Electroblowing Weakly Interacting Polymers Into Fine Fibers
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Solution Overview
Problem
Weakly interacting polymers dissolved in weakly interacting solvents result in polymer solutions with low electrical conductivity, making them unsuitable for electrospinning processes as they cannot redistribute charge quickly enough to be electrospun into fibers.
Innovation Solution
An electroblowing process is employed to spin weakly interacting polymers from polymer solutions with low electrical conductivity into fibers and webs by using a spinneret, blowing gas, and an electric field to form and collect fibers, overcoming the conductivity limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If electrospinning is used to produce fine fibers, then fiber diameter is reduced, but the polymer solution must have high electrical conductivity which excludes weakly interacting polymers
Solution Approach 1:
The invention changes the fundamental parameters of the spinning process by replacing electrospinning with electroblowing. This involves changing the polymer solution properties (using weakly interacting polymers in non-polar solvents with low conductivity) and adjusting process parameters (applying high voltage to create electric field, using blowing gas at controlled pressure) to achieve fine fiber production without requiring high electrical conductivity
Solution Approach 2:
The invention substitutes the electrospinning mechanism (which relies on electrical conductivity and charge redistribution) with an electroblowing mechanism that uses a combination of electric field and gas flow. The blowing gas provides the mechanical force to issue the polymer solution through the nozzle, while the electric field facilitates fiber formation and orientation, replacing the need for high conductivity
2Adaptability or versatility
If weakly interacting polymers are used, then fiber formation is enabled, but electrical conductivity is too low for electrospinning
Solution Approach 1:
The invention introduces blowing gas as an intermediary medium that bridges the gap between low-conductivity polymer solutions and the need for controlled fiber formation. The gas flow serves as a mediator that issues the polymer solution through the nozzle while the electric field acts on the issuing stream to create fibers, enabling the use of weakly interacting polymers without requiring high conductivity
Solution Approach 2:
The invention changes the electrical parameters by applying high voltage (e.g., 10-100 kV) to create a strong electric field that compensates for the low conductivity of weakly interacting polymer solutions. This parameter change enables the electric field to sufficiently influence the polymer stream for fiber formation despite the lack of high conductivity
3Productivity
If electroblowing is used to process low conductivity solutions, then fiber production is enabled, but process complexity increases
Solution Approach 1:
The invention merges the electrospinning concept with gas blowing technology to create electroblowing. By combining the electric field application with gas flow through the same nozzle system, the process achieves fine fiber production from low-conductivity solutions without requiring entirely separate systems, thus managing complexity while enabling new capabilities
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 process enables the production of fine fibers with diameters less than 1,000 nanometers, suitable for various applications, by utilizing weakly interacting polymers and solvents, achieving high throughput and suitable for forming commercial quantities of fibrous webs.
Implementation Method 1
the polymer solution must be conductive. Weakly interacting polymers dissolved in weakly interacting solvents provide polymer solutions that have low electrical conductivity and, therefore, unsuitable for electrospinning
Implementation Method 2
issuing the polymer solution in combination with a blowing gas in a direction from at least one spinning nozzle in the spinneret and in the presence of an electric field
Implementation Method 3
forming fibers and collecting the fibers on a collector
Data Source
AI summary
A fiber spinning process comprising the steps of providing a polymer solution, which comprises at least one weakly interacting polymer dissolved in at least one weakly interacting solvent to a spinneret; issuing the polymer solution in combination with a blowing gas in a direction from at least one spinning nozzle in the spinneret and in the presence of an electric field; forming fibers and collecting the fibers on a collector.