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WO2024031105A1 - Systèmes d'électrofilage pour la production en masse de nanofibres - Google Patents

Systèmes d'électrofilage pour la production en masse de nanofibres Download PDF

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Publication number
WO2024031105A1
WO2024031105A1 PCT/US2023/071801 US2023071801W WO2024031105A1 WO 2024031105 A1 WO2024031105 A1 WO 2024031105A1 US 2023071801 W US2023071801 W US 2023071801W WO 2024031105 A1 WO2024031105 A1 WO 2024031105A1
Authority
WO
WIPO (PCT)
Prior art keywords
spinnerets
spinneret
collector
electrospinning
convergent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2023/071801
Other languages
English (en)
Inventor
Sherif SOLIMAN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Matregenix Inc
Original Assignee
Matregenix Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Matregenix Inc filed Critical Matregenix Inc
Priority to EP23851029.1A priority Critical patent/EP4565732A1/fr
Priority to JP2025507007A priority patent/JP2025525244A/ja
Priority to CA3264239A priority patent/CA3264239A1/fr
Priority to CN202380071552.9A priority patent/CN120344726A/zh
Priority to KR1020257007400A priority patent/KR20250059410A/ko
Publication of WO2024031105A1 publication Critical patent/WO2024031105A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • D01D5/0069—Electro-spinning characterised by the electro-spinning apparatus characterised by the spinning section, e.g. capillary tube, protrusion or pin
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M10/00—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements

Definitions

  • the present disclosure relates to electrospinning systems and apparatuses.
  • Electrospinning is the most commonly used method for producing nanofibers.
  • the electrospinning process has been extensively studied on account of its potential applications in multiple industries.
  • a wealth of scientific publications explore this area and there are many reasons to believe that nanofibers are a key solution for many applications, including textiles and clothing, military applications, tissue engineering, drug delivery, cancer diagnosis, batteries, optical sensors, and air filtration.
  • the adoption of electrospinning techniques in industry settings has been extremely slow and limited. This is primarily because electrospinning is perceived as a laboratory scale technique that is difficult to scale up, and thus it is often assumed that electrospinning cannot meet the high throughput demands of industrial applications. Production rates using typical electrospinning technology are usually around 0.01-1 g/h, which is lower than most industry production requirements.
  • the instrumentation necessary for electrospinning include a high voltage power supply, a spinneret, and a collector.
  • the spinneret may be a capillary tube with a pipette or needle having a small diameter.
  • the collector may be a metal collecting plate.
  • One electrode of the high voltage power supply is placed into a polymer solution and the other electrode is attached to the collector.
  • An electric field is applied to the end of the capillary tube that contains the polymer solution held by its surface tension and forms a charge on the surface of the liquid. As the intensity of the electric field increases, the hemispherical surface of the fluid at the tip of the capillary tube elongates, forming a conical shape known as a Taylor cone.
  • a critical value is attained upon a further increase in the electric field, where the repulsive electrostatic force overcomes the surface tension and the charged jet of fluid is ejected from the tip of the Taylor cone.
  • the discharged polymer solution jet is unstable and elongates as a result, allowing the jet to become very long and thin.
  • Charged polymer fibers solidify with solvent evaporation. Randomly oriented nanofibers are collected on the collector. Nanofibers can also be collected in a highly aligned fashion using specialized collectors such as a rotating drum, metal frame, or a two-parallel plate system. Parameters such as jet stream movement and polymer concentration must be controlled to produce nanofibers with uniform diameters and morphologies.
  • Electrospinning may be used to transform many types of polymers into nanofibers.
  • An electrospun nanofiber network resembles the extracellular matrix (ECM) in important ways. This resemblance is a major advantage of electrospinning, because it allows for mimicking the ECM with respect to fiber diameters, porosity, and mechanical properties. Electrospinning is being further developed for the mass production of one-by-one continuous nanofibers.
  • Roll-to-roll electrospinning technologies typically entail the deposition of electrospun fibers onto a fabric substrate that unwinds from a first roll to a second roll.
  • the substrate typically passes in front of a metal sheet that is grounded or negatively charged during the spinning process, which may result in “over tension” of the substrate as it passes through the apparatus on account of electrical charges accumulated over the substrate that cause high friction between the substrate and the metal sheet collector. This in turn results in stretching of the fabric substrate. Such stretching may unfavorably alter the tension control of the winders and may also subsequently damage the deposited nanofibers as the substrate relaxes.
  • the present disclosure describes electrospinning systems and apparatuses that are suitable for use in high throughput industrial settings.
  • the disclosed systems and apparatuses may include a high voltage power supply having positive and negative electrodes; one or more spinnerets that include one or more convergent-divergent nozzles, one or more turbo canals, or a combination thereof; and a collector.
  • the systems and apparatuses may further include one or more peristaltic pumps.
  • the collector may be an adjustable collector.
  • the adjustable collector may be composed of multiple metal sheets.
  • the systems and apparatuses may optionally further include one or more of a ventilation system that reduces sparking inside the electrospinning chamber, a chamber for reducing power consumption when using an optional heater or dehumidifier, and an in-line quality control system.
  • FIG. 1 shows an embodiment of the disclosed apparatus.
  • FIG. 2 shows an embodiment of a peristaltic pump and a schematic representation of a method of phase compensation using multiple peristaltic pumps.
  • FIG. 3A shows a schematic representation of the configuration of a convergent- divergent nozzle.
  • FIG. 3B shows an example of a convergent-divergent nozzle.
  • FIG. 4A shows an example of a turbo canal.
  • FIG. 4B shows an example of a polymer solution being fed into a turbo canal.
  • FIG. 5 shows an example of a metal collector composed of four metal sheets.
  • FIG. 6 shows an example of an in-line quality control system.
  • the present disclosure describes electrospinning systems and apparatuses that are suitable for use in high throughput industrial settings.
  • the disclosed systems and apparatuses may include a high voltage power supply having positive and negative electrodes; one or more spinnerets that include one or more convergent-divergent nozzles, one or more turbo canals, or a combination thereof; and a collector.
  • the systems and apparatuses may further include one or more peristaltic pumps.
  • the collector may be an adjustable collector.
  • the adjustable collector may be composed of multiple metal sheets.
  • the systems and apparatuses may optionally further include one or more of a ventilation system that reduces sparking inside the electrospinning chamber, a chamber for reducing power consumption when using an optional heater or dehumidifier, and an in-line quality control system.
  • FIG. 1 shows an embodiment of the disclosed electrospinning apparatus, including unwinder 1, winder 2, lamination sandwich 3, quality control module 4, feeder 5, turbo canal 6, and collector plates 7.
  • the disclosed electrospinning apparatuses use peristaltic pumps to feed the spinneret. This eliminates the need to use syringes.
  • a peristaltic pump can draw a solution from any sized container, which eliminates the need for refilling the polymer solution during the spinning process.
  • multiple peristaltic pumps are used in the disclosed apparatuses.
  • FIG. 2 shows an example of how two peristaltic pumps having a difference in phase may be used with two separate roll sets to provide overall continuous feeding of the polymer solution. As shown, when phase B is idle, phase A is feeding, and vice versa.
  • the disclosed electrospinning apparatuses provide alternate non-needle spinnerets that may be used interchangeably, thereby increasing productivity.
  • the use of these alternate spinnerets may also prevent early solidification of the electrospun polymer as frequently results when a needle is used as the spinneret.
  • the alternate spinneret may be a convergent-divergent nozzle, a turbo canal, or another suitable alternate spinneret.
  • FIG. 3A shows a schematic representation of the configuration of a convergent- divergent nozzle.
  • FIG. 3B shows an example of a convergent-divergent nozzle.
  • the convergent- divergent nozzle is shaped to promote a polymer solution therein to adopt a cone shape.
  • FIG. 4A shows an example of a turbo canal.
  • FIG. 4B shows how a peristaltic pump feeds the U-shaped turbo canal with a polymer solution.
  • Use of a turbo canal may provide one or more advantages over the use of other types of spinnerets, including very high productivity, generation of continuous jets, production of homogeneous material, reduced problems with clogging as may occur with needles or nozzles, and simplicity of setup and cleaning.
  • the disclosed apparatuses may have one or multiple spinnerets, which may include one or more convergent-divergent nozzles, one or more turbo canals, or a combination thereof.
  • the disclosed apparatuses may have multiple spinnerets that include both needle spinnerets and one or more convergent-divergent nozzles, one or more turbo canals, or a combination thereof.
  • the disclosed apparatuses have a reduced contact area between the spinneret and the collector as compared to prior art roll-to-roll electrospinning apparatuses. This is achieved by using multiple metal sheets to form an adjustable collector that allows adjustment and optimization of the gap between the substrate and the collector. By using multiple metal sheets as a collector, the tension on the roll is decreased.
  • the collector may preferably be connected to a negative high voltage electrode to increase the attractiveness of charged fibers.
  • the adjustable collector adds one layer of the substrate to laminate the surface of the nanofiber layer, thereby protecting it. Nanofiber layers are thus sandwiched between substrate layers. This eliminates the need to laminate a protective layer as a post-process step for many industrial applications.
  • FIG. 5 shows an example of a metal collector composed of four metal sheets.
  • FIG. 1 Other features of the disclosed apparatuses include a ventilation system that reduces sparking inside the electrospinning chamber, a chamber for reducing power consumption when using an optional heater or dehumidifier, a compact size that is suitable for both research and industrial use, and an in-line quality control system that includes a scanner for measuring the differential pressure between the two surfaces of the substrate to determine the level of homogeneity of fibers produced.
  • FIG. 6 shows an example of an in-line quality control system of the disclosed electrospinning system.
  • FIG. 7 shows an example of a ventilation system of the disclosed electrospinning system.
  • An electrospinning system that includes a high voltage power supply that includes a positive electrode and a negative electrode, one or more spinnerets, and an adjustable collector, where the one or more spinnerets include at least one spinneret that is a convergent-divergent nozzle or a turbo canal, is disclosed.
  • An electrospinning system that includes a high voltage power supply that includes a positive electrode and a negative electrode, one or more spinnerets, and a collector, where the one or more spinnerets include at least one spinneret that is a convergent-divergent nozzle or a turbo canal, is disclosed.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

La présente divulgation décrit des systèmes et des appareils d'électrofilage convenant à une utilisation dans des environnements industriels à haut débit. Les systèmes et appareils divulgués peuvent comprendre une alimentation haute tension présentant des électrodes positives et négatives ; une ou plusieurs filières comprenant une ou plusieurs buses convergentes-divergentes, un ou plusieurs canaux turbo, ou une combinaison de ceux-ci ; et un collecteur. Les systèmes et les appareils peuvent en outre comprendre une ou plusieurs pompes péristaltiques. Le collecteur peut être un collecteur réglable. Le collecteur réglable peut être composé de multiples feuilles métalliques. Les systèmes et les appareils peuvent éventuellement comprendre en outre un ou plusieurs éléments parmi un système de ventilation qui réduit le stationnement à l'intérieur de la chambre d'électrofilage, une chambre pour réduire la consommation d'énergie lors de l'utilisation d'un élément chauffant ou déshumidificateur facultatif, et un système de commande de qualité en ligne.
PCT/US2023/071801 2022-08-05 2023-08-07 Systèmes d'électrofilage pour la production en masse de nanofibres Ceased WO2024031105A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP23851029.1A EP4565732A1 (fr) 2022-08-05 2023-08-07 Systèmes d'électrofilage pour la production en masse de nanofibres
JP2025507007A JP2025525244A (ja) 2022-08-05 2023-08-07 ナノファイバの大量生産のための電界紡糸システム
CA3264239A CA3264239A1 (fr) 2022-08-05 2023-08-07 Systèmes d'électrofilage pour la production en masse de nanofibres
CN202380071552.9A CN120344726A (zh) 2022-08-05 2023-08-07 用于大规模生产纳米纤维的静电纺丝系统
KR1020257007400A KR20250059410A (ko) 2022-08-05 2023-08-07 나노섬유의 대량 생산을 위한 전기방사 시스템

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263370643P 2022-08-05 2022-08-05
US63/370,643 2022-08-05

Publications (1)

Publication Number Publication Date
WO2024031105A1 true WO2024031105A1 (fr) 2024-02-08

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Family Applications (1)

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PCT/US2023/071801 Ceased WO2024031105A1 (fr) 2022-08-05 2023-08-07 Systèmes d'électrofilage pour la production en masse de nanofibres

Country Status (6)

Country Link
EP (1) EP4565732A1 (fr)
JP (1) JP2025525244A (fr)
KR (1) KR20250059410A (fr)
CN (1) CN120344726A (fr)
CA (1) CA3264239A1 (fr)
WO (1) WO2024031105A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2292060A1 (fr) * 1974-11-19 1976-06-18 Montedison Spa Procede de preparation de fibrilles ou microfibres de polymere synthetique
JP2008223187A (ja) * 2007-03-14 2008-09-25 Mecc Co Ltd ナノ・ファイバ製造方法および装置
US20120145632A1 (en) * 2009-07-15 2012-06-14 Konraad Albert Louise Hector Dullaert Electrospinning of polyamide nanofibers
US8211353B2 (en) * 2008-09-05 2012-07-03 E. I. Du Pont De Nemours And Company Fiber spinning process using a weakly interacting polymer
US9644295B2 (en) * 2012-08-16 2017-05-09 University Of Washington Through Its Center For Commercialization Centrifugal electrospinning apparatus and methods and fibrous structures produced therefrom
CN111926396A (zh) * 2020-07-31 2020-11-13 浙江理工大学 一种具有互穿结构的纳米纤维膜布的制备方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2292060A1 (fr) * 1974-11-19 1976-06-18 Montedison Spa Procede de preparation de fibrilles ou microfibres de polymere synthetique
JP2008223187A (ja) * 2007-03-14 2008-09-25 Mecc Co Ltd ナノ・ファイバ製造方法および装置
US8211353B2 (en) * 2008-09-05 2012-07-03 E. I. Du Pont De Nemours And Company Fiber spinning process using a weakly interacting polymer
US20120145632A1 (en) * 2009-07-15 2012-06-14 Konraad Albert Louise Hector Dullaert Electrospinning of polyamide nanofibers
US9644295B2 (en) * 2012-08-16 2017-05-09 University Of Washington Through Its Center For Commercialization Centrifugal electrospinning apparatus and methods and fibrous structures produced therefrom
CN111926396A (zh) * 2020-07-31 2020-11-13 浙江理工大学 一种具有互穿结构的纳米纤维膜布的制备方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
BLIM A., JARECKI L., BLONSKI S.: "Modeling of pneumatic melt drawing of polypropylene super-thin fibers in the Laval nozzle", BULLETIN OF THE POLISH ACADEMY OF SCIENCES. TECHNICAL SCIENCES, POLSKA AKADEMIA NAUK * CENTRUM UPOWSZECHNIANIA NAUKI,POLISH ACADEMY OF SCIENCES, CENTER FOR THE ADVANCEMENT OF SCIENCE, PL, vol. 62, no. 1, 1 March 2014 (2014-03-01), PL , pages 43 - 54, XP093137756, ISSN: 0239-7528, DOI: 10.2478/bpasts-2014-0005 *

Also Published As

Publication number Publication date
EP4565732A1 (fr) 2025-06-11
CA3264239A1 (fr) 2024-02-08
KR20250059410A (ko) 2025-05-02
CN120344726A (zh) 2025-07-18
JP2025525244A (ja) 2025-08-01

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