Porous substrates, articles, systems and compositions comprising nanofibers and methods of their use and production
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Solution Overview
Problem
Current nanotechnology lacks effective methods for integrating nanoscale materials into macroscale systems and assembling them into complex structures, such as nanocomputers or nanoscale machines, due to difficulties in handling, fabrication, and integration of nanomaterials.
Innovation Solution
A porous substrate with attached nanofibers is used, allowing for the synthesis and stabilization of nanofibers on curved or porous surfaces, enhancing their integration and application in various fields by providing a higher yield and density of long, unbranched nanofibers for use in filtration, electronics, and biological structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nanomaterials are used as individual elements requiring individual assembly, then unique nanoscale properties can be exploited, but integration into macroscale systems becomes extremely difficult and costly
Solution Approach 1:
The patent segments the integration challenge by treating nanomaterials as bulk processed films rather than individual elements. Nanowire films are divided into oriented layers that can be manufactured using conventional semiconductor processes, eliminating the need for individual nanoscale assembly while preserving collective nanoscale properties
Solution Approach 2:
The patent introduces an intermediary approach by using bulk processed nanowire films as a mediator between individual nanoscale elements and macroscale systems. These films serve as an intermediate form that retains nanoscale properties while being compatible with conventional manufacturing and integration processes
2Ease of manufacture
If bulk processed nanowire films are used instead of individual nanowires, then manufacturing complexity is reduced, but control over individual nanowire orientation and positioning is lost
Solution Approach 1:
The patent applies local quality by creating regions with different nanowire orientations within the bulk film. Specific areas can be engineered to have nanowires oriented along particular axes to meet local functional requirements, while other areas maintain different orientations, allowing both bulk processing and localized precision
Solution Approach 2:
The patent performs preliminary action by pre-orienting nanowires along specific axes during the bulk processing stage using conventional semiconductor manufacturing techniques. This preliminary orientation is established before final device assembly, ensuring that nanowires are properly aligned for their intended function without requiring post-processing individual manipulation
3Ease of manufacture
If conventional semiconductor processes are used for nanowire fabrication, then manufacturing cost and complexity are reduced, but performance compared to single crystal wafers deteriorates
Solution Approach 1:
The patent changes key parameters by processing nanowires at lower temperatures and using amorphous semiconductor materials instead of single crystal wafers. By optimizing these parameters and using the unique properties of nanowire structures, the patent achieves performance comparable to single crystal wafers while utilizing less expensive conventional manufacturing processes
Data Source
AI summary
Porous and/or curved nanofiber bearing substrate materials are provided having enhanced surface area for a variety of applications including as electrical substrates, semipermeable membranes and barriers, structural lattices for tissue culturing and for composite materials, production of long unbranched nanofibers, and the like. A method of producing nanofibers is disclosed including providing a plurality of microparticles or nanoparticles such as carbon black particles having a catalyst material deposited thereon, and synthesizing a plurality of nanofibers from the catalyst material on the microparticles or nanoparticles. Compositions including carbon black particles having nanowires deposited thereon are further disclosed.