CA2554687A1 - Porous substrates, articles, systems and compositions comprising nanofibers and methods of their use and production - Google Patents

Porous substrates, articles, systems and compositions comprising nanofibers and methods of their use and production Download PDF

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Publication number
CA2554687A1
CA2554687A1 CA 2554687 CA2554687A CA2554687A1 CA 2554687 A1 CA2554687 A1 CA 2554687A1 CA 2554687 CA2554687 CA 2554687 CA 2554687 A CA2554687 A CA 2554687A CA 2554687 A1 CA2554687 A1 CA 2554687A1
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CA
Canada
Prior art keywords
article
nanofibers
substrate
porous substrate
apertures
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA 2554687
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French (fr)
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CA2554687C (en
Inventor
Robert Dubrow
Chunming Niu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nanosys Inc
Original Assignee
Nanosys, Inc.
Robert Dubrow
Chunming Niu
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Application filed by Nanosys, Inc., Robert Dubrow, Chunming Niu filed Critical Nanosys, Inc.
Publication of CA2554687A1 publication Critical patent/CA2554687A1/en
Application granted granted Critical
Publication of CA2554687C publication Critical patent/CA2554687C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/14—Dynamic membranes
    • B01D69/141—Heterogeneous membranes, e.g. containing dispersed material; Mixed matrix membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0216—Bicomponent or multicomponent fibres
    • B01D2239/0225—Side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0216—Bicomponent or multicomponent fibres
    • B01D2239/0233—Island-in-sea
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0241—Types of fibres, filaments or particles, self-supporting or supported materials comprising electrically conductive fibres or particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0414—Surface modifiers, e.g. comprising ion exchange groups
    • B01D2239/0428—Rendering the filter material hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • B01D2239/0492—Surface coating material on fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0613—Woven
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1216—Pore size
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/28—Pore treatments
    • B01D2323/283—Reducing the pores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/549—Organic PV cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/24996—With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]

Abstract

Porous 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, and the like.

Claims (67)

1. An article, comprising:
a substrate having a plurality of apertures disposed therethrough, the substrate comprising an overall surface area that includes an interior wall surface area of the plurality of apertures; and a plurality of nanofibers attached to at least a portion of the overall surface area of the substrate.
2. The article of claim 1, wherein the substrate comprises a solid substrate and wherein the plurality of apertures comprises a plurality of pores disposed through the solid substrate.
3. The article of claim 2, wherein the substrate comprises a silica based wafer.
4. The article of claim 2, wherein the substrate comprises a ceramic sheet or plate.
5. The article of claim 2, wherein the substrate comprises a porated or perforated film.
6. The article of claim 2, wherein the substrate comprises a metallic plate.
7. The article of claim 1, wherein the substrate comprises a mesh.
8. The article of claim 7, wherein the mesh comprises a polymer mesh.
9. The article of claim 8, wherein the polymer mesh comprises a polymer selected from polyimide, polyetherketone; polyaramid.
10. The article of claim 7, wherein the mesh is a metallic mesh.
11. The article of claim 10, wherein the metallic mesh comprises a metal selected from nickel, titanium, platinum, aluminum, gold, and iron.
12. The article of claim 1, wherein the substrate comprises a woven fabric.
13. The article of claim 12, wherein the woven fabric comprises fiberglass.
14. The article of claim 12, wherein the woven fabric comprises carbon fiber.
15. The article of claim 12, wherein the woven fabric comprises a polymer selected from polyimide, polyetherketone, and polyaramid.
16. The article of claim 1, wherein the substrate comprises a fibrous mat.
17. The article of claim 16, wherein the fibrous mat comprises silica based fibers.
18. The article of claim 17, wherein the silica based fibers are selected from glass and silicon.
19. The article of claim 16, wherein the fibrous mat comprises metallic fibers.
20. The article of claim 16, wherein the fibrous mat comprises polymer fibers.
21. The article of claim 1, wherein the plurality of apertures have an effective pore size of less than 10 µm.
22. The article of claim 1, wherein the plurality of apertures have an effective pore size of less than 1 µm.
23. The article of claim 1, wherein the plurality of apertures have an effective pore size of less than 0.5 µm.
24. The article of claim 1, wherein the plurality of apertures have an effective pore size of less than 0.2 µm.
25. The article of claim 1, wherein the plurality of nanofibers are substantially only attached to the interior wall surfaces of the apertures.
26. The article of claim 1, wherein the plurality of nanofibers comprises a semiconductor material selected from group IV, group II-VI and group III-V
semiconductors.
27. The article of claim 1, wherein the plurality of nanofibers are comprised of silicon.
28. The article of claim 1, wherein a plurality of the nanofibers comprise a gold tip.
29. The article of claim 1, wherein the plurality of nanofibers are attached to the portion of the overall surface area of the substrate by having been grown on the portion of the surface area.
30. The article of claim 1, wherein the plurality of nanofibers is electrically coupled to the substrate.
31. The article of claim 1, further comprising a matrix material surrounding the substrate and plurality of nanofibers.
32. The article of claim 31, wherein the matrix material and the plurality of nanofibers have a type-II energy band-gap offset with respect to each other.
33. The article of claim 1, wherein the plurality of nanofibers are functionalized with a chemical binding moiety.
34. The article of claim 1, wherein the plurality of nanofibers are functionalized with a hydrophobic chemical moiety.
35. The article of claim 1, wherein the substrate comprises a planar sheet.
36. The article of claim 35, wherein the planar sheet substrate is flexible.
37. The article of claim 1, wherein the substrate comprises a non-planar three dimensional shape.
38. The article of claim 37, wherein the three dimensional shape is selected from a cube, a sphere, a cylinder, a block, a dome, and a polyhedron.
39. The article of claim 37, wherein the non-planar three dimensional shape is a cylinder.
40. The article of claim 1, further comprising a matrix material at least partially encapsulating the substrate and plurality of nanofibers attached to at least a portion of the overall surface of the substrate.
41. The article of claim 40, wherein the matrix material is at least partially intercalated into the apertures.
42. The article of claim 41, wherein the matrix material comprises a polymer.
43. The article of claim 42, wherein the polymer comprises a polymer selected from a polyester, an epoxy, a urethane resin, an acrylate resin, polyethylene, polypropylene, nylon, and PFA.
44. An article, comprising a nanofibrous mat that comprises a plurality of overlaid nanofibers, wherein said plurality of nanofibers are crosslinked together at points where such nanofibers contact or are proximal to others of said nanofibers, to form a semipermeable layer.
45. The article of claim 44, wherein the nanofibrous mat is deposited upon a surface of a porous substrate, the porous substrate and nanofibrous mat forming a semipermeable layer.
46. The article of claim 44, wherein at least a portion of the nanofibers comprise a hydrophobic moiety attached thereto.
47. A semipermeable membrane, comprising:
a porous substrate having a plurality of apertures disposed therethrough, the porous substrate having an overall surface that includes an interior wall surface of the apertures;
and a plurality of nanofibers deposited upon or attached to at least a portion of the overall surface of the porous substrate, wherein the nanofibers and apertures together define a pore through the semipermeable membrane, the pore being permeable to one or more materials and not permeable to one or more different materials.
48. The semipermeable membrane of claim 47, wherein the nanofibers are attached to at least a portion of the overall surface of the porous substrate.
49. The semipermeable membrane of claim 47, wherein the nanofibers are deposited upon a portion of the overall surface of the porous substrate.
50. The semipermeable membrane of claim 49, wherein individual nanofibers of the plurality of nanofibers are crosslinked with other individual nanofibers of the plurality of nanofibers to provide a crosslinked nanofibrous mat on the surface of the porous substrate.
51. The semipermeable membrane of claim 47, wherein the nanofibers comprise a hydrophobic moiety coupled thereto, and wherein the pore is permeable to gas, but not permeable to liquid water.
52. The semipermeable membrane of claim 47, wherein the pore comprises an effective pore size that excludes particles of a first particle size while permitting passage of particles of a second particle size, smaller than the first particle size.
53. The semipermeable membrane of claim 52, wherein the effective pore size is smaller than 10 µm.
54. The semipermeable membrane of claim 52, wherein the effective pore size is smaller than 1 µm.
55. The semipermeable membrane of claim 52, wherein the effective pore size is less than 0.2 µm.
56. The semipermeable membrane of claim 52, wherein the effective pore size is less than 100 nm.
57. The semipermeable membrane of claim 52, wherein the effective pore size is less than 20 nm.
58. A filter cartridge, comprising the semipermeable membrane of claim 52, disposed within a housing having an inlet passage in fluid communication with a first side of the semipermeable membrane and an outlet side in fluid communication with a second side of the semipermeable membrane.
59. The filter cartridge of claim 53, wherein the housing is coupled to a breathing mask to filter breathing air.
60. An article of clothing comprising the semipermeable membrane of claim 52, layered with at least a second fabric layer.
61. An implantable medical device comprising an article of claim 1 attached to and covering at least a portion of a surface of the implantable medical device.
62. An electrical device, comprising:
a porous substrate having a plurality of apertures disposed therethrough, the porous substrate having an overall surface area that includes an interior wall surface area of the plurality of apertures; and a plurality of conductive or semiconductive nanowires attached to and electrically coupled to the porous substrate.
63. A photovoltaic device, comprising:
a first electrical device of claim 48, wherein the plurality of nanowires comprises a first energy band gap; and a second electrical device of claim 48, wherein the plurality of nanowires comprises a second energy band gap; the first and second energy band gaps displaying a type-II
band gap offset relative to each other; and wherein the nanowires of the first electrical device are in electrical communication with the nanowires of the second electrical device, so as to allow charge separation between the first and second electrical devices upon exposure to light.
64. A method of producing a contiguous population of nanofibers, comprising:
providing a porous substrate having an overall surface area;
providing a plurality of nanofibers attached to the overall surface area of the porous substrate.
65. A method of producing a contiguous population of nanofibers,, comprising:
providing a porous substrate having an upper surface an a plurality of pores disposed through the porous substrate, wherein each of said pores has an effective pore size;
depositing a plurality of nanofibers onto the upper surface of the porous substrate, said nanofibers having at least one dimension greater than the effective pore size, such that the nanofibers are retained upon the upper surface as a nanofibrous mat; and crosslinking individual nanofibers in the plurality of nanofibers with other individual nanofibers of the plurality of nanofibers to produce a contiguous nanofiber population.
66. A method of filtering a fluid or gas, comprising:
providing a substrate having a plurality of apertures disposed therethrough to provide a porous substrate that has an overall surface area that includes an interior wall surface area of the apertures, the substrate comprising a plurality of nanowires attached to at least a portion of the overall surface area of the porous substrate; and passing the gas or liquid through the porous substrate to filter the gas or liquid.
67. A method of producing a gas permeable moisture barrier, comprising:
providing a porous substrate that comprises a plurality of apertures therethrough;

providing a plurality of nanofibers attached to at least a portion of an overall surface area of the porous substrate, the porous substrate and nanofibers together providing a gas permeable barrier; and treating at least the nanofibers to increase hydrophobicity of the nanofibers attached to the overall surface of the porous substrate, to provide a gas permeable moisture barrier.
CA 2554687 2004-02-02 2005-01-28 Porous substrates, articles, systems and compositions comprising nanofibers and methods of their use and production Expired - Fee Related CA2554687C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US54146304P 2004-02-02 2004-02-02
US60/541,463 2004-02-02
US10/941,746 US8025960B2 (en) 2004-02-02 2004-09-15 Porous substrates, articles, systems and compositions comprising nanofibers and methods of their use and production
US10/941,746 2004-09-15
PCT/US2005/003237 WO2005075048A1 (en) 2004-02-02 2005-01-28 Porous substrates, articles, systems and compositions comprising nanofibers and methods of their use and production

Publications (2)

Publication Number Publication Date
CA2554687A1 true CA2554687A1 (en) 2005-08-18
CA2554687C CA2554687C (en) 2012-11-27

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US (1) US8025960B2 (en)
EP (1) EP1713558A4 (en)
JP (2) JP2007528451A (en)
AU (1) AU2005210654B2 (en)
CA (1) CA2554687C (en)
WO (1) WO2005075048A1 (en)

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