Electrospinning method
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Solution Overview
Problem
Current electrospinning methods produce non-woven, isotropic fibrous structures, which are not suitable for applications requiring anisotropic mechanical properties or structures, such as directing cell growth and fluid flow, and are difficult to align accurately for complex designs.
Innovation Solution
A method and device that use a laser to selectively remove parts of the electrospun fibrous structure on a collector, allowing for controlled patterning and creation of anisotropic properties by directing a laser beam to predefined areas during the electrospinning process, enabling precise removal and patterning without deforming the structure, and optionally rotating the collector for tubular shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a rotating collector is used to align fibers, then anisotropic structure can be achieved, but the device complexity and positioning accuracy requirements become very high
Solution Approach 1:
The patent extracts the alignment function from the complex rotating collector system and transfers it to the laser cutting process. By creating patterns directly on the deposited fibrous structure, the alignment function is separated from the deposition mechanism, simplifying the overall device while maintaining the ability to create anisotropic structures.
Solution Approach 2:
The patent performs preliminary fiber deposition to create a complete fibrous structure first, then applies laser cutting to create the desired patterns and alignments afterward. This preliminary deposition followed by selective removal approach simplifies the device by eliminating the need for complex real-time steering and positioning during deposition.
2Manufacturing precision
If laser beam is used to locally remove fibrous structure, then manufacturing precision and patterning accuracy are improved, but the process time increases
Solution Approach 1:
The patent applies partial action by using laser cutting only in specific areas where pattern definition is needed, rather than processing the entire fibrous structure. This selective approach maintains high manufacturing precision for the patterned areas while minimizing the overall process time by leaving non-critical areas untouched.
3Ease of operation
If fibrous structure is removed from collector for processing, then access to the structure is improved, but deformation of the structure occurs
Solution Approach 1:
The patent uses the laser beam as an intermediary tool that can access and process the fibrous structure through the collector without requiring physical removal. The laser provides the necessary energy to cut and pattern the fibers while the collector remains in place, maintaining structural stability and avoiding deformation associated with removal and reattachment.
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 the creation of electrospun structures with tunable directional stiffness and reduced material usage, allowing for complex designs and applications like artificial tracheas and wound patches with tailored mechanical properties.
Implementation Method 1
directing a laser beam towards the collecting surface so as to locally remove part of the fibrous structure
Implementation Method 2
creating a voltage difference between the nozzle and a collecting surface
Implementation Method 3
The generated electric field causes a cone-shape deformation of the droplet at the nozzle tip. Once the surface tension of this droplet is overcome by the electrical force, a jet is formed out of the droplet and a fiber forms
Data Source
AI summary
A method of electrospinning (40) is provided, and an electrospinning device (1; 30). The method comprises (i) holding (41) a liquid comprising a polymer melt or a polymer solution in a container (2), (ii) letting out (42) a stream of the liquid from the container through at least one nozzle (3), (iii) creating (43) a voltage difference between the nozzle (3) and a collecting surface (4), (iv) collecting (44) electro spun material coming from the nozzle (3) so as to form a fibrous structure (8) on the collecting surface (4), and (v) directing (45) a laser beam (13) towards the collecting surface (4) so as to locally remove a part of the fibrous structure (8).