Porous Material Continuous Pore Structure via Degradable Polymer Template

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Solution Overview

Problem

Existing methods for producing nanoporous polymeric materials with continuous pore structures are limited by narrow composition ranges and require precise control of synthesis conditions, making them difficult to scale and replicate effectively.

Innovation Solution

A method involving the reaction of a base polymer and a degradable polymer with a crosslinker in a solvent, followed by solvent removal and degradable polymer extraction, to form a phase-separated material with a continuous pore structure, where the degradable polymer is completely or near-completely removed, allowing for the formation of a porous material with interconnected pores.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If diblock copolymer methods are used to form nanoporous polymeric materials, then a continuous pore structure can be achieved, but the composition range is limited to a very narrow range requiring precisely controlled synthesis conditions

Engineering Contradiction:

Improvecontinuous pore structure formationVSAvoidpolymer composition range

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent changes the fundamental parameters of the synthesis approach by using step-growth polymerization of telechelic polymers with multifunctional crosslinkers instead of chain-growth polymerization of diblock copolymers. This allows a broad range of polymer compositions (5-95 vol%) to form continuous pore structures, eliminating the narrow composition window constraint while maintaining structural continuity through crosslinked network formation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a degradable polymer as an intermediary component that self-assembles with the base polymer to form a bicontinuous phase structure. This intermediary phase acts as a template that, when removed, leaves behind a continuous pore structure. The intermediary enables continuous pore formation across wide composition ranges without requiring precise synthesis control.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If polymerization induced phase separation is used, then nanoporous structures can be formed, but the morphology is kinetically trapped requiring fine control of competition between phase separation and polymerization rates

Engineering Contradiction:

Improvenanoporous structure formationVSAvoidcontrol of polymerization and phase separation rates

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent performs preliminary self-assembly of the base polymer and degradable polymer phases before crosslinking occurs. The telechelic polymers and crosslinkers are first mixed and allowed to self-assemble into a bicontinuous morphology, then crosslinking is initiated to lock in the structure. This preliminary organization eliminates the need to control the competition between polymerization and phase separation rates during the reaction.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the synthesis into distinct stages: (1) mixing and self-assembly of telechelic polymers with crosslinkers to form the bicontinuous phase structure, and (2) subsequent crosslinking to stabilize the morphology. This segmentation decouples the structure formation from the chemical reaction, eliminating kinetic trapping issues.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If existing methods are used to produce porous materials, then pore structures can be formed, but scaling and replication are difficult due to precise condition control requirements

Engineering Contradiction:

Improvepore structure formationVSAvoidscalability and replicability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the synthesis methodology from chain-growth polymerization requiring precise kinetic control to step-growth polymerization with self-assembling telechelic polymers. This parameter change broadens the process window for composition, temperature, and time, making the method robust for scaling and replication while maintaining consistent pore structure formation across different production scales.

Inventive Principle:

Principle #35Parameter changes

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 enables the production of porous materials with greater than 90% interconnected pores, suitable for applications in catalysis and filtration, and can be scaled to produce materials with controlled pore structures and properties.

Implementation Method 1

removing the solvent to form a phase separated material

Methodology Applied

Scientific EffectPhase separation:

Implementation Method 2

removing the degradable polymer to form the porous material

Methodology Applied

Scientific EffectDegradation: Decomposition (biological)

Data Source

PatentUS10526467B2Porous material and methods of making and of using the same

Publication Date: 2020.01.07 UNIV OF MASSACHUSETTS

AI summary

In an embodiment, a porous material comprises a base polymer having a continuous pore structure. In another embodiment, a method of making the porous material comprises reacting a base polymer with a degradable polymer with a crosslinker in the presence of a solvent and/or reacting a base polymer and a degradable polymer with a crosslinker in the presence of the solvent; removing the solvent to form a phase separated material; and removing the degradable polymer to form the porous material.