Melt Differential Electrospinning Nozzle for Nanofiber Production
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Solution Overview
Problem
Existing melt electrospinning technologies face challenges in achieving submicrometer-level fiber diameters and efficient production for industrialization due to large fiber diameters and low output, complex structures, high energy consumption, and limitations in solvent use and fiber strength.
Innovation Solution
A melt differential electrospinning device with a spinning nozzle, high-voltage electrostatic generators, and multiple electrode plates creates a multi-level electric field to extend and refine fibers, allowing for the production of nanofibers with adjustable fineness and increased output by distributing polymer melts into Taylor cones and combining wind and electric fields for fiber extension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional melt electrospinning is used, then fiber production is achieved, but fiber diameter is large (micrometer-level) and production efficiency is low
Solution Approach 1:
The patent divides the electrospinning process into multiple stages by introducing multi-level electrode plates with different voltages and configurations. The electric field is segmented into zones that progressively refine the fiber diameter from micrometer-level to submicrometer-level while maintaining continuous production flow, thus improving manufacturing precision without sacrificing productivity.
Solution Approach 2:
The patent extends the traditional single-point electrospinning into a multi-dimensional electric field configuration using multiple electrode plates arranged at different levels and positions. This dimensional expansion creates a complex electric field distribution that enables simultaneous fiber stretching and refinement across multiple zones, achieving both fine fiber diameter and high production efficiency.
2Manufacturing precision
If single electrode configuration is used, then device structure is simple, but fiber refinement is insufficient
Solution Approach 1:
The electrode system is segmented into multiple levels with each plate serving a specific function in the fiber refinement process. The first electrode plate creates the initial electric field for fiber formation, while subsequent plates with different voltages and configurations provide progressive refinement, enabling precise control over fiber fineness through a modular yet integrated structure.
Solution Approach 2:
The multi-level electrode plates are arranged in a nested configuration where each subsequent electrode plate is positioned within the electric field zone of the previous plate. This nesting arrangement allows the electric fields to interact and build upon each other, creating a cumulative refinement effect that achieves submicrometer fiber diameter without requiring excessive structural complexity.
3Manufacturing precision
If multiple electrode plates with different voltages are used, then fiber fineness is improved, but energy consumption increases
Solution Approach 1:
The patent employs dynamic voltage adjustment across the multiple electrode plates, where the voltage on each plate can be independently optimized based on its position and function in the refinement process. This dynamic configuration allows the system to achieve high fiber fineness while minimizing energy consumption by applying appropriate voltage only where needed, rather than uniformly high voltage across all electrodes.
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 device achieves finer fibers and higher output by adjusting the distance between electrode plates and voltage, enabling batch production of nanofibers with improved efficiency and reduced energy consumption, making it suitable for industrial applications.
Implementation Method 1
n layers of electrode plates including a first electrode plate and a second electrode plate, which are set under the spinning nozzle... the first electrode plate is connected with a high-voltage positive terminal of the first high-voltage electrostatic generator, the second electrode plate is mounted at a certain distance under the first electrode plate, and the second electrode plate is connected with a high-voltage positive terminal of the second high-voltage electrostatic generator
Implementation Method 2
the polymer melt is uniformly distributed into a circle of dozens of Taylor cones along the lower end of the lateral side of the first nozzle, thereby the spinning material melt is jetted into threads; then, under the combined action of the wind field and the electric field force, the threads pass through the holes on the first electrode plate and fall onto a fiber receiving plate
Data Source
AI summary
A melt differential electrospinning device and process, the melt differential electrospinning device comprising a spinning nozzle (1), a fiber receiving device (3), a first high-voltage electrostatic generator (6), a second high-voltage electrostatic generator (7), a grounding electrode (5), and n layers of electrode plates of a first electrode plate (2) and a second electrode plate (4), n being an integer greater than or equal to 2; the spinning nozzle comprises a splitter plate (21), a nut (22), a spring spacer (23), an air pipe positioning pin (24), a screw (25), a nozzle body positioning pin (26), a nozzle body (27), an air pipe (28), a heating device (29), a temperature sensor (210) and an inner cone nozzle (211). The melt differential electrospinning process employs the melt differential electrospinning device, such that the polymer melt, under the effect of a wind field and an electric field, is uniformly distributed into a circle of dozens of Taylor cones along the conical surface end, and is further formed into dozens of jet flows and refined into nanofibers; and a plurality of melt differential electrospinning nozzles are installed below the splitter plate, thus realizing large-scale production of nanofibers, with a simple structure, and easy machining and assembly of components.