Core-Sheath Electrospinning with Multi-Slit Taylor Cone Formation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for producing core-sheath fibers, such as extrusion and melt blowing, are not suitable for thermally labile materials like drugs or polypeptides, and conventional electrospinning techniques have limited throughput and are prone to heterogeneity issues with coaxial nozzle arrays.

Innovation Solution

A device and method for high-throughput production of core-sheath fibers by co-localizing multiple materials at multiple sites of Taylor cone formation, using a hollow vessel with slits for core and sheath polymer introduction and a rotating collector for yarn formation, which allows for the simultaneous electrospinning of core-sheath fibers with controlled fiber diameter and drug release profiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional electrospinning methods with single needle are used, then fiber quality is improved, but throughput is limited

Engineering Contradiction:

ImprovethroughputVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention divides the electrospinning process into multiple independent sites by using a hollow vessel with multiple slits, allowing simultaneous electrospinning at multiple locations. This segmentation enables parallel fiber production, significantly increasing throughput while maintaining the simplicity of individual electrospinning units.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention merges multiple electrospinning operations into a single integrated system by collecting all fibers from multiple sites onto one rotating collector. This combining approach increases productivity without requiring separate collection systems for each spinning site, thereby reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If coaxial nozzle arrays are used to increase throughput, then productivity is improved, but heterogeneity among fibers increases

Engineering Contradiction:

ImprovethroughputVSAvoidfiber uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Instead of using a complex array of coaxial nozzles, the invention segments the polymer solution delivery into multiple independent slits on a hollow vessel. Each slit operates as an independent electrospinning site, ensuring uniform fiber formation at each location while collectively providing high throughput through parallel processing.

Inventive Principle:

Principle #1Segmentation

3Productivity

If high temperatures are used in extrusion and melt blowing, then manufacturing efficiency is improved, but thermal sensitivity of materials deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidthermal damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention replaces thermal-based manufacturing methods (extrusion, melt blowing) with an electrostatic field-based electrospinning process. This substitution eliminates the need for high temperatures, allowing the production of thermally sensitive materials like drugs and polypeptides while maintaining manufacturing efficiency through continuous electrospinning operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If coaxial electrospinning is used, then core-sheath fiber structure is improved, but device complexity increases

Engineering Contradiction:

Improvecore-sheath structure controlVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention achieves core-sheath fiber formation through segmentation of polymer solutions into different slits on the hollow vessel, with core polymer delivered through inner slits and sheath polymer through outer slits. This approach maintains precise control over core-sheath structure while avoiding the complexity of coaxial nozzles by using simple, separate slit openings.

Inventive Principle:

Principle #1Segmentation

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 the efficient production of core-sheath fibers with controlled drug release profiles and improved throughput, overcoming the limitations of existing methods by ensuring uniformity and scalability in fiber production.

Implementation Method 1

an electrostatic force is applied to a polymer solution to form very fine fibers

Methodology Applied

Scientific EffectElectrostatic force: Electrostatics

Implementation Method 2

As the jet stream travels in the air, solvent evaporation occurs resulting in a single long polymer fiber

Methodology Applied

Scientific EffectSolvent evaporation: Evaporation

Implementation Method 3

co-localizing multiple materials to multiple sites of Taylor cone formation

Methodology Applied

Scientific EffectTaylor cone formation:

Data Source

PatentUS20120193836A1Electrospinning Process for Manufacture of Multi-Layered Structures

Publication Date: 2012.08.02 ARSENAL MEDICAL INC

AI summary

Devices and methods for high-throughput manufacture of concentrically layered nanoscale and microscale fibers by electrospinning are disclosed. The devices include a hollow tube having a lengthwise slit through which a core material can flow, and can be configured to permit introduction of sheath material at multiple sites of Taylor cone formation.