Aligned-Random Sub-Micron Fibrous Membranes for Mass Production
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Solution Overview
Problem
Conventional electrospinning methods for producing sub-micron fibrous membranes face limitations in mass production due to the need for moving and rotating a lower substrate during the spinning process, limiting the alignment and random patterning of fibers.
Innovation Solution
A method for producing a sub-micron fibrous membrane involving the alignment of fibers along one axis and a random pattern using multiple electrospinning portions, with different diameters and materials, allowing for simultaneous spinning on a carrier to form a network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single nozzle is used for electrospinning with substrate movement and rotation, then fiber alignment in grid pattern is achieved, but mass production capability is limited
Solution Approach 1:
The patent divides the single electrospinning system into multiple nozzles (first nozzles and second nozzles) arranged in arrays. The first nozzles spin aligned fibers while the second nozzles spin random fibers, allowing simultaneous production of both fiber types across large substrate areas, thereby enabling mass production while maintaining fiber alignment where needed
Solution Approach 2:
The patent transitions from a single-point electrospinning approach to a multi-point array configuration. By arranging nozzles in spatial arrays and coordinating their operation with substrate movement, the system achieves both precise fiber alignment in specific regions and random fiber distribution in others, while dramatically increasing production capacity
2Manufacturing precision
If substrate is moved and rotated during electrospinning, then fiber alignment and grid formation are achieved, but process complexity increases
Solution Approach 1:
The patent segments the fiber spinning function across multiple nozzles with different configurations. First nozzles are designed for aligned fiber spinning while second nozzles are designed for random fiber spinning. This segmentation allows each nozzle type to operate independently with simpler control, avoiding the need to continuously move and rotate a single substrate during the process
Solution Approach 2:
Instead of moving and rotating the substrate to achieve fiber alignment as in conventional methods, the patent inverts the approach by using fixed nozzles in array configurations that inherently produce aligned or random fibers based on their design. The substrate remains stationary or moves simply, while the nozzle arrangement and electrospinning parameters control fiber orientation
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
Enables mass production of sub-micron fibrous membranes with adjustable internal space sizes, improving filtration efficiency and comfort by allowing easier airflow, while using biodegradable polymers to reduce environmental impact.
Implementation Method 1
Electrospinning is a method that applies high voltage between a nozzle for spinning a spinning solution and a stage where a substrate is placed to form a higher electric field than the surface tension of the spinning solution and spin the spinning solution into sub-micron fibers
Implementation Method 2
the guide portion generates a force exerted on sub-micron fibers spun from a first spinning nozzle in the first horizontal direction by changing an electric field formed between the first spinning nozzle which spin sub-micron fibers from a spinning solution and a stage portion to which a second voltage different than the first voltage is applied
Data Source
AI summary
Provided are a sub-micron fibrous membrane in which sub-micron fibers aligned along one axis and sub-micron fibers in a random pattern form a network, and a method for producing the sub-micron fibrous membrane.