ELECTROSPINNING OF FIBERS USING A ROTATABLE SPRAY HEAD

• US 20060228435A1
• Filed: 04/08/2004
• Published: 10/12/2006
• Est. Priority Date: 04/08/2004
• Status: Active Grant

• Current Assignee: Research Triangle Institute
• Original Assignee: Research Triangle Institute
• Inventors: Newsome, Randall J., Ensor, David S., Andrady, Anthony L.
• Granted Patent: US 7,134,857 B2
• Time in Patent Office: Days
• US Class Current: 425/174.80R
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: D01D 5/0069 characterised by the spinning section, e.g. capillary tube, protrusion or pin
• CPC Class Codes: D01D 5/18 by means of rotating spinnerets
• CPC Class Codes: D04H 1/4242 Carbon fibres
• CPC Class Codes: D04H 1/728 by electro-spinning electro-spinning methods and apparatus D01D5/0007
• CPC Class Codes: D04H 3/002 Inorganic yarns or filaments
• CPC Class Codes: D04H 3/016 characterised by the fineness
• CPC Class Codes: Y10T 442/614 Strand or fiber material specified as having microdimensions [i.e., microfiber]

Abstract

Apparatus and method for electrospinning fibers in which the apparatus includes a spray head having a longitudinal axis and including at least one electrospinning element disposed in a peripheral wall of the spray head surrounding the longitudinal axis. The electrospinning element includes a passage by which a substance from which the fibers are to be electrospun is provided to a tip of the electrospinning element. The electrospinning element extends from the peripheral wall in a direction from the longitudinal axis and is configured to electrospin the fibers by electric field extraction of the substance from the tip of the electrospinning element. Accordingly, the method includes providing a substance from which the fibers are to be composed to a tip of an electrospinning element in a peripheral wall of a spray head having a longitudinal axis, rotating the spray head or a collector configured to receive the fibers around the longitudinal axis, applying in a direction from the longitudinal axis of the spray head an electric field to the tip of the electrospinning element to electrospin by electric field extraction the substance from the tip of the electrospinning element to form the fibers, and collecting the fibers on the collector.

Claims

1. An apparatus for producing fibers, comprising:

a spray head having a longitudinal axis and including,

at least one electrospinning element having a tip, said tip extending in a radial direction from a peripheral wall of the spray head, said peripheral wall encircling the longitudinal axis, said electrospinning element having a passage by which a substance from which the fibers are to be composed is provided to an interior of the tip of the electrospinning element, and

said electrospinning element configured to electrospin said fibers by electric field extraction of the substance from the tip of the electrospinning element.

2. The apparatus of claim 1, further comprising:

a collector configured to receive said fibers from the spray head.

3. The apparatus of claim 2, further comprising:

a rotary mechanism configured to rotate at least one of the spray head and the collector around the longitudinal axis.

4. The apparatus of claim 3, wherein the rotary mechanism is configured to rotate both the spray head and the collector at different angular speeds.

5. The apparatus of claim 3, wherein the rotary mechanism is configured to rotate in opposite angular directions both the spray head and the collector.

6. The apparatus of claim 3, wherein said spray head comprises:

a rotatable spray head configured to rotate about the longitudinal axis.

7. The apparatus of claim 6, wherein said rotatable spray head comprises:

at least one of a cylindrical or polygonal structure.

8. The apparatus of claim 6, wherein said rotatable spray head is configured to rotate at an angular speed of 150-10,000 rpm.

9. The apparatus of claim 3, wherein said collector comprises a rotatable collector configured to rotate about the longitudinal axis.

10. The apparatus of claim 9, wherein said rotatable collector is configured to rotate at an angular speed of 150-10,000 rpm.

11. The apparatus of claim 6, wherein the at least one electrospinning element comprises:

plural electrospinning elements disposed equidistant along said peripheral wall.

12. The apparatus of claim 11, wherein said plural electrospinning elements define openings through the peripheral wall having an inner dimension in a range of 50-250 μ

m.

13. The apparatus of claim 11, wherein said plural electrospinning elements comprise tubes.

14. The apparatus of claim 13, wherein one of said tubes has an interior cross sectional area of 1900-50,000 μ

m².

15. The apparatus of claim 13, wherein one of said tubes has an outer dimension of less than 400 μ

m.

16. The apparatus of claim 11, wherein said plural electrospinning elements comprise at least one of capillaries, frits, needles, and foams.

17. The apparatus of claim 11, wherein at least one of said plural electrospinning elements extends past said peripheral wall of said rotatable spray head.

18. The apparatus of claim 11, wherein at least one of said plural electrospinning elements comprises a metallic member.

19. The apparatus of claim 11, wherein at least one of said plural electrospinning elements comprises an insulating member.

20. The apparatus of claim 1, wherein said spray head comprises:

a reservoir configured to hold the substance from which the fibers are to be composed.

21. The apparatus of claim 1, wherein said spray head comprises:

an electrically permeable vessel including a reservoir configured to hold the substance from which the fibers are to be composed; and

an interior electrode located inside said vessel.

22. The apparatus of claim 21, wherein said electrically permeable vessel comprises an insulator.

23. The apparatus of claim 21, wherein said electrically permeable substance comprises at least one of a rubber and a plastic substance.

24. The apparatus of claim 2, wherein said collector is circumferentially disposed about the spray head.

25. The apparatus of claim 2, wherein said collector is at a ground potential.

26. The apparatus of claim 2, wherein the spray head and the collector are maintained at opposite electric potentials.

27. The apparatus of claim 2, wherein said collector comprises at least one of a plate and a screen.

28. The apparatus of claim 2, wherein said collector is separated 1-50 cm from said spray head.

29. The apparatus of claim 2, further comprising:

a power source electrically connected between said spray head and said collector to generate an electric field between said spray head and said collector.

30. The apparatus of claim 29, wherein said power source is configured to generate an electric field strength of 2,000-400,000 V/m between said spray head and said collector.

55. The apparatus of claim 1, wherein the spray head comprises a rotatable spray head.

56. The apparatus of claim 2, wherein the collector is configured to encircle the longitudinal axis and to extend in a direction of the longitudinal axis.

31. A system for producing fibers, comprising:

a spray head having a longitudinal axis and including,

at least one-electrospinning element having a tip, said tip extending in a radial direction from a peripheral wall of the spray head, said peripheral wall encircling the longitudinal axis,

said electrospinning element having a passage by which a substance from which the fibers are to be composed is provided to an interior of the tip of the electrospinning element, and

said electrospinning element extending from the peripheral wall in a direction from the longitudinal axis in the radial direction and configured to electrospin said fibers by electric field extraction of the substance from the tip of the electrospinning element;

a collector configured to collect said fibers; and

a rotary mechanism configured to rotate at least one of the spray head and the collector.

32. The system of claim 31, wherein the rotary mechanism is configured to rotate both the spray head and the collector at different angular speeds.

33. The system of claim 31, wherein the rotary mechanism is configured to rotate in opposite angular directions both the spray head and the collector.

34. The system of claim 31, wherein said at least one electrospinning element defines an opening through the peripheral wall having an inner dimension in a range of less than 400 μ

m.

35. The system of claim 31, further comprising:

a power supply configured to establish an electric field between the spray head and the collector.

36. The system of claim 35, wherein said power supply is configured to produce said electric field having an electric field strength of 2,000-400,000 V/m.

57. The system of claim 31, wherein the spray head comprises a rotatable spray head.

58. The system of claim 31, wherein the collector is configured to encircle the longitudinal axis and to extend in a direction of the longitudinal axis.

37-54. -54. (canceled)