DEVICES AND METHODS FOR THE PRODUCTION OF MICROFIBERS AND NANOFIBERS IN A CONTROLLED ENVIRONMENT

• US 20140159262A1
• Filed: 08/06/2013
• Published: 06/12/2014
• Est. Priority Date: 08/06/2012
• Status: Active Grant

• Current Assignee: Clarcor, Inc. (Parker-Hannifin Corporation)
• Original Assignee: FibeRio Technology Corporation (Parker-Hannifin Corporation)
• Inventors: Kay, Stephen, Ner, Yogesh, Castellano, Lenard
• Granted Patent: US 9,827,728 B2
• Time in Patent Office: Days
• US Class Current: 264/8
• CPC Class Codes: B29C 48/04 Particle-shaped making granules B29B9/00
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/301 having reciprocating, oscillating or rotating parts
• CPC Class Codes: B29C 48/345 Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
• CPC Class Codes: B29D 99/0078 Producing filamentary materials
• CPC Class Codes: C03B 37/04 by using centrifugal force , e.g. spinning through radial orifices; Construction of the spinner cups therefor bonder application C03C25/00
• CPC Class Codes: C03B 37/045 Construction of the spinner cups
• CPC Class Codes: D01D 5/18 by means of rotating spinnerets

Abstract

Described herein are apparatuses and methods of creating fibers, such as microfibers and nanofibers. The methods discussed herein employ centrifugal forces to transform material into fibers. Apparatuses that may be used to create fibers are also described. To improve the formation of fibers, various devices and systems for controlling the micro-environment around the fiber producing device are described.

Claims

1-29. -29. (canceled)

30. A device for use in a microfiber and/or nanofiber producing system, the device comprising:

a body;

an internal cavity disposed in the body;

one or more openings that allow material to be passed from the internal cavity to the exterior of the body;

a coupling member, wherein the fiber producing device is couplable to a driver through the coupling member; and

one or more draft members coupled to the body, wherein one or more of the draft members create a gas flow relative to the body due to rotation of the fiber producing device,

wherein the body is configured to receive a material to be produced into a fiber, and

wherein, during use, rotation of the body causes material in the internal cavity to be passed through one or more openings to produce microfibers and/or nanofibers, and wherein the gas flow produced by one or more of the draft members conveys at least some of the produced microfibers and/or nanofibers away from the body during use.

31. The device of claim 30, wherein at least one draft member comprises:

an internal cavity,

a first end coupled to the body; and

an opening positioned at a second end of the draft member, opposite to the first end,

wherein material in the body passes into the internal cavity through the first end and through one or more of the openings to produce the microfibers and/or nanofibers.

32. The device of claim 30, wherein at least a portion of one or more of the draft members are angled with respect to a plane perpendicular to the axis of rotation.

33. The device of claim 30, wherein the body comprises a ring-shaped substrate defining the internal cavity, and wherein the draft members couple the ring shaped substrate to the coupling member.

34. The device of claim 33, wherein the ring-shaped substrate comprises a circular channel coupled to the internal cavity, wherein during use, the material is introduced into the circular channel and conveyed through the circular channel into the internal cavity.

35. The device of claim 30, wherein the body comprises a ring-shaped substrate defining the internal cavity, and wherein the draft members extend away from the ring shaped substrate, and wherein the openings are formed at an end of the draft members.

36. The device of claim 35, wherein the ring-shaped substrate comprises a circular channel coupled to the internal cavity, wherein during use, the material is introduced into the circular channel and conveyed through the circular channel into the internal cavity.

37. The device of claim 35, wherein the draft members comprise one or more raised members that are aligned with the axis rotation, and wherein, during rotation of the fiber producing device, the raised members create a gas flow in a direction both perpendicular to the axis of rotation and parallel to the axis of rotation.

38. The device of claim 30, wherein the body comprises a ring-shaped substrate defining the internal cavity and one or more coupling rods coupling the ring-shaped substrate to the coupling member, and wherein the draft members extend away from the ring shaped substrate, and wherein the openings are formed at an end of the draft members.

39. The device of claim 30, wherein the plurality of openings are in a pattern, and wherein the pattern of openings are positioned such that entwining of the produced microfibers and/or nanofibers is inhibited.

40. A system for producing microfibers and/or nanofibers comprising:

a fiber producing device comprising;

a body;

an internal cavity disposed in the body;

one or more openings that allow material to be passed from the internal cavity to the exterior of the body;

a coupling member, wherein the fiber producing device is couplable to a driver through the coupling member; and

one or more draft members coupled to the body, wherein one or more of the draft members create a gas flow relative to the body due to rotation of the fiber producing device,

wherein the body is configured to receive a material to be produced into a fiber,

a driver capable of rotating the body, wherein the body is couplable to the driver through the coupling member;

wherein, during use, rotation of the body causes material in the body to be passed through one or more openings to produce microfibers and/or nanofibers.

41-50. -50. (canceled)

51. A method of producing microfibers and/or nanofibers, comprising:

placing material in a fiber producing device, the fiber producing device comprising;

a body;

an internal cavity disposed in the body;

one or more openings that allow material to be passed from the internal cavity to the exterior of the body;

a coupling member, wherein the fiber producing device is couplable to a driver through the coupling member; and

one or more draft members coupled to the body, wherein one or more of the draft members create a gas flow relative to the body due to rotation of the fiber producing device,

rotating the fiber producing device, wherein rotation of the fiber producing device causes material in the body to be passed through one or more openings to produce microfibers and/or nanofibers; and

collecting at least a portion of the produced microfibers and/or nanofibers in a collection region, wherein one or more of the draft members create a gas flow relative to the body due to rotation of the fiber producing device which directs the produced fibers toward a collection region.

52. The method of claim 51, further comprising:

heating the material to a temperature sufficient to at least partially melt the material;

heating the fiber producing device to a temperature at or near a temperature sufficient to at least partially melt the material; and

conveying the heated material into the heated fiber producing device.

53. The method of claim 51, further comprising:

placing material in a fiber producing device; and

heating the fiber producing device to a temperature at or near the temperature sufficient to at least partially melt the material disposed in the fiber producing device.

54. The method of claim 51, further comprising mixing the material with a solvent to produce a mixture of the material in a solvent, and introducing the mixture into the fiber producing device.

55. The method of claim 51, wherein the microfibers and/or nanofibers are created without subjecting the fibers, during their creation, to an externally applied electric field.

56. The method of claim 51, further comprising:

placing a substrate on a substrate support positioned below the fiber producing device, and

directing fibers toward the substrate using the gas flow produced by the draft members.

57-118. -118. (canceled)