Electrospinning Electrode with Loose Elements
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Solution Overview
Problem
Current methods for producing nanofibres through electrospinning face challenges such as low production rates, high costs due to the need for large numbers of needles, and issues with electrical field interference and equipment maintenance, making it expensive for industrial-scale production of fibres like filtration and absorbent textiles.
Innovation Solution
A method and apparatus using a primary electrode with a surface coated by semi-submerged, loose elements that roll in a polymer solution, generating a thin layer and allowing for high voltage electrospinning, which increases throughput and avoids the limitations of needle-based systems by creating a stable, bubble-like surface for fibre formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If needle-based electrospinning is used to produce nanofibres, then fibre quality and uniformity are maintained, but production rate is low and equipment complexity increases
Solution Approach 1:
The invention segments the single needle spinneret into multiple needles arranged in a array, allowing simultaneous electrospinning from multiple points. This increases production rate while maintaining the quality characteristics of needle-based electrospinning, as each needle operates independently to produce uniform nanofibres.
Solution Approach 2:
The invention transitions from a single-point (0D) or linear (1D) needle arrangement to a two-dimensional array of needles. This dimensional expansion allows numerous needles to be packed in a compact space, dramatically increasing throughput without proportionally increasing equipment complexity.
2Productivity
If multiple needles are used to increase production rate, then throughput improves, but electrical field interference between needles increases
Solution Approach 1:
The invention applies local quality by giving each needle in the array its own independent high-voltage power supply. This allows precise control of the electrical field at each needle location, preventing interference between adjacent needles while maintaining high throughput through simultaneous operation of multiple needles.
Solution Approach 2:
The invention introduces a conductive plane as an intermediary element between the needles and ground. This conductive plane acts as a reference potential that stabilizes the electrical fields around each needle, reducing interference effects and enabling closer spacing of needles in the array.
3Ease of manufacture
If solution-based electrospinning is used, then fibre formation is achieved, but production cost increases due to solvent requirements and processing complexity
Solution Approach 1:
The invention changes the physical state parameter of the polymer material from solution (liquid) to melt (viscous liquid). By heating the polymer above its melting point, the process eliminates the need for organic solvents entirely, reducing production costs and environmental concerns while maintaining fibre formation capability through electrospinning.
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 approach enables high throughput production of nanofibres with improved process control and uniformity, reducing costs and complexity compared to traditional needle-based methods, while maintaining fibre quality and predictability.
Implementation Method 1
a droplet of polymer solution or melt is placed in a strong electric field giving rise to the repulsion between the induced like-charges in the droplet competing with the surface tension of the liquid
Implementation Method 2
Electrostatic instability leads to rapid, chaotic whipping of the jet, leading, in turn, to fast evaporation of any solvent as well as a stretching and thinning of the polymer fibre that is left behind
Implementation Method 3
fast evaporation of any solvent as well as a stretching and thinning of the polymer fibre that is left behind
Data Source
AI summary
A method and apparatus provided for the production of fine fibers by electrospinning fibers by applying an electrical field between a primary electrode and a counter electrode (5) spaced apart from the primary electrode and extending generally parallel thereto wherein at least an operative surface of the primary electrode is coated with a polymer solution (3) and an electric field of sufficient magnitude is generated between the primary electrode and counter electrode to cause the formation of fine fibers (9) in the space between the electrodes. The operative surface of the primary electrode that is coated with polymer solution is made up of appropriate portions of the surfaces of a multitude of operatively semi-submerged, loose (unattached) elements (1, 11, 17, 21) supported on the bottom of a trough (2) or tray or another support member or members (12, 18, 22). Facility is included for causing polymer solution to be applied to the exposed surfaces of the loose elements by causing them to roll in the polymer solution so that they become coated with a thin layer of polymer solution on their surfaces.