Dual Electrospinning Coating for Strong Nanostructured Microfibers
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Solution Overview
Problem
Conventional methods for producing fibers with dimensions smaller than 10-15 microns are inadequate, and electrospun yarns with nanostructures have inferior mechanical properties compared to extrusion techniques.
Innovation Solution
An electrospinning apparatus with multiple twisters, reservoirs, nozzles, electrodes, and control panels is used to coat industrial microfibers and prefabricated grafts with synthetic and natural polymer-based nanofibers, allowing precise control over twisting and collection rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional extrusion method is used to produce fibers, then robust mechanical properties are achieved, but fiber dimensions cannot be reduced to 10-15 microns or smaller
Solution Approach 1:
The patent combines two different fiber production methods by coating electrospun nanofibers onto extrusion-produced microfibers. This merging allows the base microfiber to provide robust mechanical properties while the nanofiber coating provides the desired nanostructure surface, thus achieving both small effective dimensions and strong mechanical properties simultaneously.
Solution Approach 2:
The patent creates a composite fiber structure where an extrusion-produced microfiber core is coated with electrospun nanofibers. This composite structure integrates the mechanical strength of the microfiber core with the nanostructure properties of the nanofiber coating, resolving the contradiction between fiber diameter reduction and mechanical property maintenance.
2Shape
If electrospun sheets are twisted to fabricate yarns with nanostructure, then nanostructure is achieved, but mechanical properties are inferior compared to extrusion technique
Solution Approach 1:
The patent applies local quality by providing nanostructure only on the surface coating of the fiber while maintaining the bulk mechanical properties of the core microfiber. The electrospun nanofiber coating provides the desired nanostructure locally on the surface, while the extrusion-produced core maintains robust mechanical properties throughout its volume.
3Reliability
If dual electrospinning coating is applied to microfibers and grafts, then nanostructure and biocompatibility are enhanced, but device complexity increases
Solution Approach 1:
The patent designs a dual electrospinning apparatus that can coat different types of substrates (microfibers and prefabricated grafts) with different polymer materials using the same basic system. The apparatus includes interchangeable reservoirs and nozzles that can be configured for different coating materials and parameters, providing multi-functionality that justifies the increased complexity through versatility.
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 apparatus maintains the mechanical properties of microfibers while achieving nanostructures, enhancing the microenvironment for cell growth and attachment, and improving the biocompatibility and efficacy of grafts and medical devices.
Implementation Method 1
both electrodes, wherein the power supply is configured to generate an electrostatic field between the two electrodes
Data Source
AI summary
An electrospinning apparatus includes at least two reservoirs for containing a spinning dope and at least two nozzles, one on each of the reservoirs through which the spinning dope is extruded or drawn. First and second electrodes are in contact with the nozzles and generate an electrostatic field there between the first and second electrodes. A collection surface is positioned between the first and second electrodes. The apparatus may include a controller and a user interface to control parameter(s) at a desired set point.