Polyelectrolyte Complex Fibre Drawing Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming Interfacial Polyelectrolyte Complex (IPC) fibres are limited to laboratory scale and are not easily scalable for commercial production due to the manual processes used for fibre drawing and construct formation.
Innovation Solution
An apparatus and method for drawing fibres using a system of outlets that dispense oppositely charged polyionic polymer solutions, forming a fused droplet with a polyelectrolyte complex interface, which moves under gravitational force to draw nascent fibres, and a collector system to combine and wind the fibres into constructs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes (forceps or syringe needle) are used for fibre drawing, then fibre formation is achieved, but scalability for commercial production is limited
Solution Approach 1:
The patent replaces manual mechanical operations (forceps, syringe needles, pitchfork apparatus) with an automated system using multiple outlets (102, 104, 106, 108) that automatically dispense polyelectrolyte solutions and form fibres. The system uses gravitational force and controlled dispensing mechanisms to automate fibre drawing, eliminating the need for manual manipulation and enabling continuous production.
Solution Approach 2:
The patent divides the fibre drawing process into multiple independent outlets (102, 104, 106, 108), each capable of dispensing polyelectrolyte solutions and forming individual fibres. This segmentation allows parallel fibre production from multiple outlets simultaneously, significantly increasing productivity while maintaining operational simplicity through standardized modular units.
2Productivity
If laboratory-scale IPC process is used, then fibre formation is achieved, but continuous fibre formation and scaling up are restricted
Solution Approach 1:
The patent creates a universal system where multiple outlets (102, 104, 106, 108) perform the same fibre-forming function simultaneously. Each outlet assembly can independently form fibres while contributing to the overall continuous production. The rotatable collector member (120) with multiple contact segments provides a universal collection mechanism that handles fibres from all outlets, enabling continuous production without increasing operational complexity.
Solution Approach 2:
The patent implements continuous fibre formation by having multiple outlets continuously dispense polyelectrolyte solutions and form fibres simultaneously. The rotatable collector member continuously collects fibres as they are formed, maintaining an uninterrupted production process. This eliminates the batch-wise nature of laboratory-scale processes and enables continuous manufacturing.
3Productivity
If multiple outlets dispense polymer solutions to form fused droplets, then scalable fibre production is enabled, but control of fibre drawing requires gravitational force utilization
Solution Approach 1:
The patent positions all outlets (102, 104, 106, 108) at the same vertical level, creating an equipotential arrangement where gravitational force acts uniformly on all fused droplets. This ensures that fibres from all outlets are drawn at consistent rates, maintaining uniformity in fibre production while enabling scalable output. The rotatable collector member is also positioned to receive fibres at equivalent gravitational potential.
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 the continuous and scalable production of IPC fibre constructs, allowing for the formation of thicker constructs by combining multiple fibres and achieving uniform fibre diameters through controlled flow rates of polymer solutions.
Implementation Method 1
the fused droplet is arranged to move along a fibre drawing path under gravitational force in an opposing direction from the first and second outlets such that nascent fibre is drawn from the polyelectrolyte complex interface
Implementation Method 2
the gas outlet is configured to discharge a stream of gas directed at the fused droplet to initiate movement of the fused droplet along the fibre drawing path
Implementation Method 3
polyelectrolyte complexation involves the formation of electrostatic bonds between two polyelectrolytes of opposite charges, leading to a macromolecular complex
Data Source
AI summary
There is provided an apparatus for drawing a fibre, the apparatus comprising, a first outlet for dispensing a volume of a first polyionic polymer solution; and a second outlet for dispensing a volume of a second oppositely charged polyionic polymer solution; said second outlet disposed adjacent to the first outlet such that the polymer solutions dispensed therefrom are capable of contacting each other to form a fused droplet comprising a polyelectrolyte complex interface separating the first polyionic and second polyionic polymer solutions; wherein the fused droplet is arranged to move along a fibre drawing path under gravitational force in an opposing direction from the first and second outlets such that nascent fibre is drawn from the polyelectrolyte complex interface. There is also provided a method of drawing the fibre.