Electrospinning Device Optical Thickness Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for measuring the thickness of electrospun fibrous structures are inaccurate and destructive, as they require direct contact or destructive slicing, and cannot be performed in situ during the electrospinning process.
Innovation Solution
An electrospinning device equipped with an optical measurement system that calculates the thickness of the fibrous structure in real-time by measuring the distance between the collector and the momentary top layer, allowing for in-situ, non-contact, and non-destructive thickness measurement, with the option to control the electrospinning process based on the measured thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct contact measurement methods are used, then measurement can be performed, but the fibrous structure is compressed and measurement accuracy deteriorates
Solution Approach 1:
The patent replaces mechanical contact measurement systems with an optical measurement system that uses light to measure the distance between the collector and the top layer of the fibrous structure. This substitution eliminates mechanical compression while maintaining measurement capability, directly resolving the contradiction between measurement accuracy and structural integrity.
Solution Approach 2:
The patent introduces an optical measurement system as an intermediary between the measurement device and the fibrous structure. This intermediary allows distance measurement without direct mechanical contact, enabling accurate thickness measurement while preserving the compressible nature of the electrospun structure.
2Measurement precision
If destructive slicing methods are used, then cross-section measurement is enabled, but the fibrous structure is destroyed and in-situ measurement becomes impossible
Solution Approach 1:
The patent replaces destructive mechanical slicing with non-contact optical measurement. The optical system measures the distance to the top layer of the fibrous structure without requiring physical access to the cross-section, thereby maintaining structural integrity while enabling thickness measurement.
Solution Approach 2:
The patent creates an optical copy or representation of the fibrous structure's surface position rather than physically slicing the structure. By measuring the optical distance to the top layer, the system obtains measurement data without destroying the original structure, allowing in-situ measurement throughout the electrospinning process.
3Measurement precision
If thickness measurement is performed after electrospinning, then measurement can be conducted, but real-time process control is lost and material waste increases
Solution Approach 1:
The patent performs thickness measurement during the electrospinning process rather than after completion. By continuously monitoring the distance between the collector and the top layer in real-time, the system enables preliminary detection of thickness deviations, allowing for immediate process adjustment and reducing material waste.
Solution Approach 2:
The patent implements a feedback mechanism where the optical measurement system continuously monitors fibrous structure thickness and provides real-time data to the control system. This feedback loop enables dynamic adjustment of electrospinning parameters to maintain target thickness, improving both measurement capability and process control efficiency.
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 precise control over the electrospinning process, reduces material waste, and allows for the production of complex fiber structures with varying thicknesses, while maintaining the integrity of the fibrous structure.
Implementation Method 1
an optical measurement system arranged to measure a baseline distance between the surface of the collector and the optical measurement system at at least one predefined location, and to repeatedly measure a momentary distance between a momentary top layer of the fibrous structure and the optical measurement system at the at least one predefined location during the electrospinning process
Implementation Method 2
The generated electric field causes a cone-shape deformation of the droplet at the nozzle tip
Implementation Method 3
Once the surface tension of this droplet is overcome by the electrical force, a jet is formed out of the droplet
Implementation Method 4
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
An electrospinning device is provided with a container for holding a liquid comprising a polymer melt or a polymer solution, and a nozzle arranged to outlet a stream of the liquid from the container. A collector collects electro spun material during electrospinning so as to form a fibrous structure. The device comprises an optical measurement system that measures a baseline distance between the collector and the optical measurement system for at least one location on a surface of the collector, and also measures a momentary distance between the optical measurement system and a momentary top layer of the fibrous structure during the electrospinning process. A processor calculates a momentary thickness of the fibrous structure. Once a required thickness is reached the electrospinning can be stopped.