Thermally Stabilized Electrospun Compositions Using Mixed Fiber Populations

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Solution Overview

Problem

Electrospun materials used in medical applications are unstable and undergo significant structural and thermal changes due to crystallization and residual stresses, leading to distortions in fiber topography and loss of desirable mechanical properties when exposed to heat.

Innovation Solution

A thermally stable electrospun material is created by combining two independent fiber populations, one thermally unstable and one thermally stable, which are co-mingled throughout the structure, maintaining physical and mechanical properties under thermal or mechanical stress without additional processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electrospun materials are used to maintain fibrous topography and surface area, then biological interaction capability is improved, but thermal stability deteriorates due to crystallization and shrinkage

Engineering Contradiction:

Improvebiological interaction capabilityVSAvoidthermal stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent combines thermally unstable electrospun fibers with thermally stable fibers to create a composite material. The thermally stable fibers act as a reinforcing network that prevents shrinkage and maintains structural integrity when the thermally unstable fibers undergo crystallization, thus resolving the contradiction between maintaining fibrous topography for biological interaction and achieving thermal stability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention creates a heterogeneous structure where different regions of the material have different thermal properties. The thermally stable fibers are distributed throughout the matrix of thermally unstable fibers, providing localized thermal stability at critical points to prevent overall shrinkage while allowing the majority of the material to maintain its electrospun fibrous structure for biological applications.

Inventive Principle:

Principle #3Local quality

2Productivity

If high voltage is applied to overcome surface tension and form fibers, then fiber formation is improved, but residual stresses increase leading to distortion upon heating

Engineering Contradiction:

Improvefiber formation efficiencyVSAvoidresidual stresses

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The thermally stable fibers serve as an intermediary structural framework that supports the thermally unstable fibers during thermal processing. This intermediary network prevents the distortion and shrinkage caused by residual stresses in the thermally unstable fibers, allowing high voltage fiber formation to proceed efficiently without subsequent distortion.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Speed

If fast solidification occurs during electrospinning, then fiber formation speed is improved, but crystallization is inhibited leading to amorphous structure

Engineering Contradiction:

Improvefiber formation speedVSAvoidcrystallization state

Core Design Contradiction:

SpeedVSStability of the object's composition

Solution Approach 1:

The patent performs preliminary action by incorporating thermally stable fibers into the electrospun material before thermal processing occurs. These pre-included stable fibers create a nucleation framework that promotes controlled crystallization during subsequent thermal treatment, reversing the effect of fast solidification that normally inhibits crystallization.

Inventive Principle:

Principle #10Preliminary action

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 combined fiber populations minimize thermally induced shrinkage and maintain structural integrity, allowing the material to retain desirable characteristics even when exposed to temperatures relevant for sterilization and storage.

Implementation Method 1

the electrospinning method, using an electrical charge to draw very fine, typically on the micro or nano scale, fibers from a liquid

Methodology Applied

Scientific EffectElectrostatic force: Electrostatics

Implementation Method 2

Application of a critical voltage induces a high charge density forming a Taylor cone, the cone observed in electrospinning, electrospraying and hydrodynamic spray processes from which a jet of charged material emanates

Methodology Applied

Scientific EffectElectrostatic repulsion: Electrostatics

Implementation Method 3

fiber formation occurs on the order of milliseconds due to the rapid evaporation of the solvent, inhibiting polymer crystallization

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

these materials can undergo both morphological and mechanical property changes when exposed to heat due to cold crystallization as well as stress relief via application of heat

Methodology Applied

Scientific EffectThermal energy: Heating

Data Source

PatentUS20250223729A1Thermally and dimensionally stabilized electrospun compositions and methods of making same

Publication Date: 2025.07.10 POLY MED INC

AI summary

Thermally stable absorbable fiber populations, i.e. fiber populations that do not undergo thermally induced crystallization, can be intermixed with thermally unstable fibers to yield a stabilizing effect without altering morphological properties of a fiber system. Via this, one may minimize thermally induced shrinkage and maintain physical properties of electrospun materials in the as-formed state.