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.