WO2009055413A1 - Fiber formation by electrical-mechanical spinning - Google Patents
Fiber formation by electrical-mechanical spinning Download PDFInfo
- Publication number
- WO2009055413A1 WO2009055413A1 PCT/US2008/080693 US2008080693W WO2009055413A1 WO 2009055413 A1 WO2009055413 A1 WO 2009055413A1 US 2008080693 W US2008080693 W US 2008080693W WO 2009055413 A1 WO2009055413 A1 WO 2009055413A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- rotating member
- fibers
- liquid material
- target
- periphery
- Prior art date
Links
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
- 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
- D01D5/08—Melt spinning methods
- D01D5/098—Melt spinning methods with simultaneous stretching
- D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
-
- 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
- D01D5/18—Formation of filaments, threads, or the like by means of rotating spinnerets
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/18—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
Definitions
- the present invention relates to fiber formation, particularly to fibers of nano dimensions.
- Fibers of nano dimensions can be produced by streaming an electrostatically charged liquid such as a polymeric solution through a jet or needie with a very small orifice. Scaling up this process by using multiple needles suffers from the difficulty of electrically isolating these needles from each other. Consequently, needles typically must be at least one centimeter away from the nearest neighbor. In addition, the need to draw a Tailor cone from a single droplet on the end of each needle limits the maximum flow rate per needle and increases the number of needles that are needed to achieve large scale production.
- the present invention provides a method of fiber production starting from a liquid material such as a polymer solution or a polymer melt.
- the liquid material is fed to an annular rotating member such as a disk or cup rotating around an axis concentric therewith.
- the rotating member has a relatively smooth continuous surface extending from the central area to a periphery.
- the liquid material is directed by centrifugal force radially from the central area to the periphery and is expelled from the periphery towards a target.
- Liquid material is electrically charged either by the rotating member or immediately after being expelled from the periphery of the rotating member by passing through an electric field.
- the target to which the fibers are directed is electrically grounded.
- the difference in electrical potential between the charged fibers and the target, the viscosity of the liquid material and the size and speed of the annular member, the liquid delivery rate and the optional use of shaping air are adjusted relative to one another so that the liquid material is expelled in fibrous form. Also adjusting these variables affects the quality and quantity of the fibers.
- the continuous surface of the annular rotating member is the interior surface of a substantially cylindrical member such as a cup.
- the sides of the cup may be divergent such that the cup is in the form of a truncated cone.
- the annular spinning member rotates around an axis concentric therewith.
- the rotating member may be electrically charged to impart an electrical charge to the liquid material being fed to the rotating member.
- an electrical charge can be imposed on the liquid material as it is expelled from the rotating member in fibrous form by passing the fibers through an electric field.
- the liquid material is centrifugally directed along the interior surface towards the periphery of the rotating member.
- spinning points are located along the periphery of the rotating member.
- spinning points are V-shaped serrations extending around the periphery, preferably extending outwardly and substantially parallel to the axis of rotation of the rotating member.
- the liquid material passes over the spin points and is expelled from the rotating member towards the grounded target.
- the rotating member may vary in size and geometry.
- the rotating member may be as a disk or rotating bell.
- the diameter of the rotating member may vary from 20 mm to 350 mm, such as 20 to 160, such as 30 to 80 mm.
- the difference in electrical potential between the charged fibers and the target is preferably at least 5000 volts, such as within the range of 20,000 to 100,000 volts and 50,000 to 90,000 volts. If the electrical potential is insufficient, droplets and not fibers may be formed.
- the fibers are directed towards a grounded target where the fibers are collected.
- the grounded target can be positioned behind a moving belt or conveyor where the fibers can be collected and removed from the target area.
- the distance to target can vary from 2 to 50 (5 to 130 cm), such as 2 to 30 inches (5 to 76 cm) such as 10 to 20 inches (25 - 51 cm).
- an air stream is propelled normally and concurrently against the expelled fibers so as to shape the fibers into a flow pattern concentric with the axis of rotation and towards the target.
- Air pressure measured at the entrance of the rotating member can typically be set at such as 1 - 80 PSIG (6.9 x 10 3 - 5.5 x 10 s Pascals), such as 1 - 60 PSIG (6.9 x 10 3 - 4.1 x 10 5 Pascals) such as from 5 to 40 PSIG (3.4 x 10 4 - 2.8 x 10 6 Pascals), With a rotating disk, shaping air is usually not used.
- the rotating member is connected to a drive means such as a rotating drive shaft connected to a member such as an electrical motor or air motor capable of spinning the rotary member at speeds of at least 500 rpm, such as 1000 to 100,000, and 3000 to 50,000 rpms typically with speeds of 10,000 to 100,000 rpms. if the speed of the rotating member is insufficient, fibers may not form and the liquid may be expelled from the rotary member as sheets or globs, If the speed of the rotating member is too high, droplets may form or fibers may break off.
- the liquid material is passed through the interior of the drive shaft and fed to the rotating member.
- the rotating member is cup- shaped, such as a rotating bell
- the liquid material is fed through the closed end of the cup and in the central or base area of the cup.
- the liquid enters the closed end of the cup through a supply nozzle that may range in size from 0.5 to 1.5 mm, The liquid can then travel through the inside of the cup and exits on the surface of the cup through a center orifice or series of orifices onto the cup face.
- the flow rate of liquid material to the rotating member is typically 1 ml/hour to 500 ml/minute, such as from 20 ml/hour to 50 ml/minute such as from 50 to 1000 ml/hour.
- the liquid materia! that is spun into fibers in accordance with the invention is typically a polymer solution or melt.
- the polymers can be organic polymers such as polyesters, polyamides, polymers of n-vinyl pyrrolidone polyacrylonitrile and acrylic polymers such as are described in published application U.S. 2008/0145655A1.
- the liquid can be an inorganic polymer.
- inorganic polymers are polymeric metal oxides that contain alkoxide groups and optionally hydroxy) groups.
- the alkoxide groups contains from 1 to 4 carbon atoms such as methoxide and ethoxide.
- polymeric metal oxides are poiyalkylsilicates such as those of the following structure:
- R is a!kyl containing from 1 to 4, preferably from 1 to 2 carbon atoms, and n is 3 to 10.
- hybrid organic/inorganic polymers such as acrylic polymers and polymeric metal oxides can be employed. Examples of such organic/inorganic hybrid polymers are described in published application U.S. 2008/0207798A1. Also, inorganic materials such as inorganic oxides or inorganic nitrides or carbon or ceramic precursors, such as silica, aluminia, Titania, or mixed metal oxides can be used.
- the electrical conductivity of the liquid material can vary and should be sufficiently electrically conductive such that it can accept a charge bui ⁇ d up but not to the point that electrical shorting occurs. With indirect charging, the electrical conductivity can be high since shorting is not a problem.
- the electrical conductivity can be adjusted by using appropriate amounts of salts such as ammonium salts and electrically conductive solvents such as alcohol- water mixtures.
- the surface tension of the liquid material can vary. If the surface tension is too high, atomization and droplets rather than fibers may be formed.
- the liquid preferably thickens as polymer concentration increases or polymer crosslinking occurs.
- the viscosity of the soiution can be controlled by controlling the molecular weight of the polymer, the concentration of the polymer in the solution, the presence of crosslinking of the polymer in solution, or by adding a thickening agent to the polymer solution such as polyvinyl pyrrolidone, polyvinyl alcohol, polyvinyl acetate, polyamides and a cellulosic thickener.
- a thickening agent such as polyvinyl pyrrolidone, polyvinyl alcohol, polyvinyl acetate, polyamides and a cellulosic thickener.
- the viscosity of the solution is too high, i.e., at its gel point or above, it behaves more like a solid material and may not form a fiber and may build up as solid polymer on the surface of the rotating member.
- the fibers that are formed in accordance with the invention typically have diameters of up to 5,000 nanometers, such as 5 to 5,000 nanometers or within the range of 50 to 1200 nanometers such as 50 to 700 nanometers. Fibers can also have ribbon or flat face configuration and in this case the diameter is intended to mean the largest dimension of the fiber. Typically, the width of ribbon-shaped fibers is up to 5,000, such as 500 to 5,000 nanometers, and the thickness is up to 200, such as 5 to 200 nanometers. [0016] In certain instances the nanofibers can be twisted around each other in a yarn-like structure.
- FIG. 1 is a schematic vertical cross-section through a centrifugal spinning apparatus in which the process of the invention may be practiced.
- FIG. 2 is a bottom elevation of a spinning member in accordance with the process of the invention.
- FIG. 3 is a section along line Ill-Hi of FIG. 2.
- FIG. 4 shows photomicrographs at various magnifications of nanofibers prepared in accordance with Example 1.
- FIG. 4a (comparative) shows photomicrographs at various magnifications of droplets prepared in accordance with Example 1a
- FIG. 5 is a chart showing how the variables of rotating member speed, shaping air and liquid flow effect fiber formation for the polymer solutions of Examples 1 and 1a (comparative).
- FIG. 6 shows photomicrographs at various magnifications of nanofibers prepared in accordance with Example 2.
- FIG. 6a shows photomicrographs at various magnifications of droplets prepared in accordance with Example 2a
- FlG. 7 is a chart showing how the variables of rotating member speed, shaping air and liquid flow effect fiber formation for the polymer solutions of Examples 2 and 2a (comparative).
- FIG. 8 shows photomicrographs at various magnifications of nanofibers prepared in accordance with Example 3.
- FIG. ⁇ a shows photomicrographs at various magnifications of droplets prepared in accordance with Example 3a
- FIG. 9 shows photomicrographs at various magnifications of nanofibers in the form of a twisted yarn prepared in accordance with Example 4.
- FIG. 10 shows photomicrographs at various magnifications of nanofibers prepared in accordance with Example 5.
- the apparatus 1 contains a cup-shaped rotating member 5 and an air plenum arrangement 7 through which air is directed to shape the fibrous stream 9 as it is directed towards the target 11.
- a container 13 for the liquid material 15 includes a suitable feed mechanism (not shown) for feeding the liquid material to the rotating cup 5 via a feed supply line 17 mounted concentrically with the axis 3.
- the supply line 17 has an exit in the rotating cup 5 adjacent to closed end.
- the feed supply line is located within a rotating drive shaft for rotating the cup-shaped rotary member 5.
- a voltage is imposed on the rotating cup to impart a charge on the liquid material and the fibers that are expelled from the rotating cup.
- the rotating member 5 is cup- shaped having a planar base or closed end 21 and divergent walls 23 extending from the base 21.
- the base 21 has a centra! aperture 25 through which the feed supply line extends and fixing elements 27 by which the rotating cup 5 is mounted on the drive means for rotation around the axis 3.
- the interior surface 29 of the wall 23 is relatively smooth over the region extending from the base 21 to the edge 31 of the cup 5,
- the edge of the cup 5 is serrated such that there are spinning points 33 defined by V-shaped serrations 35 on the external periphery of the cup 5.
- V-shaped serrations 35 lie in a plane parallel to the base of the cup 5,
- the cup 5 is spun at the desired rate and the liquid is fed to the rotating cup in the central area of the base of the cup and is directed to the periphery of the base 21 and across the interior surface 29 by centrifugal force.
- the liquid that is electrically charged flows across the interior surface 29 of the rotating cup through the spinning points 33 from which the liquid is expelled in fibrous form towards the grounded target 1 1.
- An acrylic-silane polymer was prepared as follows.
- a hybrid organic-inorganic polymer was prepared as follows 1 [0036] The ethanol solution of acrylic-silane polymer solution, prepared as described above, 200 grams, was poured into a jar, and deionized water (30 grams) was added. An ethanol solution of ethyl polylsilicate (Silbond 40, Akzo Chemical, Inc) was added to the polymer solution along with polyvinylpyrrolidone (4 grams, Aldrich, Catalog 437190, CAS [9003-39-8], and MW 1 ,300,000). While warming the jar with hot tap water, the mixture was hand shaken, and hand stirred with a spatula until a homogeneous solution was obtained. After this solution was allowed to stand at room temperature for about 3.5 hours, its viscosity of was determined to be C + by the method of ASTM- D 1545.
- An acrylic-silane polymer was prepared as follows.
- An inorganic so! gel polymer was prepared as follows.
- a solution of polyacrylonitrile was prepared by dissolving 12 weight percent of polyacrylonitrile resin (Aldrich, Catalog 181315, CAS [25014-41-9], MW 150,000) in dimethylformaldehyde solvent while warming on a hot plate.
- polyacrylonitrile resin Aldrich, Catalog 181315, CAS [25014-41-9], MW 150,000
- the perpendicular distance from the circular slit to the edge of the bell cup is approximately 7.85 cm.
- the bell cup referred to in this experiment is a Durr Behr Eco bell cup model N 16010037 type.
- the bell shaping air was set at 25 psig (1.72 x 10 5 Pascals) at the back of the bell via a M> inch (12.7 mm) outside diameter nylon tube.
- the rotary applicator was connected to a high voltage source with a 75,000 Volt indirect charge applied potential.
- the entire delivery tube, rotary applicator and collector were in a booth that allowed the environmental condition to maintain a relative humidity of approximately 55% to 60% at a room temperature of 70 0 F to 72 0 F (21 0 C - 22 0 C).
- Nanofibers were collected on the grounded target onto aluminum panels set at a target / collection distance of 15 inches (38 cm) from the rotary bell and were characterized by optical microscopy and scanning electron microscopy.
- the nanofibers were essentialiy cylindrical and had diameters of 600 to 1800 nanometers (nm). Some large diameter fibers were observed that appear to be assemblies of the smaller diameter fibers.
- the scanning electron micrograph is shown in Figure 4 and shows many fibers with little or no drops.
- FF Fluid Delivery Rate
- the values of the vertical axis are the product of the thickness of the nanofiber mat that is formed multiplied by the ratio of nanofiber to drops.
- the thickness of the mat is given a subjective value of 1 to 10 and the ratio of nanofibers to drops is given a subjective value of 1 to 6.
- Nanofibers were attempted to be collected on the grounded aluminum target onto aluminum panels set at a part / collection and were characterized by scanning electron microscopy as shown in Figure 4a. The electron microscopy shows very little fiber formation and many wet drops.
- Example A The hybrid organic - inorganic polymer solution of Example A was spun into nanofibers in accordance with the procedure of Example 1 , but using a Dur Behr Eco bell cup mode! N16010033.
- the nanofibers were characterized by optical microscopy and scanning electron microscopy.
- the nanofibers were somewhat flat-faced with cross-sectional dimensions that ranged from 700 nanometers (nm) to 5000 nm.
- the scanning electron micrograph is shown in Figure 6 and shows many fibers with little or no wet drops.
- Example 2 the procedure of Example 2 was generally followed with the following differences:
- Target/collector distance 10 inches (25.4 cm)
- Example 1 A Design Analysis as described in Example 1 was completed for the solution of Example 2.
- the application factors studied for this work were bell speed from 12K rpms to 28K rpms, target distance from 10 inches to 20 inches (25.4 - 38.1 cm), voltage from 60KV to 90KV, fluid delivery rate from 100 ml/hour to 300 ml/hour and bell shaping air from 15 psig to 35 psig (1.03 x 10 5 - 2,41 x 10 5 Pascals).
- the results reported in Figure 7 showed that fluid delivery rate, shaping air, bell speed and target distance were the most influential followed by KV, Figure 7 uses the same terminology as used in Figure 5.
- Example C The inorganic sol gel polymer solution of Example C was spun into nanofibers in accordance with the procedure of Example 2 using a fluid delivery rate of 100 milliliters per hour, a spin rate of 28,000 rpms, a voltage of 90,000 volts and a target collector distance of 20 inches (50.8 cm), The bell shaping air was set at 15 psig (1.03 x 10 5 Pascals) at the back of the bell. Nanofibers were collected on the grounded aluminum panel target and were characterized by optical microscopy and scanning electron microscopy.
- the nanofibers were essentially cylindrical and had diameters of
- Nanofibers were attempted to be collected on the grounded aluminum target and were characterized by scanning electron microscopy as shown in Figure 8A. The electron microscopy shows little fibers with wet drops.
- Example D The polyacrylonitrile resin solution of Example D was spun into fiber in accordance with the procedure of Example 1 using a voltage 86,000. Fibers were collected on the grounded aluminum panel target and were characterized by optical microscopy and scanning electron microscopy. Large fibers collected on the panel. One large fiber was removed from the panel and was evaluated microscopically as shown in Figure 9. A low resolution optical image (left-most image) indicated that the large fiber might be an assembly of smaller fibers. Scanning electron microscopy (center image) revealed that these large fibers are a twisted yarn 100 microns in diameter comprised of several much smaNer fibers. The yarn is formed as the smaller fibers rotate from the spinning bell cup. Higher magnification (right-most image) revealed that these smaller fibers are nano-scale in diameter within the yarn.
- Example B The organic polymer solution of Example B was spun into fibers in accordance with the procedure of Example 1 with the following differences: Fluid flow rate 200 ml/hour
- the nanofibers were somewhat flat-faced with cross-sectional dimensions and had diameters of 300 to 700 nm.
- the scanning electromicrograph is shown in Figure 10.
- the micrograph shows many small fibers with little drop formation.
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- Chemical Kinetics & Catalysis (AREA)
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- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
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Abstract
Description
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Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MX2010004467A MX2010004467A (en) | 2007-10-23 | 2008-10-22 | Fiber formation by electrical-mechanical spinning. |
EP08841904A EP2209933A1 (en) | 2007-10-23 | 2008-10-22 | Fiber formation by electrical-mechanical spinning |
CN2008801190519A CN101883882A (en) | 2007-10-23 | 2008-10-22 | Fibre forming by the electromechanical spinning |
CA2703958A CA2703958A1 (en) | 2007-10-23 | 2008-10-22 | Fiber formation by electrical-mechanical spinning |
EA201070516A EA201070516A1 (en) | 2007-10-23 | 2008-10-22 | FORMATION OF FIBER BY ELECTROMECHANICAL SPINNING |
JP2010531176A JP2011501790A (en) | 2007-10-23 | 2008-10-22 | Fiber formation by electromechanical spinning |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US98184807P | 2007-10-23 | 2007-10-23 | |
US60/981,848 | 2007-10-23 |
Publications (1)
Publication Number | Publication Date |
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WO2009055413A1 true WO2009055413A1 (en) | 2009-04-30 |
Family
ID=40228078
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2008/080693 WO2009055413A1 (en) | 2007-10-23 | 2008-10-22 | Fiber formation by electrical-mechanical spinning |
Country Status (9)
Country | Link |
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US (1) | US20090102100A1 (en) |
EP (1) | EP2209933A1 (en) |
JP (1) | JP2011501790A (en) |
KR (1) | KR20100088141A (en) |
CN (1) | CN101883882A (en) |
CA (1) | CA2703958A1 (en) |
EA (1) | EA201070516A1 (en) |
MX (1) | MX2010004467A (en) |
WO (1) | WO2009055413A1 (en) |
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- 2008-10-22 MX MX2010004467A patent/MX2010004467A/en unknown
- 2008-10-22 US US12/255,806 patent/US20090102100A1/en not_active Abandoned
- 2008-10-22 CN CN2008801190519A patent/CN101883882A/en active Pending
- 2008-10-22 EA EA201070516A patent/EA201070516A1/en unknown
- 2008-10-22 JP JP2010531176A patent/JP2011501790A/en not_active Withdrawn
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Also Published As
Publication number | Publication date |
---|---|
EP2209933A1 (en) | 2010-07-28 |
US20090102100A1 (en) | 2009-04-23 |
CA2703958A1 (en) | 2009-04-30 |
KR20100088141A (en) | 2010-08-06 |
EA201070516A1 (en) | 2010-12-30 |
CN101883882A (en) | 2010-11-10 |
MX2010004467A (en) | 2010-05-03 |
JP2011501790A (en) | 2011-01-13 |
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