Electrospun Nanofiber Alignment via Post-Drawing

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Solution Overview

Problem

Conventional methods for manufacturing nanofibers are limited by the inability to produce polymer nanofibers using mechanical extrusion, and electrospinning lacks control over fiber manipulation and assembly, resulting in mechanically weaker electrospun nanofibers that are difficult to collect and process into high-performance materials.

Innovation Solution

A system using two conductive collection surfaces with adjustable angles and speeds to align and elongate electrospun nanofibers within a continuous manufacturing process, allowing for post-drawing and collection of ordered nanofiber arrays before solvent evaporation, enhancing mechanical properties through controlled elongation and alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrospinning is used to fabricate nanofibers, then nanofiber production is enabled, but fiber manipulation and assembly control is lost resulting in mechanically weaker fibers

Engineering Contradiction:

Improvenanofiber production capabilityVSAvoidfiber mechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The system segments the fiber collection process into distinct zones: a deposition area where fibers are initially formed, and a collection compartment where fibers are manipulated. This segmentation allows different processing conditions in each zone, enabling both nanofiber production and subsequent controlled manipulation to improve mechanical strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary action by performing post-drawing operations on fibers while they are still in the collection compartment before final collection. This preliminary manipulation of fibers in a controlled environment enables molecular alignment and strength enhancement before the fibers are fully collected and processed.

Inventive Principle:

Principle #10Preliminary action

2Strength

If conventional mechanical extrusion is used, then fiber strength is improved through post-drawing, but nanofiber production is impossible

Engineering Contradiction:

Improvefiber mechanical strengthVSAvoidnanofiber production capability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The system merges electrospinning technology with conventional post-drawing operations by integrating a collection compartment that enables fiber manipulation within the electrospinning apparatus. This combination allows nanofiber production via electrospinning while simultaneously enabling strength-enhancing post-drawing operations that were traditionally only available with mechanical extrusion.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If electrospinning is used, then nanofiber fabrication is achieved, but ordered nanofiber collection in continuous manufacturing is difficult

Engineering Contradiction:

Improvenanofiber fabrication capabilityVSAvoidnanofiber alignment and ordering

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces a spatial dimension to fiber collection by creating a three-dimensional collection compartment with collection surfaces positioned at specific distances and orientations. This dimensional approach allows fibers to be collected in an ordered manner on surfaces located downstream from the deposition area, enabling continuous manufacturing of aligned nanofiber arrays.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The collection surfaces act as intermediaries between the electrospinning nozzle and the final nanofiber product. These surfaces are positioned in the collection compartment to intercept and organize fibers as they are deposited, enabling ordered collection and continuous manufacturing while maintaining the benefits of electrospinning.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 production of high-performance nanofibers with improved mechanical strength and alignment, facilitating scalable production of advanced nanomaterials by integrating post-drawing into the electrospinning process, overcoming limitations of traditional fiber processing technologies.

Implementation Method 1

an electrostatic extrusion methods known as electrospinning can be used to fabricate nanofibers

Methodology Applied

Scientific EffectElectrostatic forces: Electrostatics

Implementation Method 2

electrospinning from an electrospinning nozzle proximate to the deposition area

Methodology Applied

Scientific EffectElectric field: Electric Field

Implementation Method 3

When a fiber is deposited to the deposition area, one end of the fiber will be adhered to the first conductive collection surface and the other end of the fiber is adhered to the second conductive collection surface

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS11015267B2System and method for electrospun fiber straining and collecting

Publication Date: 2021.05.25 ROWAN UNIVERSITY

AI summary

The invention provides a system and process for manufacturing nanofibers that integrate a post-drawing process in a continuous electro spinning manufacturing process. In certain embodiments, the system and process are capable of post-drawing multiple individual electrospun nanofibers simultaneously. In certain embodiments, the system can be configured and controlled to accommodate various materials that can be electrospun.