Electrospinning process for manufacture of multi-layered structures

• US 9,194,058 B2
• Filed: 02/04/2013
• Issued: 11/24/2015
• Est. Priority Date: 01/31/2011
• Status: Expired due to Fees

• Current Assignee: Arsenal Medical, Inc
• Original Assignee: Arsenal Medical, Inc
• Inventors: Sharma, Upma, Pham, Quynh, Marini, John, Yan, Xuri, Core, Lee
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US13/758,173
• Publication Number:
  US 20130241115A1
• Time in Patent Office: 1,023 Days
• Field of Search: 264/10, 264/172.15, 264/173.16, 264/173.17, 264/173.18, 264/173.19, 264/174.1, 264/174.11, 264/211.12, 264/464, 264/465, 264/466, 264/484
• US Class Current: 1/1
• CPC Class Codes: D01D 5/0038 the fibre formed by solvent evaporation, i.e. dry electro-spinning
• CPC Class Codes: D01D 5/0061 characterised by the electro-spinning apparatus
• CPC Class Codes: D01D 5/0069 characterised by the spinning section, e.g. capillary tube, protrusion or pin
• CPC Class Codes: D01D 5/34 Core-skin structure; Spinnerette packs therefor

Abstract

Devices and methods for high-throughput manufacture of concentrically layered nanoscale and microscale fibers by electrospinning are disclosed. The devices include a hollow tube having a lengthwise slit through which a core material can flow, and can be configured to permit introduction of sheath material at multiple sites of Taylor cone formation formation.

Claims

1. A method of forming a structure, the structure comprising a core including a first material and a sheath including a second material around said core, the method comprising the steps of:

providing an apparatus, comprising;

a first wedge-shaped vessel having a first slit and comprising an electrically conductive material;

a second wedge-shaped vessel having a second slit, wherein the first wedge-shaped vessel is disposed inside of the second wedge-shaped vessel;

first and second fluid reservoirs containing the first and second materials, respectively, wherein the first and second fluid reservoirs are in fluid communication with the first and second wedge-shaped vessels, respectively; and

a voltage source configured to apply a voltage to at least one of the first and second materials;

activating the voltage source to apply a voltage of between 1 and 250 kV;

moving the first material from the first fluid reservoir to the first wedge-shaped vessel; and

moving the second material from the second fluid reservoir to the second wedge-shaped vessel.

2. The method of claim 1, wherein the structure is an elongate fiber.

3. The method of claim 1, wherein the apparatus includes a collecting area having at least one electrically grounded point thereon, the method further comprising the step of collecting the structure within the collecting area.

4. The method of claim 1, wherein the step of moving the first fluid from the first fluid reservoir to the first wedge-shaped vessel includes supplying a gas to the first fluid reservoir at a substantially constant pressure.

5. The method of claim 1, wherein the step of moving the first fluid from the first fluid reservoir to the first wedge-shaped vessel includes moving a piston within the first fluid reservoir at a constant rate.

6. The method of claim 1, wherein the step of moving the second fluid from the second fluid reservoir to the second wedge-shaped vessel includes moving a gas into the second fluid reservoir at a substantially constant pressure.

7. The method of claim 1, wherein the step of moving the second fluid from the second fluid reservoir to the second wedge-shaped vessel includes moving a piston within the second fluid reservoir at a substantially constant rate.

8. The method of claim 1, wherein the voltage applied in the step of activating the voltage source is between 1 and 100 kV.

9. The method of claim 1, wherein the first slit is positioned at an apex of the first wedge-shaped vessel.

10. The method of claim 9, wherein the second slit is positioned at an apex of the second wedge-shaped vessel.

11. The method of claim 10, wherein the first and second slits are aligned.

12. A method of forming an elongate fiber, the elongate fiber comprising a core including a first material and a sheath including a second material around said core, the method comprising the steps of:

providing an apparatus, comprising;

a first wedge-shaped vessel having a first slit and comprising an electrically conductive material;

a second wedge-shaped vessel having a second slit, wherein the first wedge-shaped vessel is disposed inside of the second wedge-shaped vessel;

first and second fluid reservoirs containing the first and second materials, respectively, wherein the first and second fluid reservoirs are in fluid communication with the first and second wedge-shaped vessels, respectively;

a voltage source configured to apply a voltage to at least one of the first and second materials; and

a collecting area having at least one electrically grounded point thereon;

activating the voltage source to apply a voltage of between 1 and 250 kV;

moving the first material from the first fluid reservoir to the first wedge-shaped vessel;

moving the second material from the second fluid reservoir to the second wedge-shaped vessel; and

collecting the elongate fiber within the collecting area.

13. The method of claim 12, wherein the step of moving the first fluid from the first fluid reservoir to the first wedge-shaped vessel includes supplying a gas to the first fluid reservoir at a substantially constant pressure.

14. The method of claim 12, wherein the step of moving the first fluid from the first fluid reservoir to the first wedge-shaped vessel includes moving a piston within the first fluid reservoir at a constant rate.

15. The method of claim 12, wherein the step of moving the second fluid from the second fluid reservoir to the second wedge-shaped vessel includes moving a gas into the second fluid reservoir at a substantially constant pressure.

16. The method of claim 12, wherein the step of moving the second fluid from the second fluid reservoir to the second wedge-shaped vessel includes moving a piston within the second fluid reservoir at a substantially constant rate.

17. The method of claim 12, wherein the voltage applied in the step of activating the voltage source is between 1 and 100 kV.

18. The method of claim 12, wherein the first slit is positioned at an apex of the first wedge-shaped vessel.

19. The method of claim 18, wherein the second slit is positioned at an apex of the second wedge-shaped vessel.

20. The method of claim 19, wherein the first and second slits are aligned.