Semiconducting Microfibers via Melt-Drawing and Spacer Modification
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Solution Overview
Problem
Existing methods for producing semiconducting polymer fibers, such as electrospinning and melt-drawing, face challenges with discontinuity, bead formation, and poor electronic properties due to limited solubility and aggregation of semiconducting polymers, which hinder scalable and efficient fabrication of high-quality semiconducting microfibers.
Innovation Solution
A method involving melting a semiconducting solid polymer material to form a polymer melt and using a tool to draw microfibers, with intentionally placed conjugation-break spacers in the polymer backbone, allowing for the formation of continuous, highly aligned microfibers with improved electronic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrospinning is used to produce semiconducting polymer fibers, then continuous mass manufacturing is achieved, but the fibers are discontinuous and contain beads due to limited solubility and aggregation
Solution Approach 1:
The patent changes the physical state parameter of the polymer from solid to melt by heating above the melting temperature, enabling continuous fiber formation without aggregation issues that plague solution-based electrospinning. The melt state allows for controlled flow and continuous extrusion through the nozzle.
Solution Approach 2:
The patent introduces a solvent-free melt as an intermediary medium to enable fiber formation. By using the polymer melt itself rather than a solvent solution, the method avoids solubility limitations and aggregation problems while maintaining processability.
2Ease of manufacture
If semiconducting polymers are blended into insulating polymers for electrospinning, then processability is improved, but electronic properties deteriorate
Solution Approach 1:
The patent extracts the insulating polymer component from the blend, using only the semiconducting polymer in its melt state. This eliminates the need for blending while maintaining both processability (through melt formation) and electronic properties (by using pure semiconducting material).
Solution Approach 2:
The patent changes the temperature parameter to above the melting point of the semiconducting polymer, transforming it from a solid that requires blending for processability into a processable melt that can be directly extruded while maintaining pure semiconducting composition and electronic properties.
3Productivity
If melt-drawing is used to produce polymer fibers, then continuous fiber formation is achieved, but high melting temperatures and decomposition before melting occur
Solution Approach 1:
The patent modifies the molecular structure by introducing conjugation-break spacers that specifically lower the melting temperature of the semiconducting polymer. This allows melt-drawing to proceed at temperatures below the decomposition point, enabling continuous fiber formation without thermal degradation.
Solution Approach 2:
The patent creates a composite molecular structure within the polymer chain by incorporating conjugation-break spacers that act as internal modifiers. These spacers reduce intermolecular interactions and lower the melting point while maintaining the semiconducting properties through controlled aggregation.
4Ease of manufacture
If conjugation-break spacers are placed in the polymer backbone, then processability at lower temperatures is improved, but electronic properties may deteriorate
Solution Approach 1:
The patent applies local quality by placing conjugation-break spacers at specific intervals along the polymer backbone rather than uniformly throughout. This localized modification allows the majority of the polymer chain to maintain its conjugated structure and electronic properties while the spacer regions provide the necessary melting point reduction for processability.
Solution Approach 2:
The patent uses a partial approach by incorporating conjugation-break spacers at controlled frequencies along the polymer chain. The spacers are present in sufficient quantity to lower the melting temperature to a processable range but in limited enough quantity to preserve the overall semiconducting electronic properties of the material.
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 enables the production of scalable, continuous, and highly aligned semiconducting microfibers with enhanced mechanical and electrical properties, suitable for flexible and stretchable electronics, demonstrating high anisotropy and stretchability up to 180% elongation without breaking.
Implementation Method 1
melting a semi-conducting solid polymer material to form a polymer melt
Implementation Method 2
dipping a tip of a tool into the polymer melt, and lifting the tip of the tool away from a surface of the polymer melt, wherein a microfiber is formed at the tip of the tool
Implementation Method 3
a microfiber is formed at the tip of the tool as the tip of the tool moves away from the surface of the polymer melt
Data Source
AI summary
A method of making a semi-conducting microfiber. The method includes melting a semi-conducting solid polymer material to form a polymer melt, dipping a tip of a tool into the polymer melt, and lifting the tip of the tool away from the polymer melt, forming a microfiber. A semiconducting microfiber. The semiconducting microfiber contains a non-conjugated semiconducting polymer matrix containing crystalline aggregates with intentionally placed conjugation-break spacers along the polymer backbone. A device containing a plurality of semiconducting microfibers. Each of the semiconducting fibers contains a non-conjugated semiconducting polymer matrix containing crystalline aggregates with intentionally placed conjugation-break spacers along the polymer backbone. An apparatus to make a semiconducting microfiber. The apparatus contains a container to melt and hold the molten polymer, a tool dipped into the polymer melt, and a means of lifting tip of the tool away from a surface of the polymer melt forming a microfiber.