Electrospinning Sideway Motion for Aligned Microtube Arrays

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Solution Overview

Problem

Current electrospinning methods face limitations in producing highly aligned and closely packed microtube arrays, with existing techniques resulting in randomly arranged fibers and limited production speed and quantity, which hinders industrial applications and tissue regeneration efforts.

Innovation Solution

An electrospinning apparatus with a rotating collector and a sideway motion device controlled by a specific angular speed formula (θ=tan−1 x/H) is used to produce flat, high-quality microtube array membranes, allowing for better fiber alignment and packing, and enabling the production of three-dimensional ordered scaffolds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional electrospinning methods are used, then fiber production is achieved, but fiber alignment and packing quality are poor

Engineering Contradiction:
Improvefiber alignment and packing qualityVSAvoidproduction speed and quantity
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies dynamics by introducing a rotating collector that moves dynamically during the electrospinning process. The collector rotates at controlled speeds (e.g., 100-1000 RPM) to actively align fibers in the deposition direction while maintaining continuous fiber production. This dynamic motion transforms the static collection process into an active alignment mechanism, simultaneously achieving high fiber alignment quality and sustained production speed.

Inventive Principle:
Principle #15Dynamics

2Productivity

If needle type spinnerets are used, then electrospinning is simple, but production speed and quantity are limited

Engineering Contradiction:
Improveproduction speed and quantityVSAvoidspinneret structure complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by replacing the single needle spinneret with a multi-nozzle array configuration. The spinneret contains multiple nozzles arranged in specific patterns (e.g., 5-20 nozzles per spinneret, with 1-5 spinnerets total) to simultaneously produce multiple fiber bundles. This segmentation dramatically increases production capacity while keeping each individual nozzle simple in structure, effectively scaling up output without proportionally increasing complexity.

Inventive Principle:
Principle #1Segmentation

3Manufacturing precision

If fibers are collected with rotating disc or drum, then fiber alignment is improved, but device complexity increases

Engineering Contradiction:
Improvefiber alignmentVSAvoidcollector structure complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a collector system that performs multiple functions simultaneously: it collects fibers, aligns them through rotation, and can be configured in various arrangements (rotating disc, rotating drum, or stationary plate with controlled motion). This multi-functional collector design achieves high fiber alignment without requiring overly complex structures, as the same rotating mechanism serves both collection and alignment purposes.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 produces smooth, flat microtube array membranes with complete fiber sealing, reducing production time and costs, and enabling the creation of three-dimensional ordered scaffolds suitable for tissue engineering and industrial use.

Implementation Method 1

Electrospinning is a process that relies on electric charges to deform a conical droplet of polymeric solution ejected from a nozzle tip into ultra-fine fibers

Methodology Applied
Scientific EffectElectrospinning: Electrohydrodynamics

Implementation Method 2

a sideway motion device disposed on or connected to the spinneret or the rotating collector and configured to propel or move the spinneret or the rotating collector

Methodology Applied
Scientific EffectControlled motion:

Implementation Method 3

a rotating collector disposed from the spinneret and configured to collect the fibers

Methodology Applied
Scientific EffectRotational motion:

Data Source

PatentUS9091007B2Electrospinning apparatus with a sideway motion device and a method of using the same
Publication Date: 2015.07.28 TAIPEI MEDICAL UNIV
  • US9091007B2 patent drawing
  • US9091007B2 patent drawing
  • US9091007B2 patent drawing

AI summary

The invention provides an electrospinning apparatus, which comprises one or more spinneret, a rotating collector disposed from the spinneret and configured to collect the fibers, and a sideway motion device disposed on or connected to the spinneret or the rotating collector and configured to propel or move the spinneret or the rotating collector, wherein the sideway motion device is controlled by a controlling unit for providing an angular speed (θ) of the sideway motion with a formula: θ=tan−1 x/H wherein x is a parallel motion speed of the device and H is a vertical height between the spinneret and the rotating collector and wherein the angular speed (θ) is in a range of about 1.0×10−4 to about 1.0 (°/sec). Also provided is the 2-D or 3-D membranes produced therefrom and a method of using the apparatus of the invention.