Covered Electro-Spinning Electrode for Solvent Loss Reduction

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Solution Overview

Problem

Existing electrostatic spinning technologies face significant solvent loss during the production of fine fibers, which affects the fiber diameter and efficiency of the process, particularly when using volatile solvents.

Innovation Solution

The introduction of a covered dipping basin and a spray electrode arrangement with an endless chain spinning electrode, where the electrode is moved around a cover to minimize solvent evaporation, and the use of a serpentine belt or metal band as spinning electrodes to maintain a consistent spacing and reduce solvent exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the spinning electrode is exposed to the environment for fiber generation, then fine fibers can be produced, but solvent loss increases

Engineering Contradiction:

Improvefine fiber productionVSAvoidsolvent loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

A flexible cover is used to enclose the dipping basin, creating a sealed environment that prevents solvent evaporation while allowing the spinning electrode to access the polymer solution. This flexible barrier maintains the polymer-to-solvent ratio without restricting the fiber generation process.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The spinning electrode is divided into segments that can be dipped into the solution and then exposed for fiber generation. This segmentation allows the electrode to cycle between solution access and fiber production, maintaining solvent efficiency while ensuring continuous fiber output.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If the dipping basin is open for electrode access, then the electrode can be dipped in polymer solution, but solvent evaporation increases

Engineering Contradiction:

Improveelectrode dipping accessVSAvoidsolvent evaporation

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The flexible cover provides a barrier that reduces solvent evaporation from the dipping basin while still allowing the spinning electrode to be dipped into the polymer solution. The cover creates a controlled environment that minimizes energy loss from solvent evaporation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The spinning electrode operates in periodic cycles, dipping into the solution and then being exposed for fiber generation. This periodic action allows the electrode to access the polymer solution when needed while minimizing the time the solvent is exposed to evaporation, thus reducing overall energy loss.

Inventive Principle:

Principle #19Periodic action

3Productivity

If traditional electro-spinning methods are used, then fine fibers are generated, but the polymer-to-solvent ratio varies

Engineering Contradiction:

Improvefine fiber generationVSAvoidpolymer-to-solvent ratio

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The flexible cover encloses the dipping basin to prevent solvent evaporation, thereby maintaining a stable polymer-to-solvent ratio in the solution. This stable composition ensures consistent fiber properties and reliable polymer-to-solvent ratios throughout the spinning process.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The system maintains a stable polymer-to-solvent ratio through controlled environmental conditions created by the flexible cover. The enclosed environment provides feedback control over solvent evaporation, ensuring the solution composition remains constant and fibers are produced with consistent properties.

Inventive Principle:

Principle #23Feedback

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

This approach significantly reduces solvent loss by up to 60% compared to traditional methods, maintaining a stable polymer-to-solvent ratio and improving the efficiency of fine fiber production while minimizing environmental impact.

Implementation Method 1

electrostatic spinning of fine fibers from a polymeric solution in an electrostatic field created by a voltage differential between a spinning electrode and a collecting electrode

Methodology Applied

Scientific EffectElectrostatic field: Electric Field

Implementation Method 2

the electrostatic potential between a grid and the emitter imparts a charge which causes the liquid to be 'spun' as thin fine fibers

Methodology Applied

Scientific EffectElectrostatic potential: Electric Field

Implementation Method 3

During this process, the solvent is evaporated off the fine fibers which draws down the fiber diameter during their flight

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

electro-spinning fine fibers from a polymer solution coating on an electrode under an electrostatic field

Methodology Applied

Scientific EffectElectro-spinning: Electrohydrodynamics

Data Source

PatentUS20090127747A1Apparatus and Method for Reducing Solvent Loss for Electro-Spinning of Fine Fibers

Publication Date: 2009.05.21 ELMARCO SRO

AI summary

A method and apparatus for generation of fine fibers via electro-spinning from a polymer solution is provided. The spray or spinning electrode is dipped in a polymer solution to maintain a polymer solution coating on the electrode for electrostatic spinning of fine fibers. A cover provides an evaporation barrier that reduces solvent loss. The drive unit may move the electrode around the cover to facilitate dipping of part of the electrode while exposing another part of the electrode for electro-spinning of fine fibers.