Gravity-Fed Electrospinning Apparatus for High-Throughput Fiber Production
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Solution Overview
Problem
Current electrospinning technologies are not suited for large-scale manufacturing of fibers due to equipment limitations and high maintenance requirements, and they often result in premature crystallization and clogging issues.
Innovation Solution
A gravity-fed electrospinning apparatus with solid, charged needles and a reservoir system that drips precursor solutions onto needles, minimizing exposure to oxygen and reducing clogging, along with a configuration that allows for high throughput and efficient fiber collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hollow needles are used to feed solution through their longitudinal axes, then the electrospinning process can be maintained, but the needles tend to clog with crystallized portions of the solution requiring maintenance downtime
Solution Approach 1:
The solution feeding function is extracted from the hollow interior of the needle and relocated to an external reservoir system. The needle becomes a solid conductor that only receives solution at its tip, eliminating the internal passages that are prone to clogging while maintaining the electrospinning function.
Solution Approach 2:
Instead of feeding solution through the needle from the inside (conventional approach), the invention inverts the approach by having the needle as a solid structure that receives solution externally at its tip. This inversion eliminates the clogging issue associated with internal needle passages.
2Ease of operation
If solution is exposed to ambient oxygen for extended periods, then the electrospinning process can be maintained, but the solution undergoes premature crystallization reducing process efficiency
Solution Approach 1:
The solution is maintained in an oxygen-excluded environment within the reservoir system until the moment of electrospinning. This inert environment protection prevents premature crystallization and oxidation, allowing the solution to remain stable and operable for extended periods.
Solution Approach 2:
The solution is prepared and held in the reservoir in advance under protected conditions, ready for immediate electrospinning when needed. This preliminary preparation ensures the solution is in optimal condition for spinning while minimizing exposure time to harmful ambient conditions.
3Productivity
If conventional electrospinning apparatus are used, then fiber production can be performed, but the equipment is not suited for large-scale manufacturing requiring high throughput
Solution Approach 1:
The electrospinning system is segmented into multiple independent needle units, each with its own solution delivery pathway from the reservoir. This segmentation allows parallel fiber production across multiple needles, significantly increasing throughput while keeping each individual needle unit relatively simple in design.
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 robust and efficient large-scale production of fibers with reduced downtime for maintenance, maintaining high throughput and producing fibers with controlled properties suitable for various applications.
Implementation Method 1
electrospinning utilizes electric force to draw charged threads of polymer solutions or polymer melts, thereby forming polymer fibers
Implementation Method 2
Electrical charge (e.g., a voltage) is applied to the needles... fibers are formed from the precursor solution proximate the needles
Implementation Method 3
A gravity-fed electrospinning apparatus with solid, charged needles and a reservoir system that drips precursor solutions onto needles
Data Source
AI summary
Embodiments of the invention include electrospinning apparatus and techniques in which a precursor solution is allowed to descend onto, rather than through, needles, and fibers are formed from the precursor solution proximate the needles and deposited on a collector.