Electrospinning Device for High-Throughput Core-Sheath Fiber Production
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Solution Overview
Problem
Current methods for producing microscale or nanoscale concentrically-layered fibers, such as extrusion, fiber spinning, and melt blowing, are not suitable for creating drug-loaded core-sheath fibers due to high temperatures and low throughput, and existing electrospinning techniques face challenges in scalability and heterogeneity.
Innovation Solution
A device comprising a hollow tube with a lengthwise slit for core polymer solution and optional sheath polymer bath or troughs for high-throughput production of core-sheath fibers, utilizing electrospinning to form fibers with a grounded collector that rotates to twist them into yarns, allowing for controlled incorporation of sheath polymer and reducing clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electrospinning methods (emulsion or coaxial) are used to produce core-sheath fibers, then fiber structure and drug delivery capability are improved, but manufacturing throughput is reduced
Solution Approach 1:
The invention divides the electrospinning process into multiple independent zones: a core polymer solution reservoir, a sheath polymer solution reservoir, and a collector. The core solution is delivered through a capillary tube while the sheath solution is applied to the outer surface, allowing simultaneous production of multiple fibers without requiring complex coaxial nozzles or emulsion systems.
Solution Approach 2:
The invention uses a liquid bridge or capillary tube as an intermediary to deliver the core polymer solution to the collection point, while the sheath polymer solution is applied externally. This intermediary mechanism simplifies the delivery system compared to traditional coaxial nozzles and enables higher throughput by allowing continuous operation without frequent nozzle changes or clogging issues.
2Productivity
If high temperature processes (extrusion, fiber spinning, melt blowing) are used to produce core-sheath fibers, then manufacturing throughput is improved, but compatibility with thermally labile materials is lost
Solution Approach 1:
The invention replaces high-temperature mechanical processes (extrusion, melt blowing) with a low-temperature electrospinning process. By using electrostatic forces to draw fibers from polymer solutions rather than heating and melting the material, the process achieves high throughput while maintaining compatibility with thermally labile materials such as drugs and polypeptides that would be damaged by conventional high-temperature methods.
3Productivity
If coaxial nozzle arrays are used to increase throughput, then production capacity is improved, but system complexity and heterogeneity increase
Solution Approach 1:
The invention merges the core and sheath polymer solution delivery systems into a single integrated apparatus with one capillary tube and one external reservoir. This unified design eliminates the need for multiple separate pumps and nozzles required by coaxial arrays, reducing system complexity while maintaining high production capacity through continuous operation and simplified maintenance.
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
Enables high-throughput production of homogeneous and core-sheath fibers with diameters suitable for medical applications, improving scalability and fiber uniformity while maintaining compatibility with thermally labile materials like drugs.
Implementation Method 1
an electrostatic force is applied to a polymer solution to form very fine fibers. Conventional electrospinning methods utilize a charged needle to supply a polymer solution, which is then ejected in a continuous stream toward a grounded collector.
Implementation Method 2
The device comprises a grounded collector for electrospun yarns, the collector being configured to rotate so that fibers are twisted into yarns as they are collected from an electrospinning apparatus.
Data Source
AI summary
Devices and methods for high-throughput manufacture of concentrically layered nanoscale and microscale fibers by electrospinning are disclosed. The devices include a hollow tube having a lengthwise slit through which a core material can flow, and can be configured to permit introduction of sheath material at multiple sites of Taylor cone formation formation.