Electrospinning Nozzle and Collector Layout for Uniform Nanofiber Scale-Up
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Solution Overview
Problem
Current electrospinning technologies face challenges in scaling up production rates, handling multiple polymer solutions, and controlling fiber deposition, leading to non-uniformity and substrate damage due to high friction and tension.
Innovation Solution
The system employs peristaltic pumps for continuous feeding, convergent-divergent nozzles and turbo canals for multiple jets, an adjustable metal sheet collector, and a conveyor belt to reduce friction, enabling high-throughput production of uniform nanofibers with precise control over deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional syringe pumps and needle spinnerets are used, then the electrospinning process can be maintained, but production rate is limited to 0.01-1 g/h
Solution Approach 1:
The system divides the single-needle spinneret into multiple needle spinnerets (e.g., 10-100 needles), each connected to its own syringe pump. This segmentation allows parallel production of nanofibers, increasing overall production rate from 0.01-1 g/h to potentially 10-100 times higher while maintaining the proven electrospinning mechanism.
Solution Approach 2:
Multiple needle spinnerets and syringe pumps are merged into a single integrated electrospinning system with a common high voltage power supply and collector. This combining approach achieves high throughput production while sharing common infrastructure, thereby managing device complexity efficiently.
2Productivity
If multiple needle spinnerets are used to increase production, then production capacity improves, but fiber jet convergence and deposition uniformity deteriorate
Solution Approach 1:
The system arranges multiple needle spinnerets in a two-dimensional array pattern rather than a single line, with needles positioned at specific angles (e.g., 30-60 degrees) relative to the substrate. This dimensional arrangement allows fiber jets from multiple needles to converge uniformly on the collector surface, maintaining deposition uniformity while increasing production capacity.
Solution Approach 2:
The needle spinnerets and substrate are configured to move relative to each other during electrospinning, with synchronized motion control that maintains optimal spacing and alignment. This dynamic adjustment ensures consistent fiber jet convergence and uniform deposition even as production capacity increases with more needles.
3Speed
If high tension is applied to move substrate through electrospinning apparatus, then processing speed improves, but substrate damage increases
Solution Approach 1:
The system replaces mechanical tension-based substrate transport with an electric field-driven approach. The high voltage electric field propels charged nanofiber jets onto the substrate, and the substrate is fed through the electrospinning zone at low tension to prevent damage to delicate materials while maintaining processing speed.
Solution Approach 2:
A conductive roller or belt acts as an intermediary between the substrate feed mechanism and the electrospinning zone. This intermediary gently holds and transports the substrate through the high voltage field without applying excessive tension, preventing substrate damage while enabling continuous processing.
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 uniform nanofibers with reduced substrate damage, allowing for composite structures and precise layering, and supports a wide range of substrates including delicate materials.
Implementation Method 1
A critical value is attained upon a further increase in the electric field, where the repulsive electrostatic force overcomes the surface tension and the charged jet of fluid is ejected from the tip of the Taylor cone.
Implementation Method 2
An electric field is applied to the end of the capillary tube that contains the polymer solution held by its surface tension
Implementation Method 3
Charged polymer fibers solidify with solvent evaporation.
Implementation Method 4
The systems and apparatuses may further include one or more peristaltic pumps.
Implementation Method 5
an adjustable metal sheet collector, and a conveyor belt to reduce friction
Data Source
AI summary
The present disclosure describes electrospinning systems and apparatuses suitable for use in high throughput industrial settings. The disclosed systems and apparatuses may include a high voltage power supply having positive and negative electrodes; one or more spinnerets that include one or more convergent-divergent nozzles, one or more turbo canals, or a combination thereof; and a collector. The systems and apparatuses may further include one or more peristaltic pumps. In some implementations, the systems and apparatuses may be designed to produce nanofibers from multiple polymer solutions simultaneously. The collector may be an adjustable collector that is composed of multiple metal sheets. The collector may alternately be a conveyor belt collector. The systems and apparatuses may optionally further include one or more of a ventilation system that reduces sparking inside the electrospinning chamber, a chamber for reducing power consumption when using an optional heater or dehumidifier, and an in-line quality control system.