Soluble Polymer Fiber with Resinous Aldehyde Coating
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Solution Overview
Problem
Existing fine fiber technologies for filtration applications face challenges in mechanical stability and environmental resistance, particularly in extreme temperature ranges, where current fibers may not perform optimally due to inadequate crosslinking and solvent compatibility.
Innovation Solution
A unique fiber material is formed by blending a nonreactive polymer with a self-crosslinkable resinous aldehyde composition, creating a semi-interpenetrating network morphology with concentric phases, including a core polymer phase and a coating phase predominantly composed of resinous aldehyde, which enhances mechanical stability and environmental resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer fibers are used for filtration, then manufacturing is simple and cost-effective, but mechanical stability and environmental resistance are insufficient in extreme temperature ranges
Solution Approach 1:
The patent applies composite materials by combining a nonreactive polymer with a resinous aldehyde composition to form a core-coating fiber structure. The core phase consists of the nonreactive polymer providing structural integrity, while the coating phase consists of the resinous aldehyde composition providing environmental resistance and crosslinking capability. This composite structure resolves the contradiction by achieving enhanced mechanical stability and environmental resistance through material composition rather than complex fiber architecture.
Solution Approach 2:
The patent applies local quality by creating distinct core and coating phases with different functional properties. The core phase is designed with nonreactive polymer for structural stability, while the coating phase is designed with resinous aldehyde composition for crosslinking and environmental resistance. This localized functional differentiation allows each phase to optimize its specific role, resolving the contradiction between simplicity and performance.
2Ease of manufacture
If fibers are formed using safe and easy solvents, then ease of manufacture is improved, but the fibers may not survive and perform well in a wide variety of environments
Solution Approach 1:
The patent applies parameter changes by transforming the fiber structure through crosslinking after formation. The fibers are first formed using safe solvents (maintaining ease of manufacture), then subjected to crosslinking treatment that fundamentally changes the molecular structure to create a three-dimensional network. This parameter change from linear chains to crosslinked network resolves the contradiction by enabling environmental performance comparable to high-performance solvents while maintaining the manufacturing advantages of safe solvents.
Solution Approach 2:
The patent applies preliminary action by forming the fiber structure first using safe and easy solvents, then subsequently applying crosslinking treatment. This sequence allows the fiber to be manufactured with ease using benign solvents, and then the environmental performance is enhanced in a separate step. The preliminary formation step resolves the contradiction by decoupling the manufacturing ease from the final performance requirement.
3Reliability
If crosslinking is increased to improve mechanical stability, then reliability is improved, but manufacturing complexity and process difficulty increase
Solution Approach 1:
The patent applies self-service by using the resinous aldehyde composition in the coating phase to self-crosslink and form a three-dimensional network structure. The crosslinking is achieved through the inherent reactivity of the resinous aldehyde composition rather than requiring external crosslinking agents or complex processing steps. This self-crosslinking capability resolves the contradiction by achieving enhanced mechanical stability through a relatively simple process where the material itself performs the crosslinking function.
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
The resulting fibers exhibit improved humidity resistance and filtration efficiency, maintaining structural integrity and performance in diverse environments, including extreme temperatures, through enhanced crosslinking and solvent compatibility.
Implementation Method 1
The resinous aldehyde composition is one that can self-crosslink
Implementation Method 2
mixing or blending a polymer material with a resinous aldehyde composition
Implementation Method 3
forms at least two (e.g., concentric or coaxial) phases. The first phase is an internal core or axial polymer phase
Data Source
Figure 1
Figure 2
Figure 3(a)~3(e')
AI summary
A fiber can be made having a structure with an axial core and a coating layer. The fiber can have a polymer core and one or two layers surrounding the core. The fine fiber can be made from a polymer material and a resinous aldehyde composition such that the general structure of the fiber has a polymer core surrounded by at least a layer of the resinous aldehyde composition.