WO2010010362A1 - Appareil et procédés de fabrication de fibres - Google Patents

Appareil et procédés de fabrication de fibres Download PDF

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Publication number
WO2010010362A1
WO2010010362A1 PCT/GB2009/001840 GB2009001840W WO2010010362A1 WO 2010010362 A1 WO2010010362 A1 WO 2010010362A1 GB 2009001840 W GB2009001840 W GB 2009001840W WO 2010010362 A1 WO2010010362 A1 WO 2010010362A1
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WO
WIPO (PCT)
Prior art keywords
band
roller
electric field
zone
electrospinning
Prior art date
Application number
PCT/GB2009/001840
Other languages
English (en)
Other versions
WO2010010362A9 (fr
Inventor
Robert Stevens
Original Assignee
The Science And Technology Facilities Council
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Publication date
Application filed by The Science And Technology Facilities Council filed Critical The Science And Technology Facilities Council
Publication of WO2010010362A1 publication Critical patent/WO2010010362A1/fr
Publication of WO2010010362A9 publication Critical patent/WO2010010362A9/fr

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
    • D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
    • D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
    • D01D5/0076—Electro-spinning characterised by the electro-spinning apparatus characterised by the collecting device, e.g. drum, wheel, endless belt, plate or grid

Definitions

  • the present invention relates to an apparatus and method for producing fibres.
  • the present invention relates to producing nanofibres using an electric field.
  • Electrospray is a technique for dispersing a liquid to produce an electrically charged aerosol as shown in figure 1.
  • a liquid is supplied through a capillary and a high voltage is applied to the tip of the capillary.
  • a plate (not shown) biased at a different potential with respect to the tip, for example the plate may be at ground.
  • the relatively high potential at the tip of the capillary results in the formation of a Taylor cone.
  • a liquid jet is emitted through the apex of the cone. The jet rapidly forms into droplets as a result of a process to minimise the surface charge density.
  • Figure 2 shows the related technique of electrospinning.
  • a voltage source is connected between the tip of a capillary 1 and a collector plate 2.
  • a Taylor cone forms.
  • the liquid comprises polymer molecules dispersed in a suitable solvent and has appropriate dielectric, conductivity, viscosity and solvent volatility
  • the liquid jet emitted from the Taylor cone does not break up due to entanglements of the polymer molecules.
  • the jet is further elongated by the process of desolvation of the solvent, this increases the localised surface charge density, which increases the electrostatic repulsion causing a rapid electrostatically driven extension of the fibre to create extremely thin fibres.
  • the fibre is finally deposited on the collector 2.
  • WO2005/024101 describes a method of nanofibre production from a polymer solution using electrostatic spinning in an electric field created between a charged electrode and a counter electrode.
  • Polymer solution is supplied into the electric field using a rotating cylinder, which also acts as the charged electrode.
  • One side of the rotating cylinder is immersed in a bath of polymer solution, while the other side is open and acts as the starting point for fibre formation.
  • the counter electrode is formed as an arc which is concentric to the cylinder.
  • the fibres are drawn from the cylinder towards the counter electrode by the electric field.
  • the fibres are deposited on a substrate which follows the surface of the counter electrode. This technique overcomes the problem of blocking of the capillary by using the rotating cylinder to supply the polymer solution.
  • nanofibres find uses in variety of fields such as filtration, energy storage, catalysis etc.
  • the present invention seeks to overcome problems of the prior art. Accordingly, the present invention provides an apparatus for producing fibres, the apparatus comprising: a band arranged around or between first and second rollers and curved around the rollers; an electric field generator adapted to provide an electric field between an electrospinning zone at the first roller and a counter electrode; a bath for containing liquid and arranged to wet regions of the band as it passes around the second roller, wherein the band is arranged to transport liquid from the bath to the electrospinning zone for the production of fibres in said electrospinning zone.
  • the electric field is sufficient to draw the fibres from the liquid.
  • the first and second rollers are preferably spaced apart.
  • the apparatus may further comprise a drive mechanism arranged to drive the band.
  • a band tensioned between rollers is mentioned above, alternatively a band may be provided around one or two slide surfaces. The slide surfaces are curved thereby replacing one or both of the rollers. In the case of both rollers being replaced by slide surfaces, the band may be driven by a separate propulsion system.
  • rollers may be used in some configurations.
  • the tension on the band may be provided by tensioning means other than the rollers or slide surfaces.
  • the band may have suitable elastic properties so that it is self tensioning when stretched over the rollers or slide surfaces .
  • the fibres may be nanofibres.
  • nanofibres we mean fibres having a diameter between 0.5 nm and 1000 nm or even up to 10000 nm. But preferably, the fibres have a diameter between IOnm and 100 nm.
  • the spacing of the wetting zone and electrospinning zone allows additional functionality to be provided between the two rollers, such as additional deposition devices.
  • additional deposition devices allow the composition of the fibres to be changed with minimal time delay.
  • the above apparatus is described for the electrospinning of fibres, but is equally applicable to the electrospray of droplets, for example on to a surface.
  • the electric field generator may be arranged to provide an electric field between the surface of the band curved around the first roller and a counter electrode.
  • the electric field may be provided between a portion of the surface of the band wherein said portion is the part of the band when curved around the first roller.
  • the electrospinning zone is at the surface of the band where curved around the first roller such that electrospinning occurs at the curved surface. Electrospinning from a curved surface has advantages in that the fibres diverge from each other as the distance from the curved surface increases. This provides greater control of the final product by reducing the amount of fibres which stick together or become entangled.
  • the band may be a continuous band formed of a belt, an array of belts, or an array of wires.
  • the band may be patterned with any combination of grooves, spikes, ridges or recesses .
  • the apparatus may further comprise extractor electrodes arranged parallel to the first roller and spaced apart from the first roller.
  • the apparatus may further comprise gas (e.g. air) assist ducts located at the sides of the electrospinning zone and arranged to provide a gas/air flow to direct the produced fibre away from the first roller and to assist in the drying process .
  • gas e.g. air
  • assist ducts located at the sides of the electrospinning zone and arranged to provide a gas/air flow to direct the produced fibre away from the first roller and to assist in the drying process .
  • the apparatus may further comprise a release head provided adjacent to the surface of the band, the release head arranged to atomise material or to deposit material on the belt.
  • the parts of the band that are carrying liquid from the bath to the electrospinning zone and back may be known as transport zones.
  • the release head may be arranged adjacent to a flat surface of the band, such as the transport zones.
  • the apparatus may further comprise a cleaning head provided adjacent to a surface of the band, and arranged to remove material deposited on the band.
  • the apparatus may further comprise a surface conditioning head provided adjacent to a surface of the band, and arranged to condition the surface of the band.
  • the cleaning head or surface conditioning head may be arranged adjacent to a flat surface of the band.
  • the first roller may comprise a cylinder or barrel mounted on a spindle, the cylinder or barrel having a groove.
  • the cylinder or barrel may be electrically conductive.
  • the spindles are either non-conducting or conducting, and may be ceramic.
  • the apparatus may further comprise a drive mechanism comprising a drive shaft and a flexible ring, such as an o-ring or elongate ring. The ring is seated within the groove and coupled to the drive shaft to drive the first roller.
  • the ring may also be electrically conductive.
  • the first or second roller, its spindle and the drive shaft are combined to form a single component. This component will be electrically conductive.
  • the apparatus may further comprise electrically conductive suppressor plates arranged parallel to, and spaced apart from, linear portions of the band. That is, the suppressor plates may be parallel plates arranged facing the transport zones of the band.
  • the present invention further provides an apparatus for producing fibres or droplets, comprising a surface translatable between a wetting zone and an electrospinning zone, the wetting zone including a means for releasing liquid onto the surface, and the electrospinning zone arranged to be provided with an electric field by an electric field generator. Between the wetting zone and electrospinning zone may be provided a material supply head for depositing material on the wetted translatable surface or for atomising material.
  • the means for releasing liquid onto the translatable surface may be an immersion bath for containing liquid or a release head.
  • the present invention further provides an apparatus for electrospray deposition of droplets onto a surface, comprising: a band tensioned between first and second rollers and curved around the rollers; an electric field generator adapted to provide an electric field between an electrospray zone at the first roller and a counter electrode; a bath for containing liquid and arranged to wet the band as it passes around the second roller, wherein the band is arranged to transport liquid from the bath to the electrospray zone where the electric field causes jets of droplets to be released from the band and deposited on said surface.
  • the deposition surface may act as the counter electrode.
  • a release head can be used to deposit polymer solutions on to the band for electrospray.
  • the present invention further provides a method of producing fibres, comprising: wetting a band with fluid, the band tensioned between first and second rollers; providing an electric field at an electrospinning zone at the first roller; driving the band to cycle the band from the first roller to the second roller, wherein the electric field at the electrospinning zone is arranged to draw fibres from the fluid on the band towards a counter electrode.
  • the present invention further provides a method of depositing droplets on a surface, comprising: wetting a band with a fluid, the band tensioned between first and second rollers; providing an electric field between a counter electrode and an electrospray zone at the first roller; driving the band to cycle the band from the first roller to the second roller; providing a deposition surface between the first roller and the counter electrode, wherein the electric field is arranged to draw droplets from the fluid on the band to be deposited on the deposition surface.
  • Figure 1 illustrates the formation of a jet of droplet from a Taylor cone
  • Figure 2 illustrates the electrospinning of a fibre from a capillary
  • Figure 3 shows the apparatus for electrospinning or electrospray according to an embodiment of the invention
  • Figure 4 shows the apparatus of figure 3 with additional functional complexity added
  • Figures 5a and 5b show schematically the lines of force produced by an electric field applied to a roller and extractor electrodes
  • Figure 6 shows an array, consisting of a plurality of the apparatus of figure 4.
  • Figure 7 shows an apparatus for electrospinning or electrospraying according to a second embodiment of the present invention.
  • Figure 3 shows a first embodiment comprising a band 30, such as a belt, tensioned between a pairs of rollers 10, 20.
  • the band 30 may either be conductive or non-conductive, or a mixture of laminated conductive and non-conductive layers.
  • the band 30 is continuous and takes the form of a conveyor belt extending from the first roller 10 to the second roller 20 and back around to the first roller 10.
  • the rollers 10, 20 may be solid or hollow cylinders, the belt or band 30 being in contact with each roller for around half of its surface.
  • the rollers 10, 20 are arranged parallel to each other but spaced apart.
  • the rollers 10, 20 rotate about central axes through the cylinder and may be supported on bearings to allow the rollers to rotate with ease.
  • An immersion bath 40 is provided in the region of the second roller 20.
  • the immersion bath is filled with a liquid such as a polymer solution or molten polymer 55.
  • the roller 20 can be partly or fully immersed in the solution, but should be sufficiently immersed that part of the band 30 passing around the second roller is immersed in the bath wetting it with liquid in the bath. This region may be known as the wetting zone.
  • the immersion bath may include a system to wet selected regions of the band.
  • One embodiment could be a rotating roller which lifts solution from the bath and coats it onto the band .
  • the two rollers 10, 20 are arranged such that the first roller 10 is vertically above the second roller 20. Other arrangements of rollers are possible.
  • the separation of the two rollers 10, 20 is arranged such that the belt 30 is tensioned.
  • a mount holding one of the rollers may be biased to urge the roller away from the other roller to thereby set the tension of the band.
  • a drive mechanism is provided to rotate the band 30 and rollers 10, 20.
  • a motor may be used to drive one of the rollers directly.
  • the first roller 10 may be driven by a drive belt 65 from a motor 60 mounted a short distance away from the roller.
  • the position of the motor 60 and drive belt 65 is not limited to being between the two surface of the band 30, as shown in figure 3, but may provided elsewhere with the drive belt driving either the first roller 10 or second roller 20.
  • the band 30, rollers 10, 20, immersion bath 40 and drive mechanism are supported by a framework.
  • the framework may be engineered to be easily dismantled for cleaning.
  • the framework holding the second roller 20, and bath are arranged to provide control of the depth of immersion of the band 30 into the fluid in the bath 40.
  • the electric field is provided by applying a voltage between the first roller 10 and a counter electrode (not shown) provided above and spaced apart from the first roller 10.
  • the counter electrode is normally at ground voltage.
  • the band may itself be conductive and the voltage may be applied directly between the band and counter electrode.
  • the region in which production of fibres occurs may be called the electrospinning zone.
  • the force provided by the electric field will be substantially radial to the roller.
  • the potential difference between the counter electrode and roller or band will be 3OkV, and the separation between the two will be approximately 0.2m.
  • rollers 10, 20 and bearings are manufactured to a high accuracy to allow the gap between the surface of the band 30 and the counter electrode to be kept constant to provide a uniform field as the rollers rotate, thereby providing uniformity of electrospun fibre or electrospray coated product .
  • the surface of the band or belt 30 may be textured in such a way as to control fluid transport from the wetting zone to the electrospinning zone.
  • the belt may also have high aspect ratio features on a large pitch to enhance the electric field on the surface of the belt 30 while in the electrospray zone. This will enhance Taylor cone formation and the generation of electrospray jets necessary for nanofibre formation.
  • the belt or band 30 may be a polished metal belt (for example, stainless steel) ; a patterned metal belt with grooves, spikes, ridges, or recesses and may be produced by photolithography and acid etching; a fabric or textile belt (for example, felt) ; a woven wire belt (for example, chain mail) ; an array of multicore twisted wire belts positioned side-by-side; a polymer foam or sponge-like belt; an array of wires side-by-side; or a patterned conductive or insulating polymer belt.
  • the rollers may be grooved to keep the wire or wire belts spaced at the desired distance.
  • these may be patterned with various coatings and structures to control fluid dynamics and the electric field in the electrospray zone.
  • Patterning of the band may allow the band to consist of wettable and non-wettable regions .
  • a solvent containing polymer molecules i.e. a solvated polymer solution
  • molten solvent may be used in conjunction with heating the bath and the band.
  • the polymer molecules should preferably be long chain molecules with a high molecular weight.
  • the immersion bath 40 can be temperature controlled. Heating allows higher melting point polymers to be maintained in liquid form. Cooling allows the evaporation rate of the solvent to be reduced. Additionally, some solutions or liquids may have their viscosity adjusted by changing the temperature of the immersion bath.
  • the band 30 is driven by the drive mechanism to pass around the second roller 20 through the immersion bath to wet the surface of the band with the liquid or solution contained in the bath 40.
  • the drive mechanism should be arranged to control the band speed accurately. By changing the band speed the exposure time of the band between the wetting zone and electrospinning zone may be controlled.
  • the electric field in the zone combined with any ripples in the surface of the liquid or features on the band will cause the liquid or solution to form into Taylor cones.
  • the cone will be increased in size until a jet forms.
  • Surface charges on the jet will cause the surface area to increase thereby causing the jet to become thinner as the distance from the band or belt 30 increases. This is known as self-extension. If the polymer molecules are of long enough chains, and any solvent evaporates then the jet will form a thin fibre. When the fibres reach a certain length they will break from the roller, partly due to the rotation of the roller. The fibres will be drawn towards the counter electrode where they will be collected. This region may be known as the collection zone.
  • the apparatus and method may also be used to deposit nanometre sized charged droplets or charged molecules by electrospray.
  • the jet from the Taylor cone breaks up into charged droplets. These droplets can be collected on a surface of a substrate located in front of the counter electrode.
  • other embodiments described below may also be used for either electrospinning or electrospray.
  • Figure 4 shows a second embodiment which is based on the embodiment of figure 3, but includes additional functionality and features.
  • the embodiment of figure 4 additionally includes an enclosure 100 which provides two main effects. Firstly, the enclosure 100 prevents solvent vapours from escaping into the local environment. Secondly, the immediate local solvent environment surrounding the band 30, rollers 10, 20, and bath 40 can be controlled. An additional effect is that the enclosure 100 also serves to protect the band and roller internal components.
  • the enclosure may be made from electrically insulating material or a material with a high sheet or bulk resistivity to prevent electrical charges building up on the material.
  • the enclosure has electrical, fluid, and fibre optic feedthroughs and at least one aperture 105 positioned above the first roller 10. The electrosprayed droplets and/or electrospun fibres emerge through this aperture 105 during production.
  • the control of the local solvent environment inside the enclosure 100 allows the desolvation of solutions deposited on the belt to be controlled. In turn, this allows the viscosity of the fluid on the belt to be held within suitable tolerances for electrospinning.
  • a solvent release mechanism or solvent extraction system may be included within the enclosure 100 to increase the precision of the amount of solvent in solution. This would allow the solution viscosity to be controlled more accurately for improved electrospinning. Such a solvent release or solvent extraction mechanism would require sensory feedback to achieve such accurate control .
  • a control system within the enclosure also provides control of the potential applied to the band 30, rollers 10, 20, and extractor electrodes 110.
  • the control system also controls the speed of the band, and any additional modules (which will be described in more detail below) .
  • Sensors provide feedback to the control system.
  • the sensors may provide feedback on solution viscosity, conductivity, dielectric constant, fluid levels, temperature, humidity, partial pressures, wear of the band etc.
  • the control system may also control the level of fluid in the immersion bath 40, the tension of the rollers 10, 20, and the depth to which the band 30 is immersed in the solution in the immersion bath 40. It may also provide to the user video information from inside the enclosure 100.
  • Figure 4 shows an optional heater 140 for heating the belt or band 30 (and solution on the surface of the belt) to control the temperature and viscosity at the electrospinning zone.
  • heaters may be used to dry the belt 30 after the electrospinning zone.
  • the heater may be located in the space enclosed by belt 30, or may be placed on one side or both sides of the belt.
  • Heaters may use radiant, convection, and/or conduction heating. Radiant heating is preferred because this allows the heat source to be isolated from the high electrical potential in the region of electrospinning zone. Pyrometers or other thermal sensors could be used to monitor the temperature uniformity of the belt 30.
  • extractor electrodes 110 located in close proximity to the electrospinning zone. These electrodes 110 enable the electrostatic potential for Taylor cone formation to be reduced and longer fibres to be produced without requiring the potential to be increased excessively.
  • the effect of the extractor electrodes 110 is to modify the lines of force between the band 30 and the first roller 10 to concentrate and focus the lines of force in the direction from band 30 to counter electrode. Additionally, the extractors act to reduce the overall potential required between the band and the collector. This allows the separation between band and collector (drift region) to be increased without requiring large potentials. The increased drift region assists in the production of dry fibres at a low electrical potential
  • the extractor electrodes 110 consist of a pair of shaped electrodes spaced apart from the first roller.
  • the electrodes may be cylindrical in the form of a wire or of a larger diameter. They are arranged parallel to the first roller as shown in figure 5a. Preferably, the extractor electrodes 110 are in a plane approximately in line with the top of the first roller, as shown in figure 5b.
  • the electrostatic potential on each of the extractor electrodes will be at an intermediate voltage which falls between the voltage of the first roller 10 (or belt 30) and the voltage of the collector.
  • Figures 5a and 5b show the lines of force in the electrospinning region as a result of the combined potentials of the extractor electrodes 110 and first roller 10.
  • the voltage difference applied between the extractor electrodes and the band depends on the geometrical configuration, the surface profile of the band, and the nature of the polymer solution.
  • the extractor electrodes 110 also localise the field established on the first roller to prevent it affecting the surroundings. Another benefit is that the more focussed electrical field provided by the extractor electrodes 110 results in the "in-flight" distance between the source and the counter electrode to be increased for the same potential between the band and the collector. Hence, a greater time and distance for the self-extension of the charged fibres is achieved. Therefore, dry finer fibres having a smaller cross-section can be achieved than without the extractor electrodes .
  • electrostatic lensing electrodes could be added running parallel to the axis of the roller and extractor electrodes. These lensing electrodes control the angular spread of the nanofibre and nanospray beam emitted from the surface of the belt .
  • Figure 4 also shows air assist ducts 120.
  • the air assist ducts 120 help to guide the desolvating fibres away from the band 30. By guiding the fibres away from the band, the emission aperture 105 in the enclosure can be kept clean and free from fibrous material. As well as helping fibre production, this also prevents arcing.
  • the additional air flow provided by the air assist ducts 120 also promotes desolvation of the fibres from solution.
  • the air could be dosed with solvent vapours to enhance the time before the jet dries to form the fibre. This would result in longer and finer fibres. Additionally, the air from the air assist ducts could be dosed with molecules and particles to be deposited on the surface of the fibre to provide an outer coating to the fibre.
  • FIG. 4 shows additional dosing modules 152, 154, 156 and 158 arranged along the outside of the band for dosing the surface of the band 30 already covered with solution from the immersion bath 40.
  • additional dosing modules are provided for dosing the wetted belt with particulates, molecules, cells, bacteria, viruses, or engineered micro and nano structures or particles, which add features to the spun fibre or electrosprayed coating.
  • controlled amounts of silver nanoparticulates may be added to the fibre for use in SERS (Surface-enhanced Raman scattering) sensors.
  • antibiotics may be added to the surface of the fibre for use in wound dressings.
  • dosing modules 150 are shown.
  • a cell, virus, or bacteria deposition head 152 there is an inkjet head 154, which could be use to deposit liquids and liquid dispersions.
  • a nebuliser or atomiser 156 which may be used for emitting a drug in a fine mist over the belt for inclusion in the fibre.
  • electrospray head 158 for the deposition of biolmolecules such as proteins.
  • the order and specific modules used in any particular application will vary and will not necessarily be that described here. Embodiments may comprise any of the modules 150 and does not require all modules to be included.
  • a cleaning station 160 may be included for cleaning of the band.
  • the cleaning may remove fibres and any remaining solvent or solution. If the surface of the band is not returned to a stable state prior to wetting, the fibre production will be inconsistent.
  • the band condition and levels of contamination may vary.
  • the band On exit from the cleaning station 160 the band will be substantially free of organic and inorganic contaminants. Production of some fibres will require the band to be cleaner than for other types of fibre and thus depends on the type of fibre being synthesised. For materials that require extremely low levels of contamination additional cleaning stations 160 could be added.
  • the cleaning station comprises four units.
  • a mechanical or liquid cleaning unit 152 mechanical, abrasively or using liquid removes the majority of contaminants on the surface of the band 30.
  • the infra-red lamp dryer 154 performs an initial dry of the band.
  • the air knife 156 finishes drying the band and may also remove any remaining lose material that is adhered to the band.
  • the EUV or UV lamp or laser can be used to modify the surface of the band 30, for example to improve wetting of the band with polymer solution.
  • surface conditioning of the band 30 may be achieved by electron, ion, or electromagnetic radiation sources emitting radiation at the surface of the band 30.
  • Linear arrays or scanning sources can be mounted adjacent to the band to irradiate the band.
  • this irradiation can occur whilst the belt is exposed to a gas to assist modification of the band surface.
  • Surface conditioning could be sterilisation or modification of the contact angle of the surface or its wettability. It may also increase the surface charge on the wetted surface to enable attraction of charged particles as the belt moves under a dosing module 150, for example, and electrospray or charged particulate source.
  • suitable radiation sources are EUV Excimer lamps, UV LED arrays, Corona discharge lamps, linear ion sources .
  • a gas jet or gas envelope may be provided at the end of the cleaning station to perform a final surface conditioning of the band before wetting. It will be apparent to the skilled person that any one, some, or all of the above units 162, 164, 166, 168 may be incorporated into the cleaning station 160.
  • the above embodiments show a single electrospinning unit 99 with a single wetting zone and consequently a single electrospinning or electrospray zone.
  • the width of the electrospinning or electrospray zone can be increased by increasing the width of the band 30, rollers 10, 20 and immersion bath 40.
  • multiple electrospinning units 99 may be placed in a line with the rollers 10, 20 effectively end-on-end to cover a larger surface area.
  • the design of the electrospinning units 99 means the units can be stacked close together with minimal space between adjacent units. As well as being able to stack the units end-on-end, lines of units can be stacked behind one another, as shown in figure 6.
  • the two dimensional stacking arrangement shown in figure 6 allows either large volumes of the same material to be deposited, or different layers or mixtures to be laminated together.
  • planar material 260 may be suspended or tensioned a short distance from a counter electrode 270.
  • the counter electrode 270 is held at 0 Volts and acts as counter electrode for all of the electrospinning units 99.
  • the planar material 260 is translated along a linear path to be subjected to deposition of droplets or fibres in the electrospinning zone of the electrospinning units 99.
  • Figure 6 shows a four by four array of units 99. Each unit can be used for depositing the same material, or each row could be used to deposit a different material to build up laminated layers on the planar material 260.
  • Figure 7 shows an apparatus 399 for electrospinning or electrospraying according to a second embodiment .
  • the apparatus comprises first 10 and second 20 rollers which are spaced apart.
  • a band or belt (not shown in figure 7) is tensioned between the two rollers.
  • Part of the band or belt passing around the second roller 20 is immersed or partly immersed in liquid in bath 40.
  • the rollers have a cylindrical drum or barrel part mounted on a spindle 12.
  • the spindle 12 extends along the axis of the cylindrical part to provide an axis for rotation.
  • the spindle locates in a circular hole in enclosure 100.
  • Spindles 12 extend from both ends of the rollers to support the rollers.
  • Circumferentially around the first roller 10 is a groove 11.
  • the groove 11 is located half way along the length of the roller.
  • the groove retains an o-ring (not shown) which is stretched between the roller and a drive shaft 360.
  • the drive shaft 360 is located between the two rollers.
  • the drive shaft and o-ring are conductive to supply a voltage to the band or belt.
  • the band or belt is stretched between the two rollers and hence forms two parallel largely flat sides separated at the top and bottom by curved parts where the band passes around the rollers.
  • an electrospinning zone is formed at the upper roller 10.
  • the largely flat sides may be known as transport zones because transport of the liquid from the bath to the electrospinning zone occurs here . Fibres are produced from the surface of the belt curved around the upper roller. Other methods of biasing the band in the electrospinning zone are also possible.
  • the drive shaft can be adapted to enable the electrospinning modules to be ganged ( i.e. arranged to act together) to form a linear array of modules.
  • the design of both ends of the spindle enables a mechanical coupling between modules to be made which is electrically conductive.
  • both ends are shaped so that when viewed end on they have a semi- circular profile at the ends.
  • the semi -circular end of the drive shaft on one module would interlock or abut with the semi-circular end of the drive shaft of its adjacent module, such that rotation of one drive shaft drives an adjacent drive shaft.
  • Alternative designs of interlocking, abutting, or other means or drive transfer are possible.
  • the drive shaft of one of the modules is driven by a motor.
  • a motor This allows a single motor to be used which if necessary can be mounted external to the array of modules.
  • the motor may be provided within one of the other modules such as the central module.
  • suppressor plates 310 are provided. These are conductive plates spaced from the flat sides (transport zones) of the band, extending from the first roller 10 to the second roller 20. Two suppressor plates 310 are provided, one adjacent to either of the flat sides of the band. The suppressor plates are preferably as wide as the rollers, and as shown in figure 7, effectively divide the space inside enclosure 100 into three chambers.
  • the central chamber includes the band, rollers 10, 20, drive shaft 360 etc.
  • the outer two chambers include apertures through which electrical connections, fluid inputs, and gas input lines may be provided. For example, electrical connection to the suppressor plates is required.
  • the suppressor plates 310 are connected to a voltage source to bias the plates at the same potential as the band, roller, driveshaft and o-ring.
  • liquid on the vertical sides of the band passes through a region of zero potential difference.
  • the liquid (or more specifically, fibre or droplet forming materials in solvent) is not subject to a force drawing them away from the band.
  • the liquid remains on the band in these regions and no Taylor cones are formed. Eletcrospinning is confined to the electrospinning zone above and around the first roller 10, thereby preventing the inside walls of the enclosure from becoming coated in electrospun material, and also preventing a reduction in material available for electrospinning at the electrospinning zone.
  • the enclosure 100 is preferably made of a ceramic such as alumina or zirconia with a diamond-like carbon (DLC) coating.
  • the enclosure 100 has circular holes in which the spindles 12 of the rollers are supported.
  • the spindles are preferably ceramic.
  • the spindle will freely rotate in the hole in the enclosure.
  • the use of ceramics for both the spindle and the structure comprising the hole provides a low friction bearing which does not require lubrication. This is particularly advantageous, because oils often used as lubricants would be a source of contamination for the electrospinning process. Additionally a oil or grease may be diluted by the action of solvents used in the electrospinning or electrospraying process. Thus, a normal lubricated bearing would be more likely to fail in an electrospinning environment because of dilution of the lubricant. Ceramics are also resistant to attack from many solvents .
  • the enclosure 100 is formed of a base 320 and housing 330.
  • the housing 330 consists of four walls which meet to form a square or rectangular outline.
  • the housing 330 may also include internal walls to support suppressor plates 310.
  • extractor electrodes may be provided in the region of the electrospinning zone.
  • the extractor electrodes may be supported in apertures 350 provided towards the top of the housing.
  • Base 320 incorporates bath 40 which is formed as a central well. The depth of liquid in the bath is controlled such the band is immersed into the liquid to the same extent for each rotation. Spaced slightly inside the outside edge of the base is a channel 340 in which the housing 330 locates.
  • the housing 330 is bonded into the channel 340 of the base 320 to provide a self contained electrospinning or electrospray unit .
  • the top of the unit is open to release the electrospun or electrosprayed material.
  • an aperture such as shown in figure 4 may be provided, or the top of the enclosure may take the form as shown in figure 7.
  • the unit shown in figure 7 may be arrayed or stacked together in lines for producing large volumes of material or multiple layers of material to be formed together in the same way as shown in figure 6.

Abstract

L’invention concerne un appareil et des procédés d’électrofilature et/ou d’électronébulisation. L’appareil et les procédés permettent de réaliser l’électrofilature de fibres ou le dépôt de gouttelettes sur une surface par électronébulisation. L’appareil comprend : une courroie tendue entre des premier et deuxième rouleaux et passant autour de ceux-ci ; un générateur de champ électrique conçu pour produire un champ électrique entre une région d’électrofilature au niveau du premier rouleau et une contre-électrode ; et un bain contenant un liquide conçu pour mouiller la courroie ou des parties de la courroie lorsqu’elle passe autour du deuxième rouleau. La courroie est conçue pour amener le liquide du bain à la région d’électrofilature pour y fabriquer des fibres. Le générateur de champ électrique peut être conçu pour produire un champ électrique entre la contre-électrode et la surface de la courroie lorsqu’elle passe autour du premier rouleau.
PCT/GB2009/001840 2008-07-24 2009-07-24 Appareil et procédés de fabrication de fibres WO2010010362A1 (fr)

Applications Claiming Priority (2)

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GB0813601.2 2008-07-24
GB0813601A GB2462112B (en) 2008-07-24 2008-07-24 An apparatus and method for producing fibres

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WO2010010362A9 WO2010010362A9 (fr) 2010-03-18

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WO2010118708A2 (fr) * 2009-04-16 2010-10-21 Spur A.S. Procédé de production de nanofibres et éléments de filage destinés à mettre en oeuvre ce procédé
CN103147226A (zh) * 2013-02-07 2013-06-12 江西师范大学 一种制备聚合物基高介电纳米复合材料的方法
CN103220882A (zh) * 2013-03-18 2013-07-24 华中科技大学 一种延性电路互联结构的制造装置、方法及产品
CN113195009A (zh) * 2018-12-05 2021-07-30 谢尔蒂斯股份公司 电纺缝合环

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DE102010012843A1 (de) * 2010-03-25 2011-09-29 Carl Freudenberg Kg Vorrichtung zum Elektrospinnen aus geschlossenem Spinnbad
US9495010B2 (en) 2011-10-26 2016-11-15 Nokia Technologies Oy Apparatus and associated methods
US9195350B2 (en) 2011-10-26 2015-11-24 Nokia Technologies Oy Apparatus and associated methods
US9733706B2 (en) 2011-10-26 2017-08-15 Nokia Technologies Oy Apparatus and associated methods for touchscreen displays
CN104313704B (zh) * 2014-09-29 2017-10-10 中鸿纳米纤维技术丹阳有限公司 一种纳米纤维静电纺丝机的供给涂覆机构
CN112946050B (zh) * 2021-03-16 2023-04-07 扬州大学 一种用于静电纺丝实验的防静电多形貌试沉积装置及方法
CN117344392B (zh) * 2023-12-06 2024-02-02 西南石油大学 一种轻质耐热pipd纳米纤维制备设备

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WO2003016601A1 (fr) * 2001-07-25 2003-02-27 Helsa-Werke Helmut Sandler Gmbh & Co. Kg Dispositif destine a produire des fibres dans le cadre d'un procede de filage electrostatique
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WO2010118708A2 (fr) * 2009-04-16 2010-10-21 Spur A.S. Procédé de production de nanofibres et éléments de filage destinés à mettre en oeuvre ce procédé
WO2010118708A3 (fr) * 2009-04-16 2013-05-10 Spur A.S. Procédé de production de nanofibres et éléments de filage destinés à mettre en œuvre ce procédé
CN103147226A (zh) * 2013-02-07 2013-06-12 江西师范大学 一种制备聚合物基高介电纳米复合材料的方法
CN103220882A (zh) * 2013-03-18 2013-07-24 华中科技大学 一种延性电路互联结构的制造装置、方法及产品
CN113195009A (zh) * 2018-12-05 2021-07-30 谢尔蒂斯股份公司 电纺缝合环
CN113195009B (zh) * 2018-12-05 2023-12-22 谢尔蒂斯股份公司 电纺缝合环

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WO2010010362A9 (fr) 2010-03-18
GB2462112B (en) 2012-11-07
GB0813601D0 (en) 2008-09-03

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