Multi-Nozzle Electrospinning System for High-Throughput Nano-Coating
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Solution Overview
Problem
Current systems for producing polymeric nanofibers and nanoparticles face challenges in industrial viability, processing time, and polymeric performance, necessitating an efficient and eco-friendly method for large-scale production.
Innovation Solution
A system for nano-coating substrates using an insulated housing with moveable panels and solution dispensing nozzles, employing electrospraying or electrospinning to deposit polymeric nanostructures, which includes a power supply and solution transport vessels to facilitate high-voltage electrospinning or electrospraying, allowing for simultaneous use of multiple spinneret nozzles for faster product coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current electrospinning and electrospraying systems are used, then polymeric nanofibers and nanoparticles can be produced, but the processing time is excessive and industrial viability is limited
Solution Approach 1:
The system divides the electrospinning/electrospraying process into multiple independent nozzle units arranged in arrays, allowing simultaneous operation of multiple nozzles. Each nozzle operates independently while contributing to overall production, thereby segmenting the production process to achieve higher throughput and reduced processing time per unit area.
Solution Approach 2:
The patent combines multiple electrospinning/electrospraying nozzles into a single integrated system that operates simultaneously. By merging multiple nozzle functions into one coordinated system, the apparatus achieves industrial-scale production capacity while maintaining control over each individual nozzle's operation.
2Adaptability or versatility
If traditional electrospinning systems are used, then nanofibers can be produced, but the system lacks adaptability for different product types and applications
Solution Approach 1:
The system is designed with universal nozzle units that can be configured for different electrospinning and electrospraying applications. The same basic nozzle structure and control system can produce various product types including nanofibers, nanoparticles, and coated substrates by adjusting parameters such as solution composition, voltage, and nozzle-to-substrate distance, thereby achieving multi-functionality without requiring entirely different systems for each application.
Solution Approach 2:
The system incorporates adjustable and reconfigurable components that allow dynamic adaptation to different production requirements. Nozzle arrays can be reconfigured, solution flow rates adjusted, and electrical parameters modified in real-time to optimize for different product types, enabling the system to adapt to varying application needs while maintaining operational 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
The system enables the rapid and efficient production of breathable, waterproof, and wound-healing products with enhanced polymeric performance, suitable for industrial-scale production of textiles and drug delivery systems, while minimizing processing time and environmental impact.
Implementation Method 1
electrospraying or electrospinning to deposit polymeric nanostructures
Implementation Method 2
electrospraying or electrospinning to deposit polymeric nanostructures
Implementation Method 3
A high voltage (typically 10 kV-50 kV) current generated from the power supply is directed toward a space between the nozzle tips and the collector
Implementation Method 4
A high voltage (typically 10 kV-50 kV) current generated from the power supply is directed toward a space between the nozzle tips and the collector to form nanostructures that are deposited on the collector
Data Source
AI summary
The system for nano-coating a substrate (10) includes a housing (12) having an upper, dispensing chamber (18) in which electrospraying or electrospinning can occur, a lower storage chamber, and a wall (16) that separates the dispensing chamber (18) from the storage chamber. The dispensing chamber (18) includes first and second panels (24a), (24b) and a moveable collector (20) between the first and second panels (24a), (24b). Solution dispensing nozzles (26) are disposed in apertures (45) in the panels (24a), (24b), and extend from a front surface of each panel (24a), (24b). A plurality of solution supply tubes (54) extend from a rear surface of each panel (24a), (24b) to a pump (34) in the lower housing. Inner panel channels (52) are defined within each panel (24a), (24b) between the tubes (54) and the nozzles (26).