Electrospinning Apparatus Dripping Solution onto Conductive Plate
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Solution Overview
Problem
Existing electrospinning machines are not suited for large-scale manufacturing of fibers due to high downtime, extensive cleaning procedures, and frequent replacement of parts.
Innovation Solution
An electrospinning apparatus where the polymer solution is dripped onto charged conductors, such as multiple needles or a conductive plate, rather than being fed through hollow needles, allowing for efficient fiber production with reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hollow needles are used to feed polymer solution in conventional electrospinning, then fibers can be produced, but the needles clog with crystallized solution requiring frequent cleaning and replacement
Solution Approach 1:
The patent inverts the conventional electrospinning configuration by positioning the solution source above the charged conductors instead of feeding solution through hollow needles. The polymer solution drips onto charged conductive needles or plates from a reservoir, eliminating the need for hollow internal channels that clog with crystallized material. This inversion allows solid conductors to be easily wiped or brushed clean, dramatically reducing maintenance downtime.
2Ease of operation
If polymer solution is exposed to ambient oxygen during feeding, then the solution can be delivered to conductors, but deleterious crystallization occurs reducing fiber quality
Solution Approach 1:
The patent implements an inert atmosphere by enclosing the polymer solution reservoir and delivery system in an oxygen-excluding environment. The solution is contained in a sealed reservoir that prevents ambient oxygen contact during storage and delivery to the charged conductors. This inert environment protection prevents oxidative crystallization that would otherwise degrade the polymer solution and compromise fiber quality.
3Reliability
If conventional electrospinning apparatus are used, then fibers can be produced, but extensive cleaning procedures and part replacement are required for large-scale manufacturing
Solution Approach 1:
The patent segments the electrospinning system into modular components: a removable reservoir, charged conductors mounted on a support structure, and a collector. The conductors themselves are segmented into multiple needles or plate sections that can be individually accessed and cleaned. This modular segmentation allows rapid replacement of contaminated components without disassembling the entire apparatus, enabling continuous large-scale production with minimal downtime.
Solution Approach 2:
The patent implements self-service maintenance by designing the charged conductors to be easily accessible and simple to clean. The solid conductor surfaces (needles or plates) can be quickly wiped or brushed clean of any accumulated material without requiring complex disassembly or specialized cleaning procedures. This self-service capability allows operators to rapidly restore conductors to working condition, maintaining high reliability for continuous manufacturing.
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 enables high-rate, large-volume fiber production with minimized downtime and maintenance, while reducing exposure to ambient oxygen to prevent deleterious crystallization.
Implementation Method 1
electrospinning utilizes electric force to draw charged threads of polymer solutions or polymer melts, thereby forming polymer fibers
Implementation Method 2
The high-voltage source is electrically coupled to the plurality of needles
Data Source
AI summary
Embodiments of the invention include electrospinning apparatus and techniques in which a precursor solution is allowed to descend onto a conductive surface, such as the surface of a conductive plate, rather than through needles, and fibers are formed from the precursor solution and deposited on a collector.