AC Electrospinning of Nanofibrous Thread With Virtual Collector Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing nanofibrous yarns face challenges with low productivity, low reliability, and limited material choices, resulting in irregular twist and poor orientation of nanofibers, making them unsuitable for industrial applications.
Innovation Solution
A method involving AC electrospinning on a spinning electrode with a supercritical alternating electric field intensity forms nanofibers that are carried away by the electric wind to create a linear ribbon, where they are partially parallelized and compacted into a nanofibrous structure, which is then wound onto a bobbin for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If nanofibers are twisted immediately after formation without parallelization, then the twisting process is simplified, but the twist becomes uneven and the yarn strength and appearance become variable
Solution Approach 1:
The patent applies preliminary action by parallelizing the nanofibers before twisting. The collecting electrode is designed with a specific geometry and positioned at an optimized distance from the spinning electrode to enable nanofiber parallelization in the collection zone before the twisting process begins. This preliminary parallelization ensures uniform twist and consistent yarn appearance while maintaining processability.
2Manufacturing precision
If a counter electrode is added to improve nanofiber orientation, then nanofiber orientation is improved, but the device complexity increases
Solution Approach 1:
The collecting electrode serves multiple functions simultaneously: it acts as a counter electrode for electrostatic field generation, a collecting surface for nanofiber accumulation, and a parallelization element through its specific geometry. This multi-functionality achieves improved nanofiber orientation without proportionally increasing device complexity, as one component performs multiple critical roles in the process.
3Productivity
If the collecting electrode is positioned close to the spinning electrode, then nanofiber collection efficiency is improved, but the electric field intensity becomes too high causing instability
Solution Approach 1:
The patent applies parameter changes by optimizing the distance between electrodes and adjusting the voltage parameters to achieve the desired balance. The collecting electrode is positioned at a specific distance from the spinning electrode, and the voltage is controlled to maintain the electric field intensity within stable limits while ensuring efficient nanofiber collection and parallelization in the collection zone.
4Speed
If air flow is used to carry nanofibers, then nanofiber transport is achieved, but the twist becomes irregular and yarn cohesion is reduced
Solution Approach 1:
The patent replaces or supplements the mechanical air flow system with an electrostatic field-based nanofiber transport mechanism. The electric field generated between the spinning electrode and collecting electrode provides a controlled force for nanofiber transport, eliminating the need for high-speed air flows that cause irregular twisting. This substitution maintains nanofiber collection efficiency while ensuring regular twist and yarn cohesion.
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 method enables the production of high-quality nanofibrous yarns with sufficient cohesion and orientation, suitable for textile processing, by ensuring uniform twist and strength through the use of a virtual collector that balances electric and gravitational forces.
Implementation Method 1
nanofibers which are carried away from the spinning electrode by the action of the electric wind in the direction of the maximum values of the electric field gradient
Implementation Method 2
a spinning area is formed with a supercritical alternating electric field intensity, in which are formed nanofibers
Data Source
AI summary
A method of producing a linear fibrous structure in an alternating electric field by spinning of a polymer solution or polymer melt on a spinning electrode, in which nanofibers are formed from the polymer solution or melt in a spinning area created on the spinning electrode and are carried away from it by the action of the electric wind. In the spinning area, a narrow flat linear structure of polymer solution is formed with a finite length. The spinning area is open in the spinning direction and in the central part thereof. The nanofibers are formed and move away from the spinning area in a flat structure in which they gradually lose their kinetic energy. In a place with zero kinetic energy, nanofibers form a linear virtual collector in which nanofibers are formed into a ribbon of nanofibers.