Electrospinning Collector Spindle Array for Fiber Throughput
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Solution Overview
Problem
The electrospinning process faces challenges in throughput and fiber morphology due to limitations in electric field distribution and management of the output from the reservoir source, which affects the dimensions and uniformity of the produced fibers.
Innovation Solution
A method and apparatus for electrospinning that includes a rotating collector with a centered disk and multiple spindles, allowing for the creation of both aligned and randomly oriented fibers. This setup enables the production of single crystal fibers with high throughput and controlled diameter, ranging from 1 nm to 5 μm, suitable for various industrial and biomedical applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high electric field is applied to generate sufficient electrostatic charge for fiber formation, then fiber production is enabled, but the electric field distribution becomes non-uniform leading to poor fiber morphology and limited throughput
Solution Approach 1:
The collector is divided into multiple spindles arranged in a circular array, with each spindle acting as an independent collection zone. This segmentation allows different regions of the collector to operate under optimized electric field conditions, improving both throughput and fiber morphology uniformity simultaneously
Solution Approach 2:
The invention transitions from a traditional flat collector to a three-dimensional arrangement of spindles in a circular array. This dimensional change creates multiple collection zones at different radial distances from the center, enabling better electric field distribution and improved fiber morphology while increasing production capacity
2Productivity
If the reservoir output is not properly managed, then the electrospinning process can operate, but the fiber volume and dimensions are limited
Solution Approach 1:
The system uses the electrostatic forces generated during the electrospinning process itself to manage and direct the fiber output. The rotating collector with spindles passively collects fibers through electrostatic attraction, eliminating the need for complex active management systems and enabling higher fiber volume production
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 described method achieves high throughput production of single crystal fibers with controlled diameters, facilitating their use in commercial and biomedical applications, such as tissue scaffolds, and allowing for distinct applications based on fiber orientation.
Implementation Method 1
An electric field is established between the reservoir/aperture and the collector by applying a specified voltage to the reservoir/aperture. Upon applying a voltage to the appropriate components, an electrostatic charge accumulates at the surface of the liquid
Implementation Method 2
Electro-spinning is a voltage-driven fabrication process governed by specific electro hydrodynamic phenomena wherein small diameter fibers are produced from a polymer-containing precursor liquid
Implementation Method 3
At the time when the electrostatic repulsion is larger than the surface tension of the liquid, the liquid meniscus forms into a conically shaped structure known as a Taylor Cone
Implementation Method 4
Upon formation of the Taylor Cone, a charged liquid jet exits the needle tip or aperture and is conveyed towards the collector by electrostatic forces
Data Source
AI summary
A method of electrospinning a plurality of fibers (150) is provided. The method includes providing at least one collector (120) and a single extruder (110). The extruder (110) includes a channel (112) housing a precursor liquid (190). The method includes dispensing the precursor liquid (190) from the extruder (110), and in response to an electric field, collecting fibers (150) formed from the precursor liquid (190) by a collector (120) to form a hollow casing (210) of fibers (150).