Nanofiber Layer Production via Segmented Electrospinning and Melt Blowing
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Solution Overview
Problem
Conventional nonwoven multilayer structures face challenges in production rates, manufacturing costs, and product properties due to slow production rates and difficulties in collecting nanofibers on microfiber or scrim layers, particularly with electrospinning methods.
Innovation Solution
A nonwoven multilayer structure comprising a first nanofiber layer produced by melt or solvent electrospinning with diameters less than 300 nanometers and a second layer produced by melt blowing with diameters between 250 nm to 950 nm, where the layers have distinct properties and are adjacent without intervening adhesives, enhancing production efficiency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If electrospinning is used to produce nanofibers, then fiber diameter is reduced to very small sizes, but production rate becomes very slow and quantities remain small
Solution Approach 1:
The invention divides the nanofiber production into two separate stages: first producing a collection medium with microfibers or larger nanofibers, then depositing a second layer of finer nanofibers onto it. This segmentation allows each electrospinning process to optimize for its specific fiber diameter range, with the first layer providing a scaffold that enables higher overall production rates while the second layer achieves the desired fine fiber dimensions for filtration applications.
Solution Approach 2:
The first nanofiber layer acts as an intermediary collection medium that facilitates the deposition of the second nanofiber layer. This intermediary structure solves the contradiction by providing a substrate that enables efficient collection of fine nanofibers while itself being producible at higher rates, thus mediating between the requirements for fine fiber diameter and high production rate.
2Length of moving object
If nanofibers are placed on microfiber or scrim layers, then collection becomes difficult and production rates remain low
Solution Approach 1:
The invention changes the parameters of the collection medium by using electrospun nanofibers with controlled charge properties rather than conventional microfibers or scrims. The charged nanofiber layer creates strong electrostatic fields that dramatically improve collection efficiency of subsequent nanofibers, transforming the collection medium from a passive substrate to an active collection mechanism that enables high production rates.
Solution Approach 2:
The invention replaces mechanical collection methods (relying on physical entanglement or adhesion to scrims) with electrostatic collection mechanisms. The charged nanofiber layer substitutes mechanical collection with electrical field-based collection, which is far more efficient for capturing fine nanofibers and enables significantly higher production rates.
3Reliability
If conventional multilayer structures are used, then manufacturing costs and process complexity increase
Solution Approach 1:
The invention merges two electrospinning processes into a single integrated production line where the first nanofiber layer is deposited and then the second nanofiber layer is immediately deposited onto it without intermediate handling. This merging of processes reduces complexity compared to conventional methods that would require separate production and assembly steps, while maintaining reliable product properties through consistent layer formation.
Solution Approach 2:
The electrospun nanofiber layer serves multiple functions simultaneously: it acts as a collection medium for the second layer, provides filtration functionality itself, and creates the necessary electrostatic fields for efficient deposition. This multi-functionality reduces the need for separate components and simplifies the overall structure while maintaining reliable product performance.
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 solution improves production rates, reduces manufacturing costs, and enhances the physical properties of the multilayer structure, such as filtration efficiency and air permeability, by eliminating the need for separate collection media and adhesives, while maintaining the benefits of both electrospinning and melt blowing processes.
Implementation Method 1
Electrospinning is a commonly used method of producing nanofibers having very small fiber diameters
Implementation Method 2
nanofibers of the second layer are made by a melt blown process
Data Source
Figure 1~2
Figure 3
AI summary
Nonwoven multilayer structures having at least two nanofiber layers are described herein. The nonwoven multilayer structure may have two nanofibers layers that have different properties from each other, such as fiber diameter. One nanofiber layer may be produced by an electrospinning process, while another nanofiber layer may be produced by a melt blown process.