process and reducing chemical waste.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If nanoporous metal is made thinner to improve flexibility, then handling improves, but mechanical durability worsens

Engineering Contradiction:

ImprovehandlingVSAvoiddurability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The composite structure allows the metal layer to be made very thin for flexibility and handling, while the porous polymer substrate provides the mechanical durability needed for long-term reliability. The thin metal layer conformally coats the substrate, maintaining electrochemical performance without compromising strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The porous polymer substrate acts as a flexible support that enables the thin metal layer to be handled without breaking. The substrate's mechanical properties transfer to the composite, improving flexibility and durability simultaneously.

Inventive Principle:

Principle #30Flexible shells and thin films

4Strength

If carrier film is used to support nanoporous metal, then mechanical strength improves, but mass transfer is blocked

Engineering Contradiction:

Improvemechanical strengthVSAvoidmass transfer

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent uses a porous polymer substrate instead of a dense carrier film. The substrate's interconnected pore network allows mass transfer and fluid access to the nanoporous metal while providing mechanical support. This eliminates the mass transfer blockage issue while maintaining structural integrity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The porous polymer substrate is designed as a thin film with controlled porosity that provides mechanical support without blocking mass transfer. The film's pore structure allows electrolyte and analyte diffusion while reinforcing the nanoporous metal layer.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12570825B2Composite material including a hierarchical and nanoporous metal in porous polymer substrate

Publication Date: 2026.03.10 WL GORE & ASSOC INC

AI summary

A composite material is disclosed including a porous polymer substrate and a nanoporous metal present within the microporous polymer substrate. The nanoporous metal may have a hierarchical structure. The nanoporous metal may have a unimodal and right-skewed number-based nanopore size distribution. The porous polymer substrate may support tissue integration and/or tissue ingrowth in certain applications. The composite material may be used in electrochemical analyte biosensors and other applications.