Electroblowing Nanofiber Web Formation with Grounded Spinneret
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Solution Overview
Problem
Existing electroblowing processes for forming nanofiber webs require maintaining all equipment in contact with the conductive polymer solution at high voltage, leading to safety hazards, insulation challenges, and the need for high voltage to generate sufficient electric fields, which is cumbersome and inefficient, especially on a commercial scale.
Innovation Solution
The process involves issuing an electrically charged polymer stream from a spinning nozzle with a grounded spinneret, using an electrode downstream of the gas nozzles to generate an electric field, allowing the spinneret and upstream equipment to be grounded, and decoupling the spinning nozzle to collector distance from the electric field, thereby reducing the required voltage and simplifying equipment design and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high voltage is applied to the spinning nozzle to generate sufficient electric field for charging polymer stream, then electrical charge is imparted on polymer stream, but equipment complexity and safety hazards increase due to need for high-voltage insulation
Solution Approach 1:
Instead of applying high voltage to the spinning nozzle (grounded), the invention applies high voltage to the collector. This inversion allows the polymer stream to be charged by the electric field between the grounded spinneret and the high-voltage collector, eliminating the need for high-voltage insulation of the spinning equipment while maintaining effective charge impartment.
Solution Approach 2:
The invention introduces an intermediary electrode system between the spinneret and collector. The electrode is held at an intermediate voltage potential and serves as a mediator to generate the necessary electric field for charging the polymer stream without requiring the spinneret itself to be at high voltage, thus simplifying insulation requirements.
2Adaptability or versatility
If spinning nozzle to collector distance is increased to accommodate equipment layout, then equipment arrangement flexibility improves, but electric field strength decreases requiring higher voltage
Solution Approach 1:
The invention employs adjustable and reconfigurable electrode positions and voltages. The intermediate electrode can be dynamically adjusted in position and voltage potential to maintain optimal electric field strength regardless of the distance between spinneret and collector, allowing flexible equipment arrangement without compromising charging effectiveness.
Solution Approach 2:
The invention changes the voltage distribution parameters along the path from spinneret to collector. By using multiple electrodes at different voltage potentials rather than a single high-voltage collector, the electric field can be optimized for longer distances, maintaining sufficient field strength for effective polymer charging even when equipment layout requires greater separation.
3Reliability
If all equipment in contact with polymer solution is maintained at high voltage, then electric field for charging is maintained, but safety hazards and insulation requirements increase
Solution Approach 1:
The invention inverts the traditional approach by grounding the spinning equipment (spinneret and spinning nozzle) and applying high voltage to the collector instead. This ensures that all equipment in contact with the polymer solution is at ground potential, eliminating safety hazards associated with high-voltage polymer handling while maintaining the necessary electric field through the inverted configuration.
Solution Approach 2:
The invention introduces grounded intermediate electrodes as mediators between the grounded spinneret and high-voltage collector. These intermediary electrodes allow the electric field to be maintained for effective polymer charging while keeping all polymer-contacting equipment at safe ground potential, thus separating the high-voltage function from the polymer handling function.
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 reduces the voltage needed to impart charge on the polymer stream, enhances safety by eliminating the need for high-voltage insulation of large equipment, and allows for more flexible operation by decoupling the spinning nozzle to collector distance from the electric field, resulting in efficient and safer production of nanofibers with uniform fiber diameters.
Implementation Method 1
an electric field is generated between the spinneret and the electrode of sufficient strength to impart said electrical charge to the polymer stream
Implementation Method 2
a forwarding gas stream aids in transporting the polymer away from the spinning nozzle
Implementation Method 3
issuing an electrically charged polymer stream from a spinning nozzle... collecting nanofibers formed from the charged polymer stream
Data Source
AI summary
An improved electroblowing process is provided for forming a fibrous web of nanofibers wherein polymer stream is issued from a spinning nozzle in a spinneret with the aid of a forwarding gas stream, passes an electrode and a resulting nanofiber web is collected on a collector. The process includes applying a high voltage to the electrode and grounding the spinneret such that an electric field is generated between the spinneret and the electrode of sufficient strength to impart an electrical charge on the polymer as it issues from the spinning nozzle.