WO2012109251A2 - Appareils et procédés de dépôt de microfibres et de nanofibres sur un substrat - Google Patents

Appareils et procédés de dépôt de microfibres et de nanofibres sur un substrat Download PDF

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Publication number
WO2012109251A2
WO2012109251A2 PCT/US2012/024154 US2012024154W WO2012109251A2 WO 2012109251 A2 WO2012109251 A2 WO 2012109251A2 US 2012024154 W US2012024154 W US 2012024154W WO 2012109251 A2 WO2012109251 A2 WO 2012109251A2
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WIPO (PCT)
Prior art keywords
fiber producing
producing device
fibers
substrate
fiber
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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
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PCT/US2012/024154
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English (en)
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WO2012109251A3 (fr
Inventor
Ed PENO
Roger LIPTON
Stephen Kay
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Fiberio Technology Corp
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Fiberio Technology Corp
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Filing date
Publication date
Application filed by Fiberio Technology Corp filed Critical Fiberio Technology Corp
Priority to JP2013553493A priority Critical patent/JP6190274B2/ja
Publication of WO2012109251A2 publication Critical patent/WO2012109251A2/fr
Publication of WO2012109251A3 publication Critical patent/WO2012109251A3/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
    • D01D5/18—Formation of filaments, threads, or the like by means of rotating spinnerets

Definitions

  • TITLE APPARATUSES AND METHODS FOR THE DEPOSITION OF MICROFIBERS
  • the present invention generally relates to the field of fiber production. More specifically, the invention relates to fibers of micron and sub-micron size diameters.
  • Fibers having small diameters are useful in a variety of fields from the clothing industry to military applications.
  • micrometer micrometer
  • nanometer nanometer
  • fibers having small diameters are useful in a variety of fields from the clothing industry to military applications.
  • biomedical field there is a strong interest in developing structures based on nanofibers that provide scaffolding for tissue growth to effectively support living cells.
  • nanofibers In the textile field, there is a strong interest in nanofibers because the nanofibers have a high surface area per unit mass that provide light, but highly wear resistant, garments.
  • carbon nanofibers are being used, for example, in reinforced composites, in heat management, and in reinforcement of elastomers.
  • Many potential applications for small-diameter fibers are being developed as the ability to manufacture and control their chemical and physical properties improves.
  • Electrospinning is a major manufacturing method to make nanofibers. Examples of methods and machinery used for electrospinning can be found, for example, in the following U.S. Patents: 6,616,435; 6,713,011 ; 7,083,854; and 7, 134,857.
  • a fiber producing system includes a fiber producing device and a driver capable of rotating the fiber producing device.
  • the fiber producing device in one embodiment, includes a body having one or more openings and a coupling member, wherein the body is configured to receive material to be produced into a fiber; and one or more nozzles coupled to one or more of the openings, wherein the one or more nozzles comprise a nozzle orifice.
  • the body of the fiber producing device is couplable to the driver through the coupling member.
  • fiber producing device coupled to the driver causes material in the body to be passed through one or more openings, into one or more nozzles, and ejected through one or more nozzle orifices to produce micro fibers and/or nanofibers.
  • fiber producing system may be configured to substantially simultaneously produce microfibers and nanofibers.
  • the nozzles of the fiber producing device are removably couplable to the body.
  • nozzles of the fiber producing device may be an integral part of the body.
  • a sealing ring may be positioned between one or more of the nozzles and the body to help maintain a secure fitting between the nozzle and the body.
  • the body includes a locking system used to couple one or more nozzles to the openings, wherein the locking system locks the coupled nozzles in a predetermined orientation with respect to the body.
  • a nozzle may be removably couplable to a fiber producing device.
  • a nozzle may formed on a sidewall of the body of the fiber producing device such that the body and nozzle are formed from a single, unitary material.
  • an opening extending through the sidewall may be formed at the junction of a pair of joined circular plates that have an alignment ring or pins.
  • a nozzle may include a nozzle body, the nozzle body defining an internal cavity and having a proximal end and a distal end, wherein the proximal end comprises a coupling portion that allows the nozzle to be coupled to a fiber producing device.
  • the coupling portion of the nozzle may, in one embodiment, be a threaded end which mates with a corresponding threaded portion of the fiber producing device.
  • a nozzle tip may be coupled to the distal end of the nozzle body, wherein the nozzle tip has an internal diameter that is less than the internal diameter of the nozzle body.
  • the nozzle body includes an opening extending through a wall of the nozzle body, the nozzle tip being aligned with the nozzle opening such that material disposed in the nozzle body passes through the opening into the nozzle tip during use.
  • the internal diameter of the nozzle tip may be set such that microfibers and/or nanofibers are produced when material is ejected through the nozzle tip when the nozzle is coupled to a fiber producing device.
  • the nozzle tip and the nozzle body are formed from a single, unitary material.
  • the nozzle tip may be removably couplable to the nozzle body.
  • a nozzle may have a length of at least about 2 mm.
  • An internal diameter of the nozzle tip may be less than about 1 mm.
  • a portion of the interior wall of the nozzle body is substantially flat and another portion of the interior wall of the nozzle body is angled and/or rounded from the flat portion toward the opening formed in the nozzle body.
  • a nozzle tip may have an angled and/or rounded nozzle outlet end.
  • a nozzle may have a non-cylindrical outer surface.
  • a nozzle has an outer surface having a tapered edge. During rotation of the body, gasses contact the tapered edge of the nozzle, creating a region of negative pressure on the side opposite to the tapered edge.
  • One or more outlet conduits may couple one or more nozzles to one or more openings.
  • Outlet conduits may have a length of at least about 10 mm.
  • Nozzles may include a nozzle orifice.
  • the body of the fiber producing device comprises one or more sidewalls and a top together defining an internal cavity, wherein one or more openings extend through a sidewall of the body, communicating with the internal cavity.
  • an interior surface of the sidewall is angled from a bottom wall toward one or more of the openings.
  • an interior surface of the sidewall is rounded from a bottom wall toward one or more of the openings.
  • An interior surface of the sidewall may have an oval shape such that the long axis of the oval interior sidewall is in alignment with one or more of the openings.
  • the driver may be positioned below the fiber producing device or above the fiber producing device, when the fiber producing device is coupled to the driver.
  • the driver may be capable of rotating the fiber producing device at speeds of greater than about 1000 RPM
  • a heating device is thermally coupled to the fiber producing device.
  • a fluid level sensor is coupled to the fiber producing device, the fluid level sensor being positioned to detect a level of fluid inside the fiber producing device.
  • the fiber producing device may be enclosed in a chamber, wherein the environment inside the chamber is controllable.
  • a fiber producing system may include a collection system surrounding at least a portion of the fiber producing device, wherein fibers produced during use are at least partially collected on the collection system.
  • the collection system in one embodiment, includes one or more collection elements coupled to a collection substrate, wherein the one or more collection elements at least partially surround the fiber producing device.
  • the collection elements comprise an arcuate or straight projection extending from the collection substrate surface.
  • a fiber producing system in another embodiment, includes a fiber producing device and a driver capable of rotating the fiber producing device.
  • the fiber producing device in one embodiment, includes a body having one or more openings and a coupling member, wherein the body is configured to receive material to be produced into a fiber; and one or more needle ports coupled to one or more of the openings, wherein one or more needles are removably couplable to the needle ports during use.
  • the body of the fiber producing device is couplable to the driver through the coupling member.
  • rotation of the fiber producing device coupled to the driver causes material in the body to be ejected through one or more needles coupled to one or more needle ports to produce microfibers and/or nanofibers.
  • needles coupled to the one or more needle ports have an angled and/or rounded outlet.
  • a fiber producing system in another embodiment, includes a fiber producing device and a driver capable of rotating the fiber producing device.
  • the fiber producing device in one embodiment, includes a body comprising two or more chambers and a coupling member, wherein a first chamber comprises one or more openings and is configured to receive material to be produced into a fiber; and wherein a second chamber comprises one or more openings and is configured to receive material to be produced into a fiber.
  • the body of the fiber producing device is couplable to the driver through the coupling member.
  • rotation of the fiber producing device coupled to the driver causes material in at least the first chamber and the second chamber to be ejected through the one or more openings to produce microfibers and/or nanofibers.
  • a fiber producing system in another embodiment, includes a fiber producing device and a driver capable of rotating the fiber producing device.
  • the fiber producing device in one embodiment, includes a body comprising one or more openings and a coupling member, wherein the body is configured to receive material to be produced into a fiber.
  • the body of the fiber producing device is couplable to the driver through the coupling member.
  • the fiber producing system further includes a collection system that collects fibers produced by the fiber producing device during use, the collection system comprising one or more collecting elements coupled to a collection element substrate, wherein one or more collection elements comprise an arcuate projection extending from the collection element substrate.
  • rotation of the body coupled to the driver causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers that are at least partially collected on the collecting elements.
  • a collection system of a fiber producing system includes one or more collecting elements coupled to a collection element substrate, wherein the collection elements are positioned surrounding at least a portion of the fiber producing device, and wherein the position of the collection elements with respect to the fiber producing device is adjustable by moving the collection elements along a portion of the collection element substrate.
  • a collection system of a fiber producing system includes one or more collecting elements coupled to a collection element substrate and a collection container, wherein the collection container at least partially surrounds the fiber producing device and wherein the collection elements are removably positionable in the collection container.
  • a collection system of a fiber producing device is configured to collect fibers produced by the fiber producing device. During use rotation of the fiber producing device causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers.
  • the collection system produces a vacuum or activated a gas flow device that causes a flow of produced fibers to the collection system.
  • a fiber producing system in another embodiment, includes a fiber producing device and a driver capable of rotating the fiber producing device.
  • the fiber producing device in one embodiment, includes a body comprising one or more openings and a coupling member, wherein the body is configured to receive material to be produced into a fiber.
  • the body of the fiber producing device is couplable to the driver through the coupling member.
  • the fiber producing system further includes a deposition system that collects fibers produced by the fiber producing device during use and directs the collected fibers toward a substrate disposed in the deposition system during use.
  • rotation of the body coupled to the driver causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers that are at least partially transferred to the deposition system.
  • FIG. 1 depicts a fiber producing system with a driver mounted above the fiber producing device
  • FIG. 2 depicts an example of a multiple level fiber producing device
  • FIG. 3 depicts an embodiment of a portion of fiber producing system configured for deposition of fibers on a substrate
  • FIG. 4 depicts an embodiment of a fiber producing system configured for continuous deposition of fibers on a substrate
  • FIG. 5 depicts a coaxial outlet element
  • FIG. 6 depicts an inverted fiber producing system having a continuous liquid mixture feed
  • FIG. 7 depicts an inverted fiber producing device having a continuous melt feed
  • FIG. 8 depicts a substrate deposition system
  • FIG. 9 depicts a fiber deposition system
  • FIG. 10 depicts a deposition system that includes multiple fiber producing devices.
  • Fiber producing system 1900 includes a fiber producing device 1910.
  • Fiber producing device includes a body 1912 and a coupling member 1914.
  • Body 1912 comprises one or more openings 1916 through which material disposed in the body may pass through during use.
  • One or more outlet elements 1918 e.g., nozzles, needles, needle ports or outlet conduits
  • interior cavity of the body may include angled or rounded walls to help direct material disposed in body 1912 toward openings 1916.
  • Coupling member 1914 may be an elongated member (as depicted in FIG.
  • coupling member may be a receiver which will accept an elongated member from a driver (e.g., the coupling member may be a chuck or a universal threaded joint).
  • Fiber producing system may include a driver 1920 coupled to coupling member 1914.
  • Driver 1920 is positioned above fiber producing device 1910 when the fiber producing device is coupled to the driver.
  • Driver 1920 is capable of rotating fiber producing device 1910 during use.
  • Suitable drivers include commercially available variable electric motors, such as a brushless DC motor.
  • Fiber producing system 1900 may further include a collection system 1930.
  • Collection system may include a collection wall 1932 at least partially surrounding fiber producing device 1910.
  • Collection system 1930 may further include a collection conduit 1934 coupled to collection wall 1932.
  • Collection conduit 1934 in one embodiment, may be an integral part of collection wall 1932.
  • fibers produced by fiber producing device 1910 may collect on collection wall 1932 and be transferred to collection conduit 1934.
  • collection conduit 1934 is positioned below fiber producing device 1910 such that the produced fibers are collected on collection wall 1932 and fall into the collection conduit.
  • a gas flow device (not shown) or a vacuum system (not shown) may be used to create a gas stream conducting fibers from collection wall 1932 toward collection conduit 1934.
  • Collection conduit 1934 may be coupled to a collection chamber that is used to collect fibers.
  • Fiber producing device 1000 includes a body 1010 having two or more levels.
  • a fiber producing device 1000 includes three levels having one or more openings (1011, 1013, and 1015, respectively) through which material disposed in the chambers may be ejected.
  • An interior cavity 1012 of body 1010 may have a curved interior surface, curving from the bottom of the cavity toward openings 1011 of the first level. In this manner, material disposed in cavity 1012 is directed toward openings.
  • the openings may be a horizontally and/or vertically displaced from each other in a predetermined pattern.
  • the openings may be positioned in an ordered manner to form one or more levels of openings, as depicted in FIG. 2.
  • openings 1011, 1013, and 1015 may have a size and/or shape that causes the creation of microfibers and/or nanofibers as material is ejecting through the openings.
  • outlet elements may be coupled to one or more of openings 1011, 1013, and 1015. If different materials are placed in different chambers, two or more different fibers may thus be simultaneously produced.
  • the levels may be removably coupled to each other.
  • a second level may be coupled to first level through a coupling mechanism.
  • coupling section 1032 having threading on the interior portion of the coupling section joins the first level to the second level.
  • Second level may have complementary threading on an exterior surface of a coupling section 1034.
  • second level may be threaded onto the first level.
  • third level may be coupled to second level.
  • first level may be coupled to body 1010 using a similar coupling mechanism. While three levels are depicted, it should be understood that more or less than three levels may be coupled together.
  • a seal 1040 e.g., an o-ring
  • a seal 1040 may be placed between coupling portions of the chambers to provide a seal.
  • the levels may be spaced apart from each other based on the size of the coupling portions.
  • the coupling portions may not create a sufficient spacing to provide the desired separation of the levels.
  • a spacer 1060 may be used to create additional separation between the levels. Use of spacers may help reduce the number of chambers needed to customize the fiber producing device.
  • Fiber producing device 1000 may be coupled to an upper support 1060 using coupling member 1030.
  • Coupling member 1030 may be used to couple fiber producing device 1000 to a coupling element 1042 of a driver 1040 (e.g., a chuck coupler or a universal threaded joint of the driver).
  • a coupling element 1042 of a driver 1040 e.g., a chuck coupler or a universal threaded joint of the driver.
  • coupling member may be a receiver which will accept an elongated member from a driver (e.g., the coupling member may be a chuck or a universal threaded joint).
  • Coupling element 1042 of driver may interact with coupling member 1030 of the fiber producing device to allow the coupling member to be adjustably positionable in the coupling element such that the distance between the fiber producing device and the driver is alterable.
  • a fiber producing system may be used to deposit microfibers and/or nanofibers on a substrate.
  • An embodiment of a deposition system 2000 configured for deposition of fibers on a substrate is shown in FIG. 3. Any fiber producing device, as described previously may be coupled to deposition system 2000.
  • Deposition system 2000 includes an inlet conduit 2010 and a substrate support 2020.
  • Inlet conduit 2010 may be coupled to either a fiber producing device, or a collection chamber that collects fibers from a fiber producing device.
  • fibers are conducted through inlet conduit 2010 into deposition system 2000 where the microfibers and/or nanofibers produced by the fiber producing device are deposited onto a substrate 2030.
  • a substrate 2030 may be held in a fixed position by substrate support 2020.
  • Substrate support 2020 may position substrate 2030 in a flow of microfibers and/or nanofibers created in deposition system 2000.
  • a flow of fibers may be created using a gas flow system, a vacuum, or a combination of a gas flow system and vacuum.
  • a gas flow generator 2040 may be disposed in a bottom of deposition system 2000. During use a flow of gas is created, flowing from the bottom of deposition system 2000 toward substrate 2030. The fibers that are generated and passed to deposition system 2000 are directed into the substrate by the gas flow.
  • a fiber collection system coupled to inlet conduit 2010 may produce a gas flow, as described above, that causes a stream of fibers to flow through the inlet conduit into deposition system 2000.
  • a fiber deflector 2012 may be coupled to inlet conduit 2010 to direct incoming fibers toward substrate 2030.
  • a vacuum device 2022 is coupled to deposition system 2000.
  • vacuum system 2022 is coupled to substrate support 2020.
  • a vacuum is applied to an upper chamber 2025 formed between substrate support 2020 and the top of deposition system 2000.
  • a lower chamber 2045 is defined by substrate support 2020 and the bottom of deposition system 2000.
  • Lower chamber 2045 includes inlet conduit 2010.
  • Substrate support 2020 may have one or more openings 2024 that pass through the substrate support, coupling upper chamber 2025 to lower chamber 2045.
  • Application of a vacuum to upper chamber 2025 creates a flow of gas from lower chamber 2045 thorough substrate support 2020, to upper chamber 2025. Thus fibers disposed in lower chamber are drawn toward and into substrate 2030 disposed on substrate support 2020.
  • a vacuum created in upper chamber may also provide a holding force to hold substrate 2030 against substrate support 2020.
  • both a gas flow device and a vacuum system may be used together to create a flow of fibers in deposition system 2000.
  • gas flow device 2040 may be disposed at the bottom of deposition system 2000, or may be part of the fiber producing system coupled to the deposition system.
  • Gas flow device 2040 creates a flow of fibers through inlet conduit 2010 into deposition system 2000 and toward substrate 2030.
  • Deposition system 2000 may also include a vacuum device 2022 coupled to upper chamber 2025. During use, a vacuum is applied to upper chamber 2025 creating a flow of gas from lower chamber 2045 toward the upper chamber. Gas coming in from gas flow device 2040 or from inlet conduit, helps provide a gas flow from lower chamber 2045 toward the substrate 2030.
  • the fibers directed to substrate 2030 may become at least partially embedded in the substrate.
  • deposition system 2000 may be used to deposit microfibers and/or nanofibers on a moving substrate.
  • substrate support 2020 may allow substrate 2030 to be moved through deposition system 2000, positioning the portion of the substrate that is disposed in the deposition system in a flow of microfibers and/or nanofibers.
  • a substrate 2030 may be a sheet of material having a length that is longer than the length of deposition system 2000. The sheet of material may be passed through deposition system 2000 at a rate that allows a predetermined amount of fibers to be deposited on the substrate before the substrate exits the deposition system.
  • the substrate may be coupled to a substrate conveyance system that moves the substrate through the deposition system.
  • fiber producing system 2100 includes a substrate support 2120 positioned around at least a portion of a fiber producing device 2010.
  • a substrate support 2120 may be configured for continuous feeding of a substrate 2130 past fiber producing device 2010.
  • substrate support 2020 may hold an entire substrate proximate to the fiber producing device.
  • substrate support 2020 is curved around at least a portion of fiber producing device 2010.
  • substrate support 2020 may be positioned substantially completely around fiber producing device 2010.
  • Substrate support 2020 includes a substantially rounded edge that allows continuous feed of the substrate at an angle.
  • a substrate may be fed through the fiber deposition system over substrate support 2020.
  • fiber producing device 2010 may be operated to produce microfibers and/or nanofibers that are deposited on the substrate.
  • one or more cutting elements 2050 may be positioned between fiber producing device 2010 and substrate support 2020. Cutting elements 2050 may be positioned to cut and/or break fibers, produced by the fiber producing device prior to the fibers reaching the substrate.
  • Fibers represent a class of materials that are continuous filaments or that are in discrete elongated pieces, similar to lengths of thread. Fibers are of great importance in the biology of both plants and animals, e.g., for holding tissues together. Human uses for fibers are diverse. For example, fibers may be spun into filaments, thread, string, or rope. Fibers may also be used as a component of composite materials. Fibers may also be matted into sheets to make products such as paper or felt. Fibers are often used in the manufacture of other materials.
  • Fibers as discussed herein may be created using, for example, a solution spinning method or a melt spinning method.
  • a material may be put into a fiber producing device which is spun at various speeds until fibers of appropriate dimensions are made.
  • the material may be formed, for example, by melting a solute or may be a solution formed by dissolving a mixture of a solute and a solvent. Any solution or melt familiar to those of ordinary skill in the art may be employed.
  • a material may be designed to achieve a desired viscosity, or a surfactant may be added to improve flow, or a plasticizer may be added to soften a rigid fiber.
  • solid particles may comprise, for example, a metal or a polymer, wherein polymer additives may be combined with the latter. Certain materials may be added for alloying purposes (e.g., metals) or adding value (such as antioxidant or colorant properties) to the desired fibers.
  • Non-limiting examples of reagents that may be melted, or dissolved or combined with a solvent to form a material for melt or solution spinning methods include polyolefin, polyacetal, polyamide, polyester, cellulose ether and ester, polyalkylene sulfide, polyarylene oxide, polysulfone, modified polysulfone polymers and mixtures thereof.
  • Non-limiting examples of solvents that may be used include oils, lipids and organic solvents such as DMSO, toluene and alcohols. Water, such as de-ionized water, may also be used as a solvent. For safety purposes, non-flammable solvents are preferred.
  • Non-limiting examples of fibers made using the melt spinning method include polypropylene, acrylonitrile butadiene styrene (ABS) and nylon.
  • Non-limiting examples of fibers made using the solution spinning method include polyethylene oxide (PEO) and beta-lactams.
  • the creation of fibers may be done in batch modes or in continuous modes. In the latter case, material can fed continuously into the fiber producing device and the process can be continued over days (e.g., 1-7 days) and even weeks (e.g., 1-4 weeks).
  • the methods discussed herein may be used to create, for example, nanocomposites and functionally graded materials that can be used for fields as diverse as, for example, drug delivery and ultrafiltration (such as electrets).
  • Metallic and ceramic nanofibers for example, may be manufactured by controlling various parameters, such as material selection and temperature.
  • the methods and apparatuses discussed herein may find application in any industry that utilizes micro- to nano-sized fibers and/or micro- to nano-sized composites.
  • industries include, but are not limited to, material engineering, mechanical engineering, military/defense industries, biotechnology, medical devices, tissue engineering industries, food engineering, drug delivery, electrical industries, or in ultrafiltration and/or micro-electric mechanical systems (MEMS).
  • MEMS micro-electric mechanical systems
  • Some embodiments of a fiber producing device may be used for melt and/or solution processes. Some embodiments of a fiber producing device may be used for making organic and/or inorganic fibers. With appropriate manipulation of the environment and process, it is possible to form fibers of various configurations, such as continuous, discontinuous, mat, random fibers, unidirectional fibers, woven and nonwoven, as well as fiber shapes, such as circular, elliptical and rectangular (e.g., ribbon). Other shapes are also possible.
  • the produced fibers may be single lumen or multi-lumen.
  • fibers can be made in micron, sub-micron and nano-sizes, and combinations thereof.
  • the fibers created will have a relatively narrow distribution of fiber diameters. Some variation in diameter and cross-sectional configuration may occur along the length of individual fibers and between fibers.
  • a fiber producing device helps control various properties of the fibers, such as the cross-sectional shape and diameter size of the fibers. More particularly, the speed and temperature of a fiber producing device, as well as the cross-sectional shape, diameter size and angle of the outlets in a fiber producing device, all may help control the cross-sectional shape and diameter size of the fibers. Lengths of fibers produced may also be influenced by the choice of fiber producing device used.
  • the temperature of the fiber producing device may influence fiber properties, in certain embodiments. Both resistance and inductance heaters may be used as heat sources to heat a fiber producing device.
  • the fiber producing device is thermally coupled to a heat source that may be used to adjust the temperature of the fiber producing device before spinning, during spinning, or both before spinning and during spinning.
  • the fiber producing device is cooled.
  • a fiber producing device may be thermally coupled to a cooling source that can be used to adjust the temperature of the fiber producing device before spinning, during spinning, or before and during spinning. Temperatures of a fiber producing device may range widely. For example, a fiber producing device may be cooled to as low as -20 C or heated to as high as 2500 C.
  • the temperature of a fiber producing device before and/or during spinning is between about 4°C and about 400°C.
  • the temperature of a fiber producing device may be measured by using, for example, an infrared thermometer or a thermocouple.
  • the speed at which a fiber producing device is spun may also influence fiber properties.
  • the speed of the fiber producing device may be fixed while the fiber producing device is spinning, or may be adjusted while the fiber producing device is spinning.
  • Those fiber producing devices whose speed may be adjusted may, in certain embodiments, be characterized as variable speed fiber producing devices.
  • the fiber producing device may be spun at a speed of about 500 RPM to about 25,000 RPM, or any range derivable therein.
  • the fiber producing device is spun at a speed of no more than about 50,000 RPM, about 45,000 RPM, about 40,000 RPM, about 35,000 RPM, about 30,000 RPM, about 25,000 RPM, about 20,000 RPM, about 15,000 RPM, about 10,000 RPM, about 5,000 RPM, or about 1,000 RPM. In certain embodiments, the fiber producing device is rotated at a rate of about 5,000 RPM to about 25,000 RPM.
  • a method of creating fibers includes: heating a material; placing the material in a heated fiber producing device; and, after placing the heated material in the heated fiber producing device, rotating the fiber producing device to eject material to create nanofibers from the material.
  • the fibers may be microfibers and/or nanofibers.
  • a heated fiber producing device is a structure that has a temperature that is greater than ambient temperature. "Heating a material” is defined as raising the temperature of that material to a temperature above ambient temperature.
  • Melting a material is defined herein as raising the temperature of the material to a temperature greater than the melting point of the material, or, for polymeric materials, raising the temperature above the glass transition temperature for the polymeric material.
  • the fiber producing device is not heated. Indeed, for any embodiment that employs a fiber producing device that may be heated, the fiber producing device may be used without heating. In some embodiments, the fiber producing device is heated but the material is not heated. The material becomes heated once placed in contact with the heated fiber producing device. In some embodiments, the material is heated and the fiber producing device is not heated. The fiber producing device becomes heated once it comes into contact with the heated material.
  • a wide range of volumes/amounts of material may be used to produce fibers.
  • a wide range of rotation times may also be employed.
  • at least 5 milliliters (mL) of material are positioned in a fiber producing device, and the fiber producing device is rotated for at least about 10 seconds.
  • the rotation may be at a rate of about 500 RPM to about 25,000 RPM, for example.
  • the amount of material may range from mL to liters (L), or any range derivable therein. For example, in certain
  • At least about 50 mL to about 100 mL of the material are positioned in the fiber producing device, and the fiber producing device is rotated at a rate of about 500 RPM to about 25,000 RPM for about 300 seconds to about 2,000 seconds.
  • at least about 5 mL to about 100 mL of the material are positioned in the fiber producing device, and the fiber producing device is rotated at a rate of 500 RPM to about 25,000 RPM for 10-500 seconds.
  • at least 100 mL to about 1,000 mL of material is positioned in the fiber producing device, and the fiber producing device is rotated at a rate of 500 RPM to about 25,000 RPM for about 100 seconds to about 5,000 seconds.
  • Other combinations of amounts of material, RPMs and seconds are contemplated as well.
  • Typical dimensions for fiber producing devices are in the range of several inches in diameter and in height.
  • a fiber producing device has a diameter of between about 1 inch to about 60 inches, from about 2 inches to about 30 inches, or from about 5 inches to about 25 inches.
  • the height of the fiber producing device may range from about 1 inch to about 10 inches, from about 2 inches to about 8 inches, or froom about 3 inches to about 5 inches.
  • fiber producing device includes at least one opening and the material is extruded through the opening to create the nanofibers.
  • the fiber producing device includes multiple openings and the material is extruded through the multiple openings to create the nanofibers.
  • These openings may be of a variety of shapes (e.g., circular, elliptical, rectangular, square) and of a variety of diameter sizes (e.g., 0.01-0.80 mm). When multiple openings are employed, not every opening need be identical to another opening, but in certain embodiments, every opening is of the same configuration.
  • Some opens may include a divider that divides the material, as the material passes through the openings. The divided material may form multi-lumen fibers.
  • coaxial fibers may be produced using an outlet element having a two or more coaxial conduits.
  • FIG. 5 depicts an outlet element 3200 having an outer conduit 3210 and an inner conduit 3220.
  • the inner conduit 3220 is sized and positioned inside of the outer conduit 3210 such that the material may flow through the inner conduit and the outer conduit during use.
  • the outlet element 3200 depicted in FIG. 5 may be part of a needle or nozzle (e.g., a nozzle tip).
  • the use of an outlet element 3200 having coaxial conduits allows the formation of coaxial fibers.
  • Different materials may be passed through each of conduits 3210/3220 to produce fibers of mixed materials in which an inner fiber (produced from the inner conduit) is at least partially surrounded by an outer fiber (produced from the outer conduit).
  • the formation of coaxial fibers may allow fibers to be formed having different properties that are selectable based on the materials used to form the fibers. Alternatively, the same material passes through each of conduits 3210/3220 forming a co
  • material may be positioned in a reservoir of a fiber producing device.
  • the reservoir may, for example, be defined by a concave cavity of the heated structure.
  • the heated structure includes one or more openings in communication with the concave cavity. The fibers are extruded through the opening while the fiber producing device is rotated about a spin axis. The one or more openings have an opening axis that is not parallel with the spin axis.
  • the fiber producing device may include a body that includes the concave cavity and a lid positioned above the body.
  • Fiber producing device variable includes the material(s) used to make the fiber producing device.
  • Fiber producing devices may be made of a variety of materials, including metals (e.g., brass, aluminum, stainless steel) and/or polymers. The choice of material depends on, for example, the temperature the material is to be heated to, or whether sterile conditions are desired.
  • any method described herein may further comprise collecting at least some of the microfibers and/or nanofibers that are created.
  • collecting of fibers refers to fibers coming to rest against a fiber collection device. After the fibers are collected, the fibers may be removed from a fiber collection device by a human or robot. A variety of methods and fiber (e.g., nanofiber) collection devices may be used to collect fibers.
  • the fibers that are collected in certain embodiments, at least some of the fibers that are collected are continuous, discontinuous, mat, woven, nonwoven or a mixture of these configurations.
  • the fibers are not bundled into a cone shape after their creation.
  • the fibers are not bundled into a cone shape during their creation.
  • fibers are not shaped into a particular configuration, such as a cone figuration, using gas, such as ambient air, that is blown onto the fibers as they are created and/or after they are created.
  • Present method may further comprise, for example, introducing a gas through an inlet in a housing, where the housing surrounds at least the heated structure.
  • the gas may be, for example, nitrogen, helium, argon, or oxygen.
  • a mixture of gases may be employed, in certain
  • the environment in which the fibers are created may comprise a variety of conditions.
  • any fiber discussed herein may be created in a sterile environment.
  • the term "sterile environment” refers to an environment where greater than 99% of living germs and/or microorganisms have been removed.
  • "sterile environment” refers to an environment substantially free of living germs and/or microorganisms.
  • the fiber may be created, for example, in a vacuum.
  • the pressure inside a fiber producing system may be less than ambient pressure. In some embodiments, the pressure inside a fiber producing system may range from about 1 millimeters (mm) of mercury (Hg) to about 700 mm Hg.
  • the pressure inside a fiber producing system may be at or about ambient pressure. In other embodiments, the pressure inside a fiber producing system may be greater than ambient pressure.
  • the pressure inside a fiber producing system may range from about 800 mm Hg to about 4 atmospheres (atm) of pressure, or any range derivable therein.
  • the fiber is created in an environment of 0-100% humidity, or any range derivable therein.
  • the temperature of the environment in which the fiber is created may vary widely. In certain embodiments, the temperature of the environment in which the fiber is created can be adjusted before operation (e.g., before rotating) using a heat source and/or a cooling source. Moreover, the temperature of the environment in which the fiber is created may be adjusted during operation using a heat source and/or a cooling source.
  • the temperature of the environment may be set at sub-freezing temperatures, such as -20°C, or lower. The temperature of the environment may be as high as, for example, 2500°C.
  • the material employed may include one or more components.
  • the material may be of a single phase (e.g., solid or liquid) or a mixture of phases (e.g., solid particles in a liquid).
  • the material includes a solid and the material is heated. The material may become a liquid upon heating.
  • the material may be mixed with a solvent.
  • a solvent is a liquid that at least partially dissolves the material.
  • solvents include, but are not limited to, water and organic solvents.
  • organic solvents include, but are not limited to: hexanes, ether, ethyl acetate, acetone, dichloromethane, chloroform, toluene, xylenes, petroleum ether, dimethylsulfoxide,
  • additives include, but are not limited to: thinners, surfactants, plasticizers, or combinations thereof.
  • the material used to form the fibers may include at least one polymer.
  • Polymers that may be used include conjugated polymers, biopolymers, water soluble polymers, and particle infused polymers. Examples of polymers that may be used include, but are not limited to polypropylenes, polyethylenes, polyolefins, polystyrenes, polyesters, fluorinated polymers (fluoropolymers), polyamides, polyaramids, acrylonitrile butadiene styrene, nylons,
  • the polymer may be a synthetic (man-made) polymer or a natural polymer.
  • the material used to form the fibers may be a composite of different polymers or a composite of a medicinal agent combined with a polymeric carrier.
  • Specific polymers that may be used include, but are not limited to chitosan, nylon, nylon-6, polybutylene terephthalate (PBT), polyacrylonitrile (PAN), poly(lactic acid) (PLA), poly(lactic-co-glycolic acid) (PLGA), polyglycolic acid (PGA), polyglactin,
  • PCL polycaprolactone
  • PMMA poly(methyl methacrylate)
  • PPS polyphenylene sulfide
  • PET polyethylene terephthalate
  • PVDF polyvinylidene fluoride
  • PP polypropylene
  • PEO polyethylene oxide
  • ABS acrylonitrile butadiene
  • PVP polyvinylpyrrolidone
  • the material used to form the fibers may be a metal, ceramic, or carbon-based material.
  • Metals employed in fiber creation include, but are not limited to, bismuth, tin, zinc, silver, gold, nickel, aluminum, or combinations thereof.
  • the material used to form the fibers may be a ceramic such as alumina, titania, silica, zirconia, or combinations thereof.
  • the material used to form the fibers may be a composite of different metals (e.g., an alloy such as nitonol), a metal/ceramic composite or a ceramic oxides (e.g., PVP with germanium/palladium/platinum).
  • the fibers that are created may be, for example, one micron or longer in length.
  • created fibers may be of lengths that range from about 1 ⁇ to about 50 cm, from about 100 ⁇ to about 10 cm, or from about 1 mm to about 1 cm.
  • the fibers may have a narrow length distribution.
  • the length of the fibers may be between about 1 ⁇ to about 9 ⁇ , between about 1 mm to about 9 mm, or between about 1 cm to about 9 cm.
  • fibers of up to about 10 meters, up to about 5 meters, or up to about 1 meter in length may be formed.
  • the cross-section of the fiber may be circular, elliptical or rectangular. Other shapes are also possible.
  • the fiber may be a single-lumen fiber or a multilumen fiber.
  • the method includes: spinning material to create the fiber; where, as the fiber is being created, the fiber is not subjected to an externally-applied electric field or an externally-applied gas; and the fiber does not fall into a liquid after being created.
  • Fibers discussed herein are a class of materials that exhibit an aspect ratio of at least 100 or higher.
  • microfiber refers to fibers that have a minimum diameter in the range of 10 microns to 700 nanometers, or from 5 microns to 800 nanometers, or from 1 micron to 700 nanometers.
  • nanofiber refers to fibers that have a minimum diameter in the range of 500 nanometers to 1 nanometer; or from 250 nanometers to 10 nanometers, or from 100 nanometers to 20 nanometers.
  • Fibers may include a blending of multiple materials. Fibers may also include holes (e.g., lumen or multi-lumen) or pores. Multi-lumen fibers may be achieved by, for example, designing one or more exit openings to possess concentric openings. In certain embodiments, such openings may include split openings (that is, wherein two or more openings are adjacent to each other; or, stated another way, an opening possesses one or more dividers such that two or more smaller openings are made). Such features may be utilized to attain specific physical properties, such as thermal insulation or impact absorbance (resilience).
  • Nanotubes may also be created using methods and apparatuses discussed herein.
  • Fibers may be analyzed via any means known to those of skill in the art. For example, Scanning Electron Microscopy (SEM) may be used to measure dimensions of a given fiber. For physical and material characterizations, techniques such as differential scanning calorimetry (DSC), thermal analysis (TA) and chromatography may be used.
  • SEM Scanning Electron Microscopy
  • DSC differential scanning calorimetry
  • TA thermal analysis
  • chromatography chromatography
  • a fiber of the present fibers is not a lyocell fiber.
  • Lyocell fibers are described in the literature, such as in U.S. Patent Nos. 6,221,487, 6,235,392, 6,51 1,930, 6,596,033 and 7,067,444, each of which is incorporated herein by reference.
  • microfibers and nanofibers may be produced substantially simultaneously. Any fiber producing device described herein may be modified such that one or more openings has a diameter and/or shape that produces nanofibers during use, and one or more openings have a diameter and/or shape that produces microfibers during use. Thus, a fiber producing device, when rotated will eject material to produce both microfibers and nanofibers.
  • nozzles may be coupled to one or more of the openings. Different nozzles may be coupled to different openings such that the nozzles designed to create microfibers and nozzles designed to create nanofibers are coupled to the openings.
  • needles may be coupled (either directly to the openings or via a needle port). Different needles may be coupled to different openings such that needles designed to create microfibers and needles designed to create nanofibers are coupled to the openings. Production of microfibers and nanofibers substantially simultaneously may allow a controlled distribution of the fiber size to be achieved, allowing substantial control of the properties of products ultimately produced from the microfiber/nanofiber mixture.
  • Fiber producing system 3300 includes a fiber producing device 3310.
  • Fiber producing device includes a body 3312 and a coupling member 3314.
  • body 3312 comprises a first member 3314 and a second member 3316 coupled together.
  • body 3312 may be a single unitary member.
  • First member 3314 and second member 3316 together define an internal cavity 3318.
  • One or more openings 3320 extend through the body through which material disposed in the body may pass through during use.
  • One or more outlet elements e.g., nozzles, needles, needle ports or outlet conduits
  • internal cavity of the body may include angled or rounded walls to help direct material disposed in internal cavity 3318 of body 3312 toward openings 3320.
  • Coupling member 3330 may be an elongated member extending from the body.
  • coupling member 3330 is coupled to the second member 3316 of body 3312 and extends away from the second member through internal cavity 3318.
  • Coupling member 3330 may be used to couple fiber producing device 3310 to a coupling element 3342 of a driver 3340 (e.g., a chuck coupler or a universal threaded joint of the driver).
  • driver 3340 e.g., a chuck coupler or a universal threaded joint of the driver.
  • coupling member may be a receiver which will accept an elongated member from a driver (e.g., the coupling member may be a chuck or a universal threaded joint).
  • Coupling element 3342 of driver may interact with coupling member 3330 of the fiber producing device to allow the coupling member to be adjustably positionable in the coupling element such that the distance between the fiber producing device and the driver is alterable. This may be useful for applications where the produced fibers are delivered to a substrate positioned below the fiber producing device. Assuming the substrate and driver are at a fixed distance from each other, altering the vertical distance between the fiber producing device and the driver also alters the vertical distance between an underlying substrate and the fiber producing device. Being able to alter the distance between the underlying substrate and the fiber producing device allows the fiber deposition patterns to be altered and customized for different substrates.
  • Fiber producing system 3300 may include a driver 3340 coupled to coupling member 3330.
  • Driver 3340 is positioned above fiber producing device 3330 when the fiber producing device is coupled to the driver.
  • Driver 3330 is capable of rotating fiber producing device 3310 during use.
  • Suitable drivers include commercially available variable electric motors, such as a brushless DC motor.
  • Fiber producing system 3330 may further include a material delivery system 3350.
  • Material delivery system 3350 includes a material storage container 3352, a pump 3354, and a conduit 3356 for conducting a liquid mixture to fiber producing device 3310.
  • a mixture of material in a liquid is stored in storage container 3352.
  • a mixture of material in a liquid may be formed by dissolving the material in a suitable solvent to form a solution of the material.
  • the mixture of material in a liquid is transferred to fiber producing device 3352 using pump 3354 coupled to storage container 3352.
  • Pump 3352 collects the liquid mixture and creates a flow of liquid material through conduit 3356.
  • the liquid mixture enters fiber producing device 3310 from conduit 3356 through an opening 3313 formed in the fiber producing device.
  • a fluid level sensor 3358 is optically coupled to the liquid mixture disposed in the fiber producing device.
  • Fluid sensor 3358 provides a measurement of the amount of fluid disposed in the fiber producing device. During use, the pump flow rate may be adjusted based on the amount of fluid in the fiber producing device. In one embodiment, material delivery system 3350 substantially continuously delivers material to fiber producing device 3310 while the fiber producing device is rotating.
  • Positioning of conduit 3356 outside of the fiber producing device allows continuous delivery of material while the fiber producing device is rotating.
  • Driver 3340 may be mounted to arm 3360.
  • arm 3360 may be coupled to a support (not shown).
  • Arm 3360 may be coupled to a support such that the arm is movable with respect to the support.
  • arm 3360 may allow driver 3340 and the coupled fiber producing device 3310 (referred to as the "driver/fiber producing device assembly") to be moved (e.g., swung) away from the substrate to allow maintenance to be performed on the fiber producing device (e.g., changing the fiber producing device, purging the fiber producing device, etc.
  • Arm 3360 may also allow the horizontal position of the driver/fiber producing device assembly to be altered.
  • arm 3360 allows the driver/fiber producing device assembly to be moved along a horizontal fixed path. This allows the placement of the driver/fiber producing device assembly to be altered with respect to an underlying substrate.
  • a motor may be coupled to the driver/fiber producing device assembly to allow automated movement of the driver/fiber producing device assembly with respect to the substrate.
  • the pattern of fibers deposited by a fiber producing device 3310 in an inverted configuration, as described with respect to FIG. 6, may not be sufficient to provide uniform coverage of the underlying substrate.
  • the driver/fiber producing device assembly may be horizontally moved with respect to the substrate to provide a more even coverage to the underlying substrate.
  • arm may allow the driver/fiber producing device assembly to be moved along a fixed horizontal path. When the substrate is positioned below the fiber producing device, fiber production may be started and the driver/fiber producing device assembly may be horizontally moved to produce a more homogenous deposition of fibers on the substrate. The horizontal movement of the driver/fiber producing device assembly may be coordinated with the movement of the underlying substrate through the fiber deposition system.
  • the arm may be configured to rotate the driver/fiber producing device assembly with respect to the substrate. Rotation of the driver/fiber producing device assembly may allow a more even distribution of the fibers in the substrate.
  • fiber producing device may be heated.
  • One or more heating devices 3370 and 3372 may be thermally coupled to fiber producing device 3310.
  • a heating device 3370 may be ring shaped heating device to allow the coupling member to extend through the heating device.
  • Heating device 3372 may be a planar substrate disposed below the fiber producing device or ring shaped.
  • heating devices 3370 and 3372 may have a diameter that is less than the diameter of fiber producing device 3310. It has been generally found that during production of fibers, the produced fibers may be drawn to the heat from the heating devices if the fibers come to close to such devices. By reducing the diameter of the heating devices to be less then the diameter of the fiber producing devices, the loss of fiber due to contact with the heating devices is minimized.
  • FIG. 7 Another embodiment of a fiber producing system is depicted in FIG. 7.
  • the fiber producing system depicted in FIG. 7 is similar to the system depicted in FIG. 6.
  • the system in FIG. 7, however, is configured for use in melt spinning procedures, while the system of FIG. 6 is configured for use in solution spinning procedures.
  • the material delivery system 3350 includes a material storage container 3380 and an extruder 3382. Solid material is stored in material storage container 3380 and transferred to extruder 3382. Extruder 3382 receives material from material storage container 3380 and melts the material producing a melt. The melt is transferred to metered melt pump 3385 that meters and pumps the molten material though the conduit 3386 to the fiber producing device.
  • Conduit 3386 is formed of a material capable of transporting the heated material from the extruder to the fiber producing device.
  • conduit 3386 is at least partially surrounded by insulation 3384 to inhibit cooling of the heated material as it is transferred to the fiber producing device.
  • Heating devices 3370 and 3372 are used to keep the fiber producing device at a sufficient temperature to maintain the material in a melted state.
  • extruder 3382 may be replaced with a material feed hopper.
  • Material feed hopper may be used to channel a solid material disposed in material storage container 3380 directly into the fiber producing device.
  • the fiber producing device may be heated to melt at least a portion of the solid material that is transferred from the material storage container into the fiber producing device. Heating devices, as described previously, may be used to heat the fiber producing device prior to or after the solid material is placed in the fiber producing device. In this manner, the use of an extruder and insulated conduits may be avoided, reducing the energy requirements of the system.
  • a top driven fiber producing system is particularly useful for depositing fibers onto a substrate.
  • An embodiment of a system for depositing fibers onto a substrate is shown in FIG. 8.
  • Substrate deposition system 3500 includes a deposition system 3600 and a substrate transfer system 3550.
  • Deposition system 3600 includes a fiber producing system 3610, as described herein.
  • Deposition system produces and directs fibers produced by a fiber producing device toward a substrate 3520 disposed below the fiber producing device during use.
  • Substrate transfer system moves a continuous sheet of substrate material through the deposition system.
  • Deposition system 3600 in one embodiment, includes a top mounted fiber producing device 3610. During use, fibers produced by fiber producing device 3610 are deposited onto substrate 3520. A schematic diagram of deposition system 3600 is depicted in FIG. 9.
  • Fiber deposition system may include one or more of: a vacuum system 3620, an electrostatic plate 3630, and a gas flow system 3640.
  • a vacuum system produces a region of reduced pressure under substrate 3520 such that fibers produced by fiber producing device 3610 are drawn toward the substrate due to the reduced pressure.
  • oneor more fans may be positioned under the substratre to create an air flow through the substrate.
  • Gas flow system 3640 produces a gas flow 3642 that directs fibers formed by the fiber producing device toward the substrate.
  • Gas flow system may be a pressurized air source or one or more fans that produce a flow of air (or other gase).
  • the combination of vacuum and air flow systems are used to produce a "balanced air flow" from the top of the deposition chamber through the substrate to the exhaust system by using forced air (fans, pressurized air) and exhaust air (fans, to create an outward flow) and balancing and directing the airflow to produce a fiber deposition field down to the substrate.
  • Deposition system 3600 includes substrate inlet 3614 and substrate outlet 3612.
  • An electrostatic plate 3630 is also positioned below substrate 3520.
  • the electrostatic plate is a plate capable of being charged to a predetermined polarity.
  • fibers produced by the fiber producing device have a net charge.
  • the net charge of the fibers may be positive or negative, depending on the type of material used.
  • an electrostatic plate may be disposed below substrate 3520 and be charged to an opposite polarity as the produced fibers. In this manner, the fibers are attracted to the electrostatic plate due to the electrostatic attraction between the opposite charges. The fibers become embedded in the substrate as the fibers move toward the electrostatic plate.
  • a pressurized gas producing and distribution system may be used to control the flow of fibers toward a substrate disposed below the fiber producing device.
  • fibers produced by the fiber producing device are dispersed within the deposition system. Since the fibers are composed primarily of micro fibers and/or nanofibers, the fibers tend to disperse within the deposition system.
  • the use of a pressurized gas producing and distribution system may help guide the fibers toward the substrate.
  • a pressurized gas producing and distribution system includes a downward gas flow device 3640 and a lateral gas flow device 3645. Downward gas flow device 3640 is positioned above or even with the fiber producing device to facilitate even fiber movement toward the substrate.
  • One or more lateral gas flow devices 3645 are oriented perpendicular to or below the fiber producing device.
  • lateral gas flow devices 3645 have an outlet width equal to the substrate width to facilitate even fiber deposition onto substrate.
  • the angle of the outlet of one or more lateral gas flow devices 3645 may be varied to allow better control of the fiber deposition onto the substrate.
  • Each lateral gas flow devices 3645 may be independently operated.
  • fiber producing device 3610 may produce various gasses due to evaporation of solvents (during solution spinning) and material gasification (during melt spinning). Such gasses, if accumulated in the deposition system may begin to effect the quality of the fiber produced.
  • the deposition system includes an outlet fan 3650 to remove gasses produced during fiber production from the deposition system.
  • Substrate transfer system 3550 in one embodiment, is capable of moving a continuous sheet of substrate material through the deposition system.
  • substrate transfer system 3550 includes a substrate reel 3552 and a take up reel system 3554. During use, a roll of substrate material is placed on substrate reel 3552 and threaded through deposition system 3600 to the substrate take up reel system 3554. During use, substrate take up reel system 3554 rotates, pulling substrate through deposition system at a predetermined rate. In this manner, a continuous roll of a substrate material may be pulled through fiber deposition system.
  • a substrate deposition system may include two or more fiber producing devices, as depicted in FIG. 10.
  • a fiber deposition system 3700 may include two or more fiber producing devices 3710 coupled to a driver unit 3720.
  • Driver unit is coupled to fiber producing devices 3710.
  • driver unit 3720 includes a plurality of drivers, each driver being coupled to a fiber producing device 3710.
  • the drive unit includes a controller capable of individually operating each of the drive units such that two or more of the fiber producing devices substantially simultaneously produce fibers.
  • driver unit includes a single driver that simultaneously operates all of the fiber producing devices coupled to the driver unit. In such an embodiment, all of the fiber producing devices substantially simultaneously produce fibers to ensure complete coverage of the underlying substrate 3730.
  • Micro fibers and nano fibers produced using any of the devices and methods described herein may be used in a variety of applications.
  • Some general fields of use include, but are not limited to: food, materials, electrical, defense, tissue engineering, biotechnology, medical devices, energy, alternative energy (e.g., solar, wind, nuclear, and hydroelectric energy);
  • therapeutic medicine drug delivery (e.g., drug solubility improvement, drug encapsulation, etc.); textiles/fabrics, nonwoven materials, filtration (e.g., air, water, fuel, semiconductor, biomedical, etc); automotive; sports; aeronautics; space; energy transmission; papers; substrates; hygiene; cosmetics; construction; apparel, packaging, geotextiles, thermal and acoustic insulation.
  • micro fibers and/or nanofibers include but are not limited to: filters using charged nanofiber and/or microfiber polymers to clean fluids;
  • NF ceramic nanofibers
  • CNT carbon nanotube
  • polyester infused into cotton for denim and other textiles
  • metallic nanoparticles or other antimicrobial materials infused onto/coated on NF for filters
  • wound dressings, cell growth substrates or scaffolds battery separators; charged polymers or other materials for solar energy
  • NF for use in environmental clean-up; piezoelectric fibers; sutures; chemical sensors; textiles/fabrics that are water & stain resistant, odor resistant, insulating, self-cleaning, penetration resistant, anti-microbial, porous/breathing, tear resistant, and wear resistant; force energy absorbing for personal body protection armor; construction reinforcement materials (e.g., concrete and plastics); carbon fibers; fibers used to toughen outer skins for aerospace applications; tissue engineering substrates utilizing aligned or random fibers; tissue engineering Petri dishes with aligned or
  • nanofibers (aspect ratio of more than 1,000 to 1); paints/stains; building products that enhance durability, fire resistance, color retention, porosity, flexibility, anti microbial, bug resistant, air tightness; adhesives; tapes; epoxies; glues; adsorptive materials; diaper media; mattress covers; acoustic materials; and liquid, gas, chemical, or air filters.
  • Fibers may be coated after formation.
  • microfibers and/or nanofibers may be coated with a polymeric or metal coating.
  • Polymeric coatings may be formed by spray coating the produced fibers, or any other method known for forming polymeric coatings.
  • Metal coatings may be formed using a metal deposition process (e.g., CVD).

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

Abstract

La présente invention porte sur des appareils et sur des procédés de création de fibres, telles que des microfibres et des nanofibres. Les procédés décrits présentement emploient des forces centrifuges pour transformer un matériau en fibres. Des appareils qui peuvent être utilisés pour créer des fibres sont également décrits.
PCT/US2012/024154 2011-02-07 2012-02-07 Appareils et procédés de dépôt de microfibres et de nanofibres sur un substrat Ceased WO2012109251A2 (fr)

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