Rotating Electrode Nanofiber Production via Electrostatic Spinning
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Solution Overview
Problem
Conventional methods for producing nanofibers from polymer solutions using electrostatic spinning have limited industrial scalability due to low processing capacity and dependence on precise ratios of air flow to electrostatic field intensity, resulting in inefficient production of nanofibers with small diameters.
Innovation Solution
A method and device where a rotating charged electrode delivers polymer solution into an electrostatic field, creating a spinning surface that allows for the formation of Taylor cones on the electrode's surface, enabling the production of nanofibers that drift towards a counter electrode, with an air stream and auxiliary drying air enhancing productivity and uniformity of fiber layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrostatic spinning methods are used with stationary jets, then nanofibres can be produced, but the production capacity is very low (0.1 g to 1 g per hour)
Solution Approach 1:
The patent applies the dynamics principle by replacing stationary jets with a rotating charged electrode that continuously moves through the polymer solution. This rotation creates dynamic Taylor cones at different positions on the electrode surface, enabling continuous nanofibre production without the limitations of fixed jet positions. The rotating electrode systematically covers the entire surface area, dramatically increasing production capacity from 0.1-1 g/hour to industrial-scale output.
Solution Approach 2:
The patent transitions from one-dimensional stationary jet spinning to two-dimensional surface spinning by using a rotating electrode. The electrode's rotation introduces a temporal dimension, converting a static process into a dynamic one where Taylor cones form and dissipate continuously across the electrode surface, enabling high-volume production while maintaining nanofibre quality.
2Productivity
If the electrostatic field intensity is increased to improve fibre formation, then fibre production efficiency increases, but discharges between electrodes occur beyond the dielectric strength of air
Solution Approach 1:
The rotating electrode creates dynamically forming and dissipating Taylor cones that continuously move through the electrostatic field. This dynamic operation allows the system to operate at higher field intensities than static systems because the Taylor cones exist only momentarily at each position, reducing the risk of sustained electrical discharges while maintaining high fibre formation efficiency.
Solution Approach 2:
The rotation of the electrode preliminarily distributes the polymer solution across its surface before entering the electrostatic field. This pre-distribution ensures uniform solution thickness and controlled discharge points, preventing uncontrolled electrical breakdown while maximizing fibre production within the dielectric strength limits of air.
3Productivity
If polymer solution concentration is increased to improve production rate, then more polymer can be processed, but the viscosity increases making fibre formation difficult
Solution Approach 1:
The rotating electrode creates continuously forming Taylor cones that process polymer solution in thin, uniform layers. This dynamic surface processing allows higher polymer concentrations to be handled effectively because the solution is distributed thinly and uniformly across the rotating surface, maintaining low local viscosity while increasing overall production rate through continuous rotation and multiple discharge points.
Solution Approach 2:
The rotating electrode divides the polymer solution processing into multiple segmental Taylor cones distributed around the electrode circumference. Each Taylor cone processes a small portion of the solution, maintaining optimal local conditions for fibre formation even when the overall polymer concentration is high. This segmentation allows high production rates while preserving fibre diameter uniformity.
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 method significantly increases the production capacity of nanofibers with uniform diameters, allowing for high-quality layers to be formed in arbitrary widths, improving the efficiency and scalability of nanofiber production.
Implementation Method 1
mechanical forces of a flowing gaseous medium or coulombic forces in an electrostatic field can be used
Implementation Method 2
forming fibres by processing polymer solutions... in an electrostatic field created by a potential difference between a charged electrode and a counter electrode
Implementation Method 3
there must be formed a so called Taylor cone at the throat of the spinning jet, whose existence is a requirement for fibres formation
Implementation Method 4
Electrostatic spinning leads to fibres of lower diameters because a single fibre will split into a number of filaments owing to the distribution of equivalent charge in their volume
Implementation Method 5
mechanical forces of a flowing gaseous medium... can be used
Implementation Method 6
The solutions are then formed by a mechanical action of an air stream delivered inside of the annulus
Data Source
AI summary
A method of nanofibers production from a polymer solution uses electrostatic spinning in an electric field created by a potential difference between a charged electrode and a counter electrode. The polymer solution for spinning is supplied into the electric field using the surface of a rotating charged electrode. On a part of the circumference of the charged electrode near to the counter electrode, a spinning surface is created for attaining a high spinning capacity. In a device for carrying out the method, the charged electrode is pivoted and part of its circumference is immersed in the polymer solution. The free part of the circumference of the charged electrode is positioned opposite the counter electrode.