US20260097369
2026-04-09
Performing operations; transporting
B01D67/0011
The nanofiber membrane with dual-scale porosity is fabricated using a phase-separation electrospinning process. It features interconnected inter-fiber and surface pores, which significantly enhance air permeability, diffusion rates, and filtration performance. The method utilizes solvents with distinct evaporation rates to create a highly porous structure, making it suitable for applications in air filtration, medical dressings, drug delivery systems, and diagnostic test strips. The process is scalable and cost-effective, ensuring consistent fiber morphology.
Nanofibers are widely used in various fields due to their high surface area and porosity. However, conventional nanofibers have limitations such as dense surfaces with minimal porosity, leading to higher pressure drops in filtration and slower release rates in controlled-release systems. In diagnostic applications, insufficient surface area reduces capillary action and sensitivity. Traditional manufacturing methods involve multiple steps and complex materials, increasing production costs and complicating scalability.
This invention introduces a nanofiber membrane with dual-scale porosity, featuring both surface and inter-fiber pores. The interconnected pore structure improves filtration efficiency, lowers pressure drops, and enhances diffusion rates. The manufacturing process is simplified, avoiding additional treatments and offering improved performance and manufacturability. The membrane's pore sizes range from 100-900 nm for inter-fiber pores and 1-100 nm for surface pores, ensuring uniform distribution.
The nanofibers are produced using a formulation that includes water-immiscible and water-miscible solvents, along with a base polymer. The water-immiscible solvent, such as chloroform or dichloromethane, has a boiling point between 40-80°C, while the water-miscible solvent, like methanol or ethanol, ranges from 60-200°C. The base polymer can include PLA, PVDF, or other suitable materials. Phase separation during electrospinning, driven by evaporation rate differences, creates the dual-scale pores.
The nanofiber membrane is versatile, applicable as a wound dressing, drug delivery system, or cosmetic patch. It offers improved absorption, controlled release, and active ingredient diffusion. As an air filter, it reduces pressure drops and increases filtration efficiency, suitable for HVAC systems or face masks. In diagnostic test strips, it enhances capillary action and sensitivity. The membrane's specific area is at least 30 m²/g, and it achieves significant active ingredient release rates, demonstrating its efficiency across applications.