Electrospinning system for mass production of nanofibers
The electrospinning system addresses scaling challenges by using peristaltic pumps and advanced spinnerets with adjustable collectors to achieve high-throughput production of uniform nanofibers, enhancing industrial applicability and fiber quality.
Patent Information
- Application Number
- JP2025507007
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-08-05
- Filing Date
- 2023-08-07
- Publication Date
- 2025-08-01
AI Technical Summary
Current electrospinning technology is limited by low production speed and difficulty in scaling up for industrial applications due to issues with syringe pumps, needle spinnerets, and substrate tension during roll-to-roll processing, leading to inefficiencies and potential damage to nanofibers.
An electrospinning system utilizing peristaltic pumps, converging-diverging nozzles, turbo tubes, and adjustable metal sheet collectors, along with optional ventilation and quality control systems, to ensure continuous polymer supply, reduce substrate tension, and enhance fiber production efficiency.
Enables high-throughput production of uniform nanofibers with reduced substrate stretching and improved productivity, eliminating the need for post-treatment laminating and minimizing fiber damage, while maintaining fiber quality control.
Smart Images
Figure 2025525244000001_ABST
Abstract
Description
Technical Field
[0001] This application claims priority based on U.S. Provisional Patent Application No. 63 / 370,643, filed on August 5, 2022, the entire disclosure of which is incorporated herein by reference. The present disclosure relates to an electrospinning system and an electrospinning apparatus for mass production of nanofibers.
Background Art
[0002] Electrospinning is the most commonly used method for manufacturing nanofibers. The electrospinning method has been extensively studied for potential applications in multiple industries. There are numerous scientific publications researching this field, and there are many reasons to believe that nanofibers are an important solution for many applications such as fibers, clothing, military applications, tissue engineering, drug delivery, cancer diagnosis, batteries, optical sensors, air filtration, etc. Nevertheless, the adoption of electrospinning technology in the industry has been very slow and limited. This is mainly because electrospinning is considered a laboratory-scale technology that is difficult to scale up, and thus it is often considered that electrospinning cannot meet the high throughput requirements of industrial applications. The production speed using general electrospinning technology is usually about 0.01 - 1 g / h, which is lower than the production requirements of most industries.
[0003] The equipment required for electrospinning includes a high-voltage power supply, a spinneret, and a collector. The spinneret is a capillary tube equipped with a small-diameter pipette or needle. The collector is a metal collecting plate. One electrode of the high-voltage power supply is placed in the polymer solution, and the other electrode is attached to the collector. An electric field is applied to one end of the capillary tube containing the polymer solution held by surface tension, and charges are formed on the liquid surface. As the intensity of the electric field increases, the hemispherical surface of the fluid at the tip of the capillary tube extends, forming a conical shape called a Taylor cone. When the electric field further increases and reaches a critical value, the repulsive electrostatic force overcomes the surface tension, and a charged fluid jet ejects from the tip of the Taylor cone. The jet of the ejected polymer solution is unstable and consequently elongates and becomes very slender. The charged polymer fibers solidify by evaporation of the solvent. The irregularly oriented nanofibers are collected on the collector. Special collectors such as a rotating drum, a metal frame, or a two-parallel-plate system can also be used to collect the nanofibers in a highly aligned state. To produce nanofibers with a uniform diameter and morphology, it is necessary to control parameters such as the movement of the jet flow and the polymer concentration.
[0004] Electrospinning is used to convert many types of polymers into nanofibers. The electrospun nanofiber network is similar to the extracellular matrix (ECM) in important aspects. This similarity is a major advantage of electrospinning because the ECM can be mimicked in terms of fiber diameter, porosity, and mechanical properties. Electrospinning is being further developed for the mass production of continuous nanofibers one by one.
[0005] In current electrospinning technology, usually, the polymer solution is fed into the spinneret by using a syringe pump. Since the syringe pump usually has limited flow rate and loading capacity, it is necessary to stop the electrospinning method to refill the syringe.
[0006] In current electrospinning technology, usually, a needle is used as the spinneret, so the production capacity is limited.
[0007] In roll-to-roll electrospinning technology, typically, electrospun fibers are deposited on a fabric substrate that is unwound from a first roll to a second roll. The substrate typically passes in front of a grounded or negatively charged metal sheet during the spinning process, but during this passage, a large friction occurs between the substrate and the metal sheet collector due to the charges accumulated on the substrate, which may cause "excessive tension" on the substrate. As a result, the fabric substrate stretches. Such stretching may adversely affect the tension control of the winding machine and may also damage the deposited nanofibers if the substrate loosens.
[0008] There is still a need for an electrospinning system and apparatus that can overcome the above problems and produce nanofibers at high speed. SUMMARY OF THE INVENTION
[0009] The present disclosure describes an electrospinning system and apparatus suitable for use in high-throughput industries. The system and apparatus can include a high-voltage power supply having a positive electrode and a negative electrode, one or more spinnerets including one or more converging-diverging nozzles, one or more turbo tubes, or combinations thereof, and a collector. The system and apparatus can further include one or more peristaltic pumps. The collector may be an adjustable collector. The adjustable collector can be composed of a plurality of metal sheets. The system and apparatus can optionally further include one or more of a ventilation system for reducing sparks in the electrospinning chamber, a chamber for reducing power consumption when using an optional heater or dehumidifier, and an in-line quality control system. BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
Figure 1
Figure 2
Figure 3A
Figure 3B
Figure 4A
Figure 4B
Figure 5
Figure 6
[0011] The present disclosure describes an electrospinning system and apparatus suitable for use in high-throughput industries. The system and apparatus can include a high-voltage power supply having a positive electrode and a negative electrode, one or more spinnerets including one or more converging-diverging nozzles, one or more turbo tubes, or combinations thereof, and a collector. The system and apparatus can further include one or more peristaltic pumps. The collector may be an adjustable collector. The adjustable collector can be composed of a plurality of metal sheets. The system and apparatus can optionally further include one or more of a ventilation system for reducing sparks in the electrospinning chamber, a chamber for reducing power consumption when using an optional heater or dehumidifier, and an in-line quality control system.
[0012] Figure 1 shows an electrospinning apparatus according to an embodiment. The electrospinning apparatus includes a pay-off machine 1, a take-up machine 2, a quality control module 4, a feeder 5, a turbo tube 6, and a collector plate 7.
[0013] The electrospinning device of the present disclosure uses a peristaltic pump for supplying to a spinneret. As a result, it becomes unnecessary to use a syringe. Since the peristaltic pump can suck up a solution from a container of any size, it becomes unnecessary to replenish the polymer solution in the spinning process.
[0014] To prevent the interruption and instability of the rotating jet caused by the discontinuous supply of a single peristaltic pump due to the peristaltic motion, a plurality of peristaltic pumps are used in the device of the present disclosure. FIG. 2 shows an example of a method of using two peristaltic pumps with different phases together with two separate roll sets to achieve an overall continuous supply of the polymer solution. As shown in the figure, when phase B is in the stationary state, phase A is in the supply state, and vice versa.
[0015] The electrospinning device of the present disclosure is equipped with an exchangeable alternative non-needle spinneret, so productivity is improved. Using these alternative spinnerets can also prevent the premature solidification of the electrospinning polymer that frequently occurs when using a needle as a spinneret.
[0016] The alternative spinneret may be a converging-diverging nozzle, a turbo tube, or other suitable alternative spinneret.
[0017] FIG. 3A is a schematic diagram showing the configuration of a converging-diverging nozzle. FIG. 3B shows an example of a converging-diverging nozzle. The converging-diverging nozzle is formed such that the polymer solution therein becomes conical. When using a plurality of converging-diverging nozzles in a rod system, since there are a plurality of rods in one device, a plurality of jets come out from one nozzle, and a large number of rotating jets are generated.
[0018] Figure 4A shows an example of a turbo tube. Figure 4B shows how a peristaltic pump supplies a polymer solution to a U-shaped turbo tube. Using a turbo tube provides one or more advantages such as very high productivity, generation of continuous jets, generation of homogeneous materials, reduction of clogging problems that may occur with needles or nozzles, and ease of setup and cleaning compared to using other types of spinnerets.
[0019] The apparatus of the present disclosure has one or more spinnerets, and the spinnerets may include one or more converging-diverging nozzles, one or more turbo tubes, or a combination thereof. Alternatively, the apparatus of the present disclosure may have a needle spinneret and a plurality of spinnerets including both one or more converging-diverging nozzles, one or more turbo tubes, or a combination thereof.
[0020] The apparatus of the present disclosure has a smaller contact area between the spinneret and the collector compared to a conventional roll-to-roll electrospinning apparatus. This is achieved by using a plurality of metal sheets to form an adjustable collector that can adjust and optimize the gap between the substrate and the collector. By using a plurality of metal sheets as the collector, the tension on the roll is reduced. The collector is preferably connected to a negative high-voltage electrode to increase the attractive force of the charged fibers.
[0021] In some implementations, the adjustable collector adds one layer of the substrate to laminate the surface of the nanofiber layer, thereby protecting the nanofiber layer. In this way, the nanofiber layer is sandwiched between the substrate layers. This eliminates the need to laminate a protective layer as a post-treatment step in many industrial applications.
[0022] Figure 5 shows an example of a metal collector consisting of four metal sheets.
[0023] Other features of the apparatus of the present disclosure include a ventilation system that reduces sparks in the electrospinning chamber, a chamber that reduces power consumption when using an optional heater or dehumidifier, a compact size suitable for both research and industrial applications, and an in-line quality control system that includes a scanner for measuring the differential pressure between two surfaces of a substrate to determine the level of fiber homogeneity generated.
[0024] Figure 6 shows an example of an in-line quality control system of the electrospinning system of the present disclosure.
[0025] Figure 7 shows an example of a ventilation system of the electrospinning system of the present disclosure.
[0026] The following numbered examples are further descriptions of the implementation of the system of the present disclosure.
[0027] (1) An electrospinning system including a high-voltage power supply including a positive electrode and a negative electrode, one or more spinnerets, and an adjustable collector, wherein the spinneret includes at least one spinneret that is a converging-diverging nozzle or a turbo tube is disclosed.
[0028] (2) In the system of (1), it is disclosed that the collector is composed of a plurality of metal sheets.
[0029] (3) In the system of (1) or (2), it is disclosed that the spinneret is at least two, at least one of the spinnerets is a converging-diverging nozzle, and at least one of the spinnerets is a turbo tube.
[0030] (4) In the system of (1) or (2), it is disclosed that the spinneret is at least two, and at least one of the spinnerets is a converging-diverging nozzle or a turbo tube.
[0031] (5) In any one of the systems (1) to (4), it is disclosed that at least one peristaltic pump for supplying a polymer solution to the spinneret is further provided.
[0032] (6) In any one of the systems (1) to (4), at least two peristaltic pumps for supplying a polymer solution to the spinneret are further provided, and the at least two peristaltic pumps have a phase difference to enable continuous supply of the polymer solution, which is disclosed.
[0033] (7) In any one of the systems (1) to (6), it is disclosed that a ventilation system is further provided.
[0034] (8) In any one of the systems (1) to (7), it is disclosed that a chamber for reducing power consumption is further provided.
[0035] (9) In any one of the systems (1) to (8), it is disclosed that an in-line quality control system is further provided.
[0036] (10) In the system of (9), it is disclosed that the in-line quality control system further includes a scanner for measuring the differential pressure between two surfaces of a substrate to determine the level of homogeneity of the produced nanofibers.
[0037] (11) An electrospinning system including a high-voltage power supply including a positive electrode and a negative electrode, one or more spinnerets, and a collector, wherein the spinneret includes at least one spinneret that is a converging-diverging nozzle or a turbo tube, is disclosed.
[0038] (12) In the system of (11), it is disclosed that there are at least two spinnerets, at least one of the spinnerets is a converging-diverging nozzle, and at least one of the spinnerets is a turbo tube.
[0039] In the system of (13)(11), it is disclosed that there are at least two spinarets, and at least one of the spinarets is a converging-diverging nozzle or a turbo pipe.
[0040] In any one of the systems of (14)(11) to (13), it is disclosed that it further includes at least one peristaltic pump for supplying a polymer solution to the spinaret.
[0041] In any one of the systems of (15)(11) to (13), it further includes at least two peristaltic pumps for supplying a polymer solution to the spinaret, and the at least two peristaltic pumps have a phase difference to enable continuous supply of the polymer solution.
[0042] The foregoing embodiments are provided to enable those skilled in the art to manufacture or use the invention of the present disclosure. Although various aspects of the invention are disclosed in the context of specific illustrated embodiments, implementations, and examples, those skilled in the art should understand that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses of the invention, as well as their obvious modifications and equivalents. Furthermore, although some variations of various aspects of the invention are shown and described in detail, other modifications within the scope thereof will be readily apparent to those skilled in the art upon examination of this disclosure. Also, the scope of this disclosure includes various combinations or sub-combinations of the specific features and aspects of the embodiments disclosed herein, and it should be understood that the various features, implementation modes, and aspects of the disclosed subject matter can be combined with or replaced by each other. The general principles defined herein can be applied to other embodiments without departing from the spirit or scope of the disclosure. Therefore, this disclosure is not intended to be limited to the embodiments shown herein, and the broadest scope consistent with the principles and novel features disclosed herein should be given.
[0043] Each of the foregoing aspects and various aspects, together with those summarized above or otherwise disclosed herein (including figures), can be combined without limitation to form claims for devices, apparatuses, systems, manufacturing methods, and / or methods of use.
[0044] All references cited herein are hereby expressly incorporated by reference into this disclosure.
Claims
1. a. A high-voltage power supply including a positive electrode and a negative electrode; b. One or more spinnerets; c. An adjustable collector, and The electrospinning system, wherein the spinneret includes at least one spinneret that is a converging-diverging nozzle or a turbo pipe.
2. In the electrospinning system according to Claim 1, The electrospinning system, wherein the collector is composed of a plurality of metal sheets.
3. In the electrospinning system according to Claim 1 or 2, There are at least two spinnerets, At least one of the spinnerets is a converging-diverging nozzle, and at least one of the spinnerets is a turbo pipe in the electrospinning system.
4. In the electrospinning system according to Claim 1 or 2, There are at least two spinnerets, At least one of the spinnerets is a converging-diverging nozzle or a turbo pipe in the electrospinning system.
5. In the electrospinning system according to any one of Claims 1 to 4, The electrospinning system further includes at least one peristaltic pump for supplying a polymer solution to the spinneret.
6. In the electrospinning system according to any one of Claims 1 to 4, The electrospinning system further includes at least two peristaltic pumps for supplying a polymer solution to the spinneret, The at least two peristaltic pumps have a phase difference to enable continuous supply of the polymer solution in the electrospinning system.
7. In the electrospinning system according to any one of Claims 1 to 6, The electrospinning system further includes a ventilation system.
8. In the electrospinning system according to any one of Claims 1 to 7, The electrospinning system further includes a chamber for reducing power consumption.
9. In the electrospinning system according to any one of Claims 1 to 8, The electrospinning system further includes an in-line quality management system.
10. In the electrospinning system according to Claim 9, The in-line quality management system further includes a scanner for measuring the differential pressure between two surfaces of a substrate to determine the level of homogeneity of the produced nanofibers in the electrospinning system.
11. a. A high-voltage power supply including a positive electrode and a negative electrode; b. One or more spinnerets; c. A collector, and An electrospinning system including at least one spinneret that is a converging-diverging nozzle or a turbo tube.
12. In the electrospinning system according to Claim 11, the spinneret is at least two, at least one of the spinnerets is a converging-diverging nozzle, and at least one of the spinnerets is a turbo tube electrospinning system.
13. In the electrospinning system according to Claim 11, the spinneret is at least two, at least one of the spinnerets is an electrospinning system that is a converging-diverging nozzle or a turbo tube.
14. In the electrospinning system according to any one of Claims 11 to 13, an electrospinning system further comprising at least one peristaltic pump for supplying a polymer solution to the spinneret.
15. In the electrospinning system according to any one of Claims 11 to 13, further comprising at least two peristaltic pumps for supplying a polymer solution to the spinneret, the at least two peristaltic pumps having a phase difference enabling continuous supply of the polymer solution, an electrospinning system.