Double‐nozzle air‐jet electrospinning for nanofiber fabrication

A novel double‐nozzle air‐jet electrospinning apparatus was developed to fabricate nanofibers on a large scale. The distribution of the electric field at different nozzle distances was simulated to analyze the jet path, productivity, and deposition area of nanofiber webs and the nanofiber morphology. Our experiments showed that the bubbles usually ruptured intermittently on the top surface of the two nozzles and the jets traveled in a straight path with a high initial velocity. A continuous and even thickness of the nanofiber webs were obtained when the nozzle distances was less than 55 mm. At nozzle distances of 55 mm, the received fibers were thin with the lowest standard deviation. Experimental parameters involving the applied voltage, collecting distance, and air flow rate were also investigated to analyze the nanofiber morphology at a nozzle distance of 55 mm. The results show that the nanofibers presented a finer and thinner diameter at an applied voltage of 36 kV, a collecting distance of 18 cm, and an air flow rate of 800 mL/min. The nanofiber production of this setup increased to nearly 70 times that with a single‐needle electrospinning setup. On the basis of the principle of this air‐jet electrospinning setup, various arrangements of multinozzle electrospinning setups could be designed for higher throughput of nanofibers. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2014 , 131, 40040.     

Effects of reversed arrangement of electrodes on electrospun nanofibers

The process of electrospinning can be affected by various parameters, leading to as‐prepared nanofibers with different morphology and properties. In order to explore the impact of DC(+) high‐voltage position on the resultant nanofibers, two setups with DC(+) high‐voltage individually tethered to the needle (S‐1) and the collecting plate (S‐2) were fabricated. Nanofibers produced by both setups under the same conditions were examined to distinguish their differences in morphology and electrostatic properties. It was found that the nanofibers with positive surface potential produced by the S‐1 setup have a larger surface coverage and porosity, smaller average diameter, and wider distribution of diameters. Furthermore, the differences between both setups in the trajectory of flying jets and the distribution of electric field intensity were studied. The results showed that the volume charge density (VCD) of the flying jets plays a crucial role in determining the morphology and electrostatic properties of the resultant nanofibers. The relationship between the position of DC(+) high‐voltage and the VCD of flying jets was then discussed, which could develop a better understanding of the process of electrospinning and deliver more accurate control over the production of various functional nanofibers. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 44687.     

Fabrication of nanofibers by a modified air-jet electrospinning method

A modified air-jet electrospinning (MAE) setup was demonstrated for contributing to the large-scale nanofibers production. With this single nozzle air-jet electrospinning device, the productivity of nanofibers can be increased more than forty times as compared with using the single-needle electrospinning (SNE) setup. When compared with other needle-less electrospinning setups, the benefits of this setup include ability to keep stable concentration of electrospun solution and to produce more uniform and thinner fibers, controlling of the jets formed speed and position, higher throughput, lower critical voltage, easier assembling, simpler operation, and so on. Four different parts of the fiber generator were, respectively, charged as electrospun electrodes to produce fibers. The distributions of the electric field with different electrodes were simulated and investigated for explaining the experimental results including the fibers productivity, the deposition area of nanofiber mats, as well as the surface morphology of the fibers. When the whole nozzle was charged, as compared with charging other electrodes, the MAE system produced thinner fibers with larger standard deviation on a much larger scale. By reduction of charged area, the received fibers presented lower productivity and thicker diameter with lower standard deviation. Especially, when a half of the nozzle was charged, the deposition area of nanofiber mats was larger than charging other electrodes. Besides, when a half of the nozzle was charged, the influences of electrospinning parameters such as applied voltage, collecting distance and the flow rate of air on nanofibers morphology were also investigated. Furthermore, based on this spinning unit, multi-nozzle air-jet electrospinning setup can be designed for larger production of nanofibers.     

Control of the electric field–polymer solution interaction by utilizing ultra-conductive fluids

Dramatically raising the conductivity of a polymer solution by using a salt additive allows control over the electric field-induced jet feed rate when electrospinning from an unconfined fluid without altering the applied voltage. As the solution conductivity increases, the flow rate drops by an order of magnitude. At a high voltage level and fluid conductivity value, the jets undergo a whipping instability over almost the entire path from the source to the collector experiencing only a negligibly short linear region which, along with the flow rate data, indicates that the jet narrows due to the high conductivity. Under these conditions, even while possessing relatively large individual jet feed rates, thin diameter nanofibers (200–300 nm) are readily produced. In contrast with other approaches to obtain narrow fibers from unconfined fluids (e.g., voltage reduction to control feed rate), here the fiber forming jets are present indefinitely. Continuous, scaled up nanofiber production rate of >125× over the traditional single needle electrospinning method is observed from the presence of multiple jets, each possessing a relatively high solution feed rate. These fundamental experiments reveal new pathways for exploring novel electrospinning configurations where the jet feed rate can be controlled by manipulating the solution conductivity.     

Stretching-induced orientation of polyacrylonitrile nanofibers by an electrically rotating viscoelastic jet for improving the mechanical properties

An additional centrifugal field applied to an electrostatic field in a novel electrospinning technique was proposed in this study. An additional centrifugal field can not only remove bending instability of electrically charged liquid jets during the electrospinning process but can also fabricate aligned and molecularly oriented nanofibers. The results indicated that combining a strong stretching force from an additional centrifugal field and an electrostatic field can be used to align polymer chains parallel to the nanofiber axis, producing polyacrylonitrile (PAN) nanofibers with superior molecular orientation and mechanical properties. The optimal stretching force of an electrically rotating viscoelastic jet was obtained from high-speed videography and dimensionless groups (Re, We, and Oh numbers) analysis. The dichroic ratio (D) was 0.78, and the chain orientation factor (f), measured via Polarized FT-IR was 0.21. These measurements indicated an increase in the molecular orientation for the fabricated PAN nanofibers via the optimal stretching force. The elastic modulus of PAN nanofibers with f = 0.21 was 6.29 GPa and 4.55 GPa when measured by atomic force microscopy (AFM) and nanoindenter experiments, respectively. These results demonstrated that superior mechanical properties of PAN nanofibers could be improved by conducting the proposed electrospinning technique. Furthermore, carbon nanofibers produced from the optimal PAN nanofibers through the proposed method could potentially be applied for the reinforcement of composites.     

Splashing needleless electrospinning of nanofibers

This article proposes a new needleless electrospinning apparatus applying the method of splashing polymer solution onto the surface of a metal roller spinneret. When a high voltage is applied, many spinning jets form on the free surface of polymer solutions. Multiple electrified jets undergo strong stretching and bending instability, solvent evaporates, and solidified nanofibers deposit on the collector, as in an ordinary single‐needle electrospinning process. The production of nanofibers is enhanced by 24–45 times comparing with a single‐needle system. And the productivity is easy to scale up. The effects of processing parameters, including solution concentration, applied voltage, distance between spinneret to collector, and rotational speed of the roller spinneret on the morphology of nanofibers are investigated in this article. POLYM. ENG. SCI., 2010. © 2010 Society of Plastics Engineers     

静电纺丝/静电喷雾技术在电池领域的应用进展

在制备纳米材料的各种方法中,静电纺丝和静电喷雾技术在过去数十年中开辟了低成本、简便、高效和可连续的纳米纤维制造技术路线,引起了科研工作者的广泛关注。本文介绍了静电纺丝和静电喷雾技术的基本原理、影响参数及种类（溶液静电纺丝、熔融静电纺丝、气流静电纺丝、乳液静电纺丝、同轴静电纺丝、多喷嘴静电纺丝和无针静电纺丝）,并阐明了不同静电纺丝技术种类的原理及特点。文章进一步着重介绍了静电纺丝和静电喷雾技术的优势及其在电池领域的前沿应用,特别是在锂离子电池、燃料电池、太阳能电池及超级电容器的应用,最后展望了静电纺丝和静电喷雾先进制造技术面临的挑战和发展前景。     

A Review on the Impact of Humidity during Electrospinning: From the Nanofiber Structure Engineering to the Applications

Electrospinning is the process of choice for the elaboration of nanofibrous mats. During the process, a thin and continuous charged jet of a polymer solution is traveling from an emitter subjected to a high voltage toward a grounded collector. Although the duration of the jet travel is in the order of few tens of milliseconds, the physical interactions acting between the jet and the air play a key role on the resulting fiber morphology. These interactions mainly rely on the amount of water molecules in air. This review deals with the effect of humidity during electrospinning on solvent evaporation, the solidification rate of nanofibers and finally, on the morphology at length scales ranging from the non-woven mat, the nanofiber itself down to the polymer crystal. Original electrospinning processes operating under specific environmental conditions as well as specificities encountered in needleless and free-surface electrospinning dedicated to industrial-scale mass production are also discussed. Then, it is shown how the control of humidity during electrospinning and the understanding of its influence on the fibrous structure can be exploited to target various applications dedicated to energy, environment, and health. Finally, current challenges and ideas for future research and new developments are presented.     

Theory and kinematic measurements of the mechanics of stable electrospun polymer jets

We present a simplified approach to understanding the mechanics of stable electrospinning jets based on electrohydrodynamic theory that explicitly incorporates the extensional rheology of polymeric fluids. Flow regimes of electrospun jets are identified by analogy to uniaxial extension of a fluid jet. These flow regimes predict the limiting kinematics of electrospinning jets and identify dimensionless parameters important to the control and operation of electrospinning processes. In situ kinematic measurements validate model assumptions and scaling predictions, and allow the reduction of entire jet radius and velocity profiles to several key parameters. The model predictions are shown to hold both above and below the entanglement concentration, as well as for solutions with added electrolyte and increased conductivity. The analysis also enables direct measurement of the apparent extensional viscosity of solutions at the high extension rates experienced during electrospinning. Finally, dimensional analysis of the model yields a correlation for electrospun fiber diameter in terms of measurable fluid properties, controlled process parameters, and measured jet variables, demonstrating the influence of mechanics in the straight portion of the jet on ultimate fiber morphology.     

The use of Weber number to predict morphology in the electrospinning of poly(ethylene oxide) nanofibers

In the electrospinning of polymer nanofibers, an electrically driven jet of polymer solution travels to a grounded target to be collected. The morphology of the resulting nanofibers can be manipulated through process parameters, though little work has been done to correlate electrospinning parameters with those of the free‐jet flow of pure liquids. This is essential when the nanofibers hold entrained beaded structures indicative of jet breakup. The effects of applied voltage and solution concentration on the fiber morphology of electrospun aqueous solutions of poly(ethylene oxide) were investigated. Solution concentrations of 4–8 wt % were used along with voltages of 4.5–11 kV to produce nanofibers with and without entrained beads. It was determined that the calculated Weber number for each condition correlated well with the resulting morphology. These results may suggest that Weber number may also be used to predict nanofibers morphology in the electrospinning of other polymer systems. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Polymeric nanofibers via flat spinneret electrospinning

Electrospun nanofibers are most often produced by needle electrospinning process, which has inherent disadvantages like clogging and low efficiency. In this study, an alternative needleless electrospinning process is reported for the fabrication of nanofibers based on a novel spinneret. Firstly, a spinneret with a 0.5‐mm diameter hole in the middle of a flat plastic cap was custom‐made that may be readily scaled up for mass production. Then, polyethylene oxide (PEO) aqueous solution with 6.0 wt% concentration was used to demonstrate the needleless electrospinning process. The processing window for the jet formation in the flat spinneret electrospinning process was determined. The relationships between various processing parameters (applied voltage, working distance, and flow rate) and the resultant PEO nanofibers were also investigated. It was found that stable fluid jet launched from the tip of the coned droplet anchored at the rim of the hole and formed fibers. The morphology and diameter of electrospun fibers were examined using scanning electron microscopy. The results show that PEO nanofibers produced by this needleless electrospinning have similar structure and morphology to those from the single needle source. Finally, the hole number of spinneret was increased to four holes, which was still able to produce smooth nanofibers with a higher production rate. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

Influence of electric field interference on double nozzles electrospinning

The low production rate of electrospinning process may limit the industrial use of single needle system. To meet high yield requirement and uniform fibers, a bottom‐up multiple jets electrospinning nozzle was designed, each nozzle can emit 6–18 jets. The influence of electric field interference on jet path, membrane shape, and fiber morphology were investigated. Experiment finds that electrical field strength in the closer part of two nozzles is weakened because of electric field interference when the distance between two nozzles is 30 mm, making the jet hard to emit in this section, and closer part of electrospun fiber webs has fewer fibers. The spinning in far side part of two nozzles is similar to that of single nozzle. While in middle part of one nozzle, the jet path is short, elongation of jets smaller, the formed fibers thicker, solvent evaporation less sufficient. When the distance of two nozzles is increased to 50 mm, influence of electric field interference is weaker, the electrospun fiber web and average diameter of fibers are almost the same as that of single nozzle electrospinning. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

High-efficiency preparation of polypropylene nanofiber by melt differential centrifugal electrospinning

Melt differential centrifugal electrospinning (MDCE) method is proposed by integrating the advantages of centrifugal spinning and melt differential electrospinning, including high efficiency, solvent-free, multiple jets formation from nozzle-less spinning system, and small diameter. A mathematical model of jet diameter in MDCE is established. An orthogonal experiment is carried out to explore the effects of main processing parameters on the average diameter and the diameter standard deviation of the prepared fibers. Ultimately, polypropylene (PP) nanofibers with an average diameter of 790 nm are successfully prepared in a higher flow rate of 124.26 g h⁻¹ than that of other methods. The X-ray diffraction and differential scanning calorimeter indicate that the introduction of high-voltage electrostatic field in centrifugal spinning contribute to the crystal orientation of the PP molecular chain. Therefore, tensile mechanical strength is enhanced as the increase of the loading voltage. MDCE may provide an efficient and eco-friendly method for nanofiber manufacturing in the future. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48299.     

Multiple jets in electrospinning: experiment and modeling

The electric forces are the main factor responsible for the characteristic jet path and stretching in electrospinning. The present work describes the results of the experimental investigation and modeling of multiple jets during the electrospinning of polymer solutions. Realistic configurations of the external electric field between the electrodes were employed, as well as the linear and non-linear, Upper-Convected Maxwell, models were used to describe the viscoelastic behavior of the polymer jets. The results demonstrate how the external electric fields and mutual electric interaction of multiple charged jets influence their path and evolution during electrospinning.     

Needleless electrospinning of nanofibers with a conical wire coil

In this article, we have demonstrated a novel needleless electrospinning of PVA nanofibers by using a conical metal wire‐coil as spinneret. Multiple polymer jets were observed to generate on the coil surface. Up to 70 kV electric voltage can be applied to this needleless electrospinning nozzle without causing “corona discharge.” Compared with conventional needle electrospinning, this needleless electrospinning system produced finer nanofibers on a much larger scale, and the fiber processing ability showed a much greater dependence on the applied voltage. Finite element calculation indicates that the electric field intensity profiles for the two systems are also quite different. This novel concept of using wire coil as the electrospinning nozzle will contribute to the further development of new large‐scale needleless electrospinning system for nanofiber production. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

Shear-aided high-throughput electrospinning: A needleless method with enhanced jet formation

In this article, we introduce a novel high productivity electrospinning setup for scaling up the classical method. We propose a new spinneret concept, which allows the shearing of the polymer solution prior to electrospinning. Most of the solutions used in electrospinning are shear-thinning, that is, as they are sheared, they show smaller resistance against the deformations caused by the electrostatic field. Therefore, enhanced Taylor-cone formation can be achieved, and it also gives a hand in controlling the nanofiber morphology easily, even during operation. In this study, we investigated the influence of shearing on the electrospinning process and the fiber morphology. When shearing was applied by rotation, the operation became more stable and the fiber morphology improved. Multiple jets were observed along the circular edges of the spinneret, also became thinner as an effect of the shearing rotation. The average diameter of the electrospun nanofibers was decreased by 18% with rotation speed applied, compared to those of the nonrotating condition (0 rpm). Besides that, we found that the electrospun nanofiber diameter distribution was significantly different for the various rotation speeds for which we found an applicable explanation with the aid of high-speed camera recordings.     

Multi‐jet nozzle electrospinning on textile substrates: observations on process and nanofibre mat deposition

Electrospinning is a simple and versatile process for producing small‐diameter fibres (nanofibres). However, in spite of the many potential applications of electrospun nanofibres, further process developments are still necessary to achieve a decisive productivity breakthrough for electrospinning plants. Increasing knowledge of multi‐jet electrospinning is crucial for developing industrial devices for large‐scale nanofibre production. This paper reports on the effect of a non‐conducting textile substrate placed between a jet‐emitting source (nine‐nozzle arrangement) and collector. Shielding the electric field changes the electrospinning conditions, nanofibre morphology, stability of jets and fibre deposition on the collecting surface. Various perturbation phenomena of the electrically driven jets were recorded and are described. The intensity of the perturbations increases as the weight of the non‐woven substrate increases resulting in defects in the nanofibrous mat (i.e. beaded nanofibres), production of tick fibres or failure to produce fibrous materials (e.g. films, droplets). The paper also reports an objective image‐processing procedure to enhance the evaluation of the collector after nanofibre deposition. Copyright © 2010 Society of Chemical Industry     

Preparation of poly(ether sulfone) nanofibers by gas‐jet/electrospinning

Poly(ether sulfone) (PES) nanofibers were prepared by the gas‐jet/electrospinning of its solutions in N,N‐dimethylformamide (DMF). The gas used in this gas‐jet/electrospinning process was nitrogen. The morphology of the PES nanofibers was investigated with scanning electron microscopy. The process parameters studied in this work included the concentration of the polymer solution, the applied voltage, the tip–collector distance (TCD), the inner diameter of the needle, and the gas flow rate. It was found from experimental results that the average diameter of the electrospun PES fibers depended strongly on these process parameters. A decrease in the polymer concentration in the spinning solutions resulted in the formation of nanofibers with a smaller diameter. The use of an 18 wt % polymer solution yielded PES nanofibers with an average diameter of about 80 nm. However, a morphology of mixed bead fibers was formed when the concentration of PES in DMF was below 20 wt % during gas‐jet/electrospinning. Uniform PES nanofibers with an average diameter of about 200 nm were prepared by this electrospinning with the following optimal process parameters: the concentration of PES in DMF was 25 wt %, the applied voltage was 28.8 kV, the gas flow was 10.0 L/min, the inner diameter of the needle was 0.24 mm, the TCD was 20 cm, and the flow rate was 6.0 mL/h. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2008     

Multi‐jet electrospinning with high‐throughput using a coaxial grooved nozzle and two fluids

To broaden the applications of the electrospinning technique, high throughput is one of the primary goals of many researchers. To overcome the throughput limitation, we have introduced coaxial grooved nozzles. By using a coaxial grooved nozzle and two fluids, including polyethylene oxide (PEO), we are able to achieve stable multi‐jet operation and relatively high throughput. The multi‐jets are initiated by the multi‐jet mode of the inner fluid, and share the total flow rate of the polymer solution. We have investigated the operating conditions for various flow rate combinations of two fluids. The morphology of the resulting nanofibers is uniform without bead formation. The fibers have an average diameter of about 350 nm. POLYM. ENG. SCI., 58:416–421, 2018. © 2017 Society of Plastics Engineers     

A Review on Current Nanofiber Technologies: Electrospinning,Centrifugal Spinning,and Electro-Centrifugal Spinning

Nanofiber-based products are widely used in the fields of public health, air/water filtration, energy storage, etc. The demand for nonwoven products is rapidly increasing especially after COVID-19 pandemic. Electrospinning is the most popular technology to produce nanofiber-based products from various kinds of materials in bench and commercial scales. While centrifugal spinning and electro-centrifugal spinning are considered to be the other two well-known technologies to fabricate nanofibers. However, their developments are restricted mainly due to the unnormalized spinning devices and spinning principles. High solution concentration and high production efficiency are the two main strengths of centrifugal spinning, but beaded fibers can be formed easily due to air perturbation or device vibration. Electro-centrifugal spinning is formed by introducing a high voltage electrostatic field into the centrifugal spinning system, which suppresses the formation of beaded fibers and results in producing elegant nanofibers. It is believed that electrospinning can be replaced by electro-centrifugal spinning in some specific application areas. This article gives an overview on the existing devices and the crucial processing parameters of these nanofiber technologies, also constructive suggestions are proposed to facilitate the development of centrifugal and electro-centrifugal spinning.