JP6190274B2 - Apparatus and method for depositing microfibers and nanofibers on a substrate - Google Patents

Description

  The present invention relates generally to the field of fiber manufacturing. More specifically, the present invention relates to micron and submicron sized fibers.

  Fibers with small diameters, for example, from micrometer ("micron") to nanometer ("nano") are useful in a variety of fields ranging from the garment industry to military applications. For example, in the biomedical field, there is a strong interest in developing nanofiber-based structures that provide a scaffold material for tissue growth that effectively supports living cells. In the field of fibers, there is a strong interest in nanofibers because nanofibers have a large surface area per unit mass, resulting in a light but wear-resistant garment. As one of its classes, carbon nanofibers are used, for example, in reinforced composite materials, in thermal management, and in reinforcing elastomers. As the technology for producing small diameter fibers and controlling their chemical and physical properties has improved, many potential uses for small diameter fibers have been developed.

  In fiber production, it is well known to produce very fine fibrous materials of organic fibers. For example, in Patent Document 1 and Patent Document 2, an organic material is electrostatically spun and then spun fibers Describes the production of a microfiber mat product by collecting it on a suitable surface, and US Pat. No. 6,057,049 applies a controlled pressure to the molten polymer, which is released through the opening of the charging plate. It is described. In US Pat. No. 6,057,049, a series of intervals are formed in an electric field that includes a charged metal mandrel around which a water-soluble polymer is wrapped with an aluminum foil wrapper that can be coated with a PTFE (Teflon®) release agent. It is described that it is fed by a syringe having a gap. Further, Patent Literature 2, Patent Literature 5, Patent Literature 6, Patent Literature 7, Patent Literature 8, Patent Literature 9, and Patent Literature 10 are all noted, all of which feature a polymer nanofiber production mechanism.

  Electrospinning is the main manufacturing method for making nanofibers. Examples of methods and machines used for electrospinning can be found in, for example, Patent Document 11, Patent Document 12, Patent Document 13, and Patent Document 14.

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  Described herein are devices and methods for making fibers such as microfibers and nanofibers. The method discussed herein is a method that utilizes centrifugal force to convert material into fibers. In one embodiment, the fiber manufacturing system includes a fiber manufacturing apparatus and a drive unit that can rotate the fiber manufacturing apparatus. The fiber manufacturing apparatus, in one embodiment, includes a body having one or more openings and a coupling member, the body configured to receive a material produced as a fiber, The apparatus further includes one or more nozzles coupled to the one or more openings, wherein the one or more nozzles include a nozzle orifice. The body of the fiber manufacturing apparatus is coupled to the drive unit via a coupling member. In use, rotation of the fiber manufacturing equipment coupled to the drive causes material in the body to be sent through one or more openings to one or more nozzles and ejected through one or more nozzle orifices. To produce microfibers and / or nanofibers. In some embodiments, the fiber manufacturing system can be configured to produce microfibers and nanofibers substantially simultaneously.

  The nozzle of the fiber manufacturing device can be removably coupled to the body in one embodiment. Alternatively, the nozzle of the fiber production device can be an integral part of the body. A sealing ring is placed between one or more nozzles and the body to help maintain a secure fit between the nozzles and the body. In one embodiment, the body includes a locking system that is used to couple one or more nozzles to the opening, and the locking system places the coupled nozzles in a predetermined direction relative to the body. Fix it.

  The nozzle can be removably coupled to the fiber manufacturing apparatus. Alternatively, the nozzle can be formed from a single integral material on the side wall of the body of the fiber manufacturing apparatus. Alternatively, an opening extending through the side wall is formed at the junction of a pair of joining discs having alignment rings or pins. The nozzle may include a nozzle body, the nozzle body defining an internal cavity and having a proximal end and a distal end, the proximal end comprising a coupling portion that couples the nozzle to the fiber manufacturing apparatus. Yes. The coupling portion of the nozzle may be a threaded end that meshes with a corresponding threaded portion of the fiber manufacturing device in one embodiment. A nozzle tip can be coupled to the distal end of the nozzle body, the nozzle tip having an inner diameter that is smaller than the inner diameter of the nozzle body. The nozzle body includes an opening that extends through the wall of the nozzle body, and the nozzle tip is aligned with the nozzle opening so that material disposed within the nozzle body passes through the opening and reaches the nozzle tip during use. Is done. The inner diameter of the nozzle tip is set so that microfibers and / or nanofibers are produced when material is ejected through the nozzle tip when the nozzle is coupled to the fiber manufacturing apparatus.

  In one embodiment, the nozzle tip and nozzle body are formed from a single unitary material. Alternatively, the nozzle tip can be removably coupled to the nozzle body. The nozzle can be at least about 2 mm long. The inner diameter of the nozzle tip can be smaller than about 1 mm. A portion of the inner wall of the nozzle body is substantially flat and another portion of the inner wall of the nozzle body is angled and / or rounded from the flat portion toward an opening formed in the nozzle body. It is done. In one embodiment, the nozzle tip has a nozzle outlet end that is angled and / or rounded. The nozzle can have a non-cylindrical outer surface. In one embodiment, the nozzle has an outer surface with a tapered end. During the rotation of the body, the gas contacts the tapered end of the nozzle, forming a negative pressure region on the opposite side of the tapered end.

  One or more outlet conduits are coupled to the one or more nozzles to the one or more openings. The outlet conduit can be at least about 10 mm long. The nozzle includes a nozzle orifice.

  The body of the textile manufacturing apparatus includes one or more side walls and an upper portion that together define an internal cavity, and one or more openings extend through the side walls of the body and communicate with the internal cavity. In one embodiment, the inner surface of the sidewall is angled from the bottom wall toward one or more openings. In an alternative embodiment, the inner surface of the sidewall is rounded from the bottom wall toward one or more openings. The inner surface of the side wall may have an oval shape so that the major axis of the oval inner side wall is aligned with one or more openings.

  The drive unit can be disposed below the fiber production device or above the fiber production device when the fiber production device is coupled to the drive unit. The drive can rotate the fiber manufacturing device at a speed in excess of about 1000 RPM.

  In one embodiment, the heating device is thermally coupled to the fiber manufacturing device. In one embodiment, a liquid level sensor is coupled to the fiber manufacturing apparatus, and the liquid level sensor is arranged to detect the liquid level in the fiber manufacturing apparatus.

  The fiber manufacturing apparatus can be sealed in the chamber, and the environment inside the chamber can be controlled. The fiber manufacturing system includes a collection system that surrounds at least a portion of the fiber manufacturing apparatus, and the fibers produced during use are collected at least partially on the collection system. The collection system, in one embodiment, includes one or more collection elements coupled to the collection substrate, the one or more collection elements at least partially surrounding the fiber manufacturing apparatus. Yes. In one embodiment, the collection element includes an arcuate or straight protrusion extending from the collection substrate surface.

  In another embodiment, the fiber manufacturing system includes a fiber manufacturing apparatus and a drive unit that rotates the fiber manufacturing apparatus. In one embodiment, a fiber manufacturing apparatus includes a body having one or more openings and a coupling member, the body configured to receive material produced as a fiber, the fiber manufacturing apparatus comprising: And further including one or more needle ports coupled to the one or more openings, wherein the one or more needles can be removably coupled to the needle ports during use. The body of the fiber manufacturing apparatus is coupled to the drive unit via a coupling member. In use, rotation of the fiber manufacturing device coupled to the drive causes material in the body to be ejected through one or more needles coupled to one or more needle ports, resulting in microfibers and / or Nanofibers are produced. In one embodiment, a needle coupled to one or more needle ports has an angled and / or rounded outlet.

  In another embodiment, the fiber manufacturing system includes a fiber manufacturing apparatus and a drive unit that rotates the fiber manufacturing apparatus. The fiber manufacturing apparatus, in one embodiment, includes a body with two or more chambers and a coupling member, wherein the first chamber has one or more openings and the fibers The second chamber is configured with one or more openings and configured to receive the material produced as fibers. The body of the fiber manufacturing apparatus is coupled to the drive unit via a coupling member. During use, rotation of the fiber manufacturing device coupled to the drive causes at least the material in the first chamber and the second chamber to be ejected through one or more openings, producing microfibers and / or nanofibers. Is done.

  In another embodiment, the fiber manufacturing system includes a fiber manufacturing apparatus and a drive unit that rotates the fiber manufacturing apparatus. The fiber manufacturing apparatus, in one embodiment, includes a body having one or more openings and a coupling member, the body being configured to receive material produced as fibers. The body of the fiber manufacturing apparatus is coupled to the drive unit via a coupling member. The fiber manufacturing system further includes a collection system that collects fibers produced by the fiber manufacturing apparatus during use, the collection system including one or more collection elements coupled to the collection element substrate, One or more collection elements include arcuate protrusions extending from the collection element substrate. In use, rotation of the body coupled to the drive causes material in the body to be ejected through one or more openings to produce microfibers and / or nanofibers, which are at least partially on the collection element. To be collected.

  In one embodiment, the collection system of the fiber production system includes one or more collection elements coupled to the collection element substrate, the collection elements arranged to surround at least a portion of the fiber production apparatus. The position of the collecting element relative to the fiber manufacturing apparatus can be adjusted by moving the collecting element along a portion of the collecting element substrate.

  In other embodiments, a collection system of a fiber manufacturing system includes one or more collection elements coupled to a collection element substrate and a collection container, the collection container at least partially comprising a fiber manufacturing apparatus. The enclosure and collection element is removably disposed within the collection container.

  In other embodiments, the collection system of the fiber manufacturing system is configured to collect fibers produced by the fiber manufacturing apparatus. In use, rotation of the fiber manufacturing device causes material in the body to be ejected through one or more openings, producing microfibers and / or nanofibers. The collection system creates a vacuum or activates a gas flow device, which creates a flow of generated fibers toward the collection system.

  In another embodiment, the fiber manufacturing system includes a fiber manufacturing apparatus and a drive unit that rotates the fiber manufacturing apparatus. The fiber manufacturing apparatus, in one embodiment, includes a body having one or more openings and a coupling member, the body being configured to receive material produced as fibers. The body of the fiber manufacturing apparatus is coupled to the drive unit via a coupling member. The fiber manufacturing system further includes a deposition system that collects the fibers produced by the fiber manufacturing device during use and, during use, collects the collected fibers into a substrate disposed within the deposition system. Guide you to head. In use, rotation of the body coupled to the drive causes material in the body to be ejected through one or more openings to produce microfibers and / or nanofibers that are at least partially in the deposition system. Be transported.

  Advantages of the present invention will become apparent to those skilled in the art from the following detailed description of the embodiments and with reference to the accompanying drawings.

FIG. 1 is a cross-sectional view showing a fiber manufacturing system in which a drive unit is mounted above a fiber manufacturing apparatus. FIG. 2 is a cross-sectional view showing an example of a multi-level fiber manufacturing apparatus. FIG. 3 is a schematic cross-sectional view illustrating an embodiment of a portion of a fiber manufacturing system configured to deposit fibers on a substrate. FIG. 4 is a cross-sectional view illustrating an embodiment of a fiber manufacturing system configured to continuously deposit fibers on a substrate. FIG. 5 is a perspective view showing a coaxial outlet element. FIG. 6 is a cross-sectional view showing a fiber manufacturing system of the present invention having a continuous liquid mixture supply unit. FIG. 7 is a cross-sectional view showing a fiber manufacturing system of the present invention having a continuous melt supply section. FIG. 8 is a perspective view showing a substrate deposition system. FIG. 9 is a schematic view showing a fiber deposition system. FIG. 10 is a perspective view showing a deposition system including a plurality of fiber manufacturing apparatuses.

  While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will be described in detail herein. The drawings are not necessarily drawn to scale. However, the drawings and detailed description thereof are not intended to limit the invention to the particular forms disclosed, but rather to the spirit and scope of the invention as defined by the appended claims. It should be understood that it is intended to cover all modifications, equivalents, and alternatives that come in.

  A fiber manufacturing system is shown in FIG. The fiber manufacturing system 1900 includes a fiber manufacturing apparatus 1910. The fiber manufacturing apparatus includes a body 1912 and a coupling member 1914. The body 1912 includes one or more openings 1916 through which material disposed within the body passes. One or more outlet elements 1918 (eg, nozzles, needles, needle ports or outlet conduits) are coupled to one or more openings 1916. As described above, the interior cavity of the body includes an angled or rounded wall to help guide the material disposed within the body 1912 toward the opening 1916. The coupling member 1914 is an elongate member (as shown in FIG. 1) extending from the body and couples it to a portion of the drive unit 1920 (eg, a chuck of the drive unit or a universal threaded joint). Alternatively, the coupling member can be a receptacle that will receive an elongate member from the drive (eg, the coupling member may be a chuck or a universal thread joint).

  The fiber manufacturing system includes a drive unit 1920 that is coupled to the coupling member 1914. The drive unit 1920 is disposed above the fiber manufacturing apparatus with the fiber manufacturing apparatus 1910 coupled to the drive unit. During use, the drive unit 1920 rotates the fiber manufacturing apparatus 1910. Suitable drive units include commercially available variable electric motors such as brushless DC motors.

  The fiber manufacturing system 1900 further includes a collection system 1930. The collection system includes a collection wall 1932 that at least partially surrounds the fiber manufacturing apparatus 1910. Collection system 1930 further includes a collection conduit 1934 coupled to collection wall 1932. Collection conduit 1934 is an integral part of collection wall 1932 in one embodiment. In use, the fibers produced by the fiber manufacturing device 1910 collect on the collection wall 1932 and transfer it to the collection conduit 1934. In one embodiment, the collection conduit 1934 is positioned below the fiber production device 1910 so that the produced fibers are collected on the collection wall 1932 and fall into the collection conduit. In some embodiments, a gas flow device (not shown) or a vacuum system (not shown) is used to create a gas flow that directs fibers from collection wall 1932 to collection conduit 1934. Collection conduit 1934 is coupled to a collection chamber used to collect the fibers.

  Another example of the fiber manufacturing apparatus is shown in FIG. The fiber manufacturing apparatus 1000 includes a body 1010 having two or more levels. For example, in the embodiment shown in FIG. 2, the fiber manufacturing apparatus 1000 includes three levels having one or more openings 1011, 1013, 1015 through which the material disposed in the chamber is ejected. To do. The internal cavity 1012 of the body 1010 has a curved inner surface that curves from the bottom of the cavity toward the first level opening 1011. In this way, the material placed in the cavity 1012 is guided towards the opening. In general, the diameters of the openings 1011, 1013, 1015 are set so that the material rising on the inner surface of the cavity 1012 quickly reaches all the openings. The openings are arranged in a predetermined pattern so as to be displaced from each other in the horizontal direction and / or in the vertical direction. For example, as shown in FIG. 2, the openings can be regularly arranged to form one or more levels of openings.

  In use, rotation of the fiber production equipment causes material to be ejected through one or more of each level of openings 1011, 1013, 1015 to produce fibers. In some embodiments, the apertures 1011, 1013, 1015 have a size and / or shape that results in the creation of microfibers and / or nanofibers when material is ejected through the apertures. In other embodiments, the outlet element can be coupled to one or more openings 1011, 1013, 1015. When different materials are placed in different chambers, two or more different fibers can be produced simultaneously.

  In one embodiment, the levels can be removably coupled to each other. For example, as shown in FIG. 2, the second level can be coupled to the first level by a coupling mechanism. In one embodiment, a coupling area 1032 having a threaded portion on the inner portion of the coupling area is joined from the first level to the second level. The second level has a complementary threaded portion on the outer surface of the coupling area 1034. To assemble the multi-chamber device, the second level is screwed into the first level. Similarly, the third level is coupled to the second level. Furthermore, the first level is coupled to the body 1010 using a similar coupling mechanism. Although three levels are illustrated, it should be understood that more or less than three levels can be combined with each other. A seal 1040 (eg, an o-ring) is sealed by placing it at the coupling portion of the chamber.

  In some embodiments, it may be desirable to control the spacing between chambers. For example, as shown in FIG. 2, the levels are separated from each other based on the size of the coupling portion. However, the coupling portions may not be sufficiently spaced to provide the desired level of separation. In some embodiments, the spacer 1060 can be used to form an additional level of separation. The use of spacers helps to reduce the number of chambers required to customize the fiber manufacturing equipment.

  The fiber manufacturing apparatus 1000 is coupled to the upper support portion 1060 using a coupling member 1030. Using the coupling member 1030, the fiber manufacturing apparatus 1000 is coupled to the coupling element 1042 of the driving unit 1040 (for example, a chuck coupler or a universal threaded joint of the driving unit). Alternatively, the coupling member may be a receptacle that will receive an elongate member from the drive (eg, the coupling member may be a chuck or a universal threaded joint). The coupling element 1042 of the drive part interacts with the coupling member 1030 of the fiber production device so that the coupling member can be adjusted within the coupling element so that the distance between the fiber production device and the drive part can be changed. It is formed so that it can be arranged. This is useful for applications in which the produced fiber is delivered to a substrate placed below the fiber production equipment. Assuming that the substrate and the drive are at a fixed distance from each other, changing the vertical distance between the fiber manufacturing device and the drive is the vertical between the underlying substrate and the fiber manufacturing device. The distance in the direction will also change. If the distance between the underlying substrate and the fiber manufacturing equipment can be changed, the fiber deposition pattern can be changed and customized for different substrates.

  In one embodiment, microfibers and / or nanofibers are deposited on a substrate using a fiber manufacturing system. One embodiment of a deposition system 2000 configured to deposit fibers on a substrate is shown in FIG. Any fiber manufacturing equipment as described above is coupled to the deposition system 2000. The deposition system 2000 includes an inlet conduit 2010 and a substrate support 2020. The inlet conduit 2010 is coupled to a fiber manufacturing device or a collection chamber that collects fibers from the fiber manufacturing device. In use, the fibers are routed through the inlet conduit 2010 to the deposition system 2000 where the microfibers and / or nanofibers produced by the fiber manufacturing apparatus are deposited on the substrate 2030. The base material 2030 is held at a fixed position by the base material support unit 2020. The substrate support 2020 places the substrate 2030 in a microfiber and / or nanofiber flow created in the deposition system 2000.

  In the above embodiment, the fiber flow is created by a gas flow system, a vacuum system, or a combination of a gas flow system and a vacuum system. For example, in one embodiment, the gas flow generator 2040 is located at the bottom of the deposition system 2000. Thus, a gas flow is created that flows from the bottom of the deposition system 2000 toward the substrate 2030 during use. The fibers that are generated and sent to the deposition system 2000 are guided to the substrate by a gas stream. Alternatively, a fiber collection system coupled to the inlet conduit 2010 generates a gas flow as described above, which causes a flow of fibers that flows into the deposition system 2000 through the inlet conduit. A fiber deflector 2012 can be coupled to the inlet conduit 2010 to direct incoming fibers to the substrate 2030.

  In an alternative embodiment, the vacuum device 2022 is coupled to the deposition system 2000. In this embodiment, the vacuum system 2022 is attached to the substrate support 2020. Thus, during use, the upper chamber 2025 formed between the substrate support 2020 and the top of the deposition system 2000 is evacuated. The lower chamber 2045 is provided between the substrate support 2020 and the bottom of the deposition system. The lower chamber 2045 includes the inlet conduit 2010. The substrate support 2020 has one or more openings 2024 that penetrate the substrate support and couple the upper chamber 2025 to the lower chamber 2045. By evacuating the upper chamber 2025, a gas flow from the lower chamber 2045 through the substrate support 2020 to the upper chamber 2025 is created. The fiber introduced into the lower chamber 2045 is directed toward the base material 2030 disposed in the base material support portion 2020 and drawn therein. The vacuum created in the upper chamber also provides a holding force that holds the substrate 2030 against the substrate support 2020.

  In the above embodiment, both a gas flow device and a vacuum system can be used together to create a flow of fibers in the deposition system 2000. For example, the gas flow device 2040 can be located at the bottom of the deposition system 2000 or can be part of a fiber manufacturing system that is coupled to the deposition system. The gas flow device 2040 enters the deposition system 2000 through the inlet conduit 2010 and further creates a flow of fibers toward the substrate 2030. The deposition system 2000 also provides a vacuum apparatus 2022 attached to the upper chamber 2025 to evacuate the upper chamber 2025 during use, creating a gas flow from the lower chamber 2045 toward the upper chamber. The gas coming from the gas flow device 2040 or from the inlet conduit helps to provide a gas flow from the lower chamber 2045 toward the substrate 2030. The fibers directed to the substrate 2030 will be at least partially embedded within the substrate in some embodiments.

  In the above embodiment, the deposition system 2000 can be used to deposit microfibers and / or nanofibers on a moving substrate. In this embodiment, the substrate support 2020 moves the substrate 2030 through the deposition system 2000 and places the portion of the substrate disposed within the deposition system into the microfiber and / or nanofiber flow. Can be arranged. In this embodiment, the substrate 2030 can be a sheet of material having a length that is longer than the length of the deposition system 2000. This sheet of material is passed through the 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 can be coupled to a substrate transport system that moves the substrate through the deposition system.

  An alternative embodiment of a continuous feed substrate deposition system is shown in FIG. In FIG. 4, the deposition of microfibers and / or nanofibers is performed in a fiber manufacturing system rather than in a separate deposition system. For example, instead of the collection elements described above with respect to the fiber manufacturing system, the fiber manufacturing system 2100 includes a substrate support 2120 disposed about at least a portion of the fiber manufacturing apparatus 2010. As shown in FIG. 4, the base material support 2120 is configured such that the base material 2130 is continuously supplied through the fiber manufacturing apparatus 2010. Alternatively, the base material support 2020 can hold the entire base material in the vicinity of the fiber manufacturing apparatus. In the embodiment shown in FIG. 4, the substrate support 2020 is curved around at least a part of the fiber manufacturing apparatus 2010. In some embodiments, the substrate support 2020 is disposed so as to substantially completely surround the fiber manufacturing apparatus 2010. The substrate support 2020 has a substantially rounded end that allows continuous supply of the substrate at a constant angle. In use, the substrate is fed through the fiber deposition system over the substrate support 2020. When the substrate is being fed into the fiber manufacturing system, the fiber manufacturing apparatus 2010 is activated to produce microfibers and / or nanofibers that are deposited on the substrate.

  In one embodiment, one or more cutting elements 2050 are disposed between the fiber manufacturing apparatus 2010 and the substrate support 2020 to control the length of the fibers. The cutting element 2050 is arranged to cut and / or sever the fiber produced by the fiber manufacturing device before the fiber reaches the substrate.

  Fiber refers to a continuous filament class material or a discontinuous elongated segment class material, similar to yarn length. Fiber is very important in both plant and animal biology, for example to hold tissue. The use of fiber by humans is diverse. For example, the fibers can be spun into filaments, threads, strings, or ropes. Fibers can also be used as components of composite materials. Fibers can be matted into sheets to make products such as paper or felt. Fiber is often used in the manufacture of other materials.

  The fibers discussed herein can be made using, for example, solution spinning or melt spinning. In both melt spinning and solution spinning, the material is placed in a fiber manufacturing apparatus that is rotated at various speeds until the appropriate size of fiber is made. The material can be formed, for example, by melting a solute, or can be a solution formed by dissolving a mixture of a solute and a solvent. Any solution or melt well known to those skilled in the art can be used. For solution spinning, the material can be designed to achieve the desired viscosity, or a surfactant can be added to improve flowability, or a plasticizer can be added to soften the stiff fibers. can do. In melt spinning, the solid particles can include, for example, a metal or polymer, where a polymer additive can be added to the polymer. Certain materials can be added for alloying (eg, metal) or to add value (such as antioxidant or colorant properties) to the desired fiber.

  Non-limiting examples of reagents that can be melted or dissolved in a solvent or mixed with a solvent to form a melt or solution spinning material include polyolefins, polyacetals, polyamides, polyesters, cellulose ethers and esters , Polyalkylene sulfides, polyarylene oxides, polysulfones, modified polysulfone polymers, and mixtures thereof. Non-limiting examples of solvents that can be used include oils, lipids, and organic solvents such as DMSO, toluene and alcohols. Water such as deionized water can also be used as a solvent. For safety, non-flammable solvents are preferred.

  In either the solution spinning method or the melt spinning method, the material is ejected from a rotating fiber manufacturing device, and the fine material ejection is simultaneously stretched and dried, or stretched and cooled in the surrounding environment. . The interaction between the material and the environment at high strain rates (due to stretching) results in the material solidifying into fibers, which may be accompanied by evaporation of the solvent. By manipulating the temperature and strain rate, the viscosity of the material can be controlled to manipulate the size and morphology of the fibers produced. A variety of fibers can be made using the method of the present invention, including novel fibers such as polypropylene (PP) nanofibers. Non-limiting examples of fibers made using a melt spinning process 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 lactam.

  Fabrication of the fibers can be done in batch mode or continuous mode. In the latter case, the material can be continuously fed to the fiber production equipment and the process continues for several days (eg, 1-7 days) or weeks (eg, 1-4 weeks).

  The methods discussed herein can be used in a variety of fields, such as drug delivery and ultrafiltration (such as electrolets), for example, to make nanocomposites or functionally graded materials. For example, metal and ceramic nanofibers can be produced by controlling various parameters such as material selection and temperature. At least, the methods and apparatus discussed herein may find application in any industry that utilizes micro-sized to nano-sized fibers and / or micro-sized to nano-sized composite materials. Such industries include material engineering, mechanical engineering, military / defense industry, biotechnology, medical equipment, tissue engineering industry, food engineering, drug delivery, electrical industry, or ultrafiltration and / or microelectromechanical systems (MEMS). ), But is not limited thereto.

  Some embodiments of the fiber production equipment can be used for melting and / or solution processes. Some embodiments of the fiber manufacturing apparatus can be used to make organic and / or inorganic fibers. By appropriate manipulation of the environment and process, various structures such as continuous, discontinuous, matte, random fiber, unidirectional fiber, woven or non-woven, and various fiber shapes such as round, oval And fibers such as rectangles (eg, ribbons) can be formed. Other shapes are possible. The fibers produced can be single lumen (single lumen) or multiple lumen (multilumen).

  By controlling process parameters, fibers can be made in micron, submicron and nanosize, and combinations thereof. In general, the fibers produced will have a relatively narrow fiber diameter distribution. There may be some variation in diameter and cross-sectional configuration along the length of individual fibers and between fibers.

  Generally speaking, fiber production equipment helps to control various properties of the fiber, such as the cross-sectional shape and diameter of the fiber. More specifically, the speed and temperature of the fiber production equipment, and the cross-sectional shape, diameter and angle of the outlet in the fiber production equipment are all useful in controlling the fiber cross-sectional shape and diameter. The length of fiber produced is also affected by the choice of fiber production equipment used.

  The temperature of the fiber production equipment affects the properties of the fibers in certain embodiments. As a heat source for heating the fiber manufacturing apparatus, both a resistance heater and an induction heater can be used. In certain embodiments, the fiber manufacturing device is thermally coupled to a heat source that is used to regulate the temperature of the fiber manufacturing device before spinning, during spinning, or both before and during spinning. In some embodiments, the fiber manufacturing apparatus is cooled. For example, the fiber manufacturing device can be thermally coupled to a cooling source used to adjust the temperature of the fiber manufacturing device before spinning, spinning, or before and during spinning. The temperature of the fiber manufacturing equipment can range widely. For example, the fiber production equipment can be cooled to as low as -20 ° C or heated to as high as 2500 ° C. Temperatures below or above these exemplary values are also possible. In certain embodiments, the temperature of the fiber production apparatus before and / or during spinning is between about 4 ° C. and about 400 ° C. The temperature of the fiber manufacturing apparatus is measured using, for example, an infrared thermometer or a thermocouple.

  The speed at which the fiber production equipment is rotated also affects the fiber properties. The speed of the fiber manufacturing device can be constant while the fiber manufacturing device is rotating, or can be adjusted while the fiber manufacturing device is rotating. A fiber manufacturing device whose speed can be adjusted is characterized as a variable speed fiber manufacturing device in certain embodiments. In the methods described herein, the fiber manufacturing equipment is rotated from about 500 RPM to about 25,000 RPM, or any range that can be derived therein. In certain embodiments, the fiber manufacturing apparatus is configured to have a fiber manufacturing device of 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, Rotate at a speed not exceeding 000 RPM, about 10,000 RPM, about 5,000 RPM, or about 1,000 RPM. In certain embodiments, the fiber production equipment is rotated at a speed from about 5,000 RPM to about 25,000 RPM.

  In one embodiment, a method of making fibers such as microfibers and / or nanofibers includes heating a material, placing the material in a heated fiber manufacturing device, and heating the material. After placement in the heated fiber production device, the fiber production device is rotated to eject the material and create nanofibers from the material. In some embodiments, the fibers can be microfibers and / or nanofibers. A heated fiber manufacturing device is a structure having a temperature above ambient temperature. “Heating a material” is defined as raising the temperature of the material to a temperature above ambient temperature. “Melting a material” as used herein refers to raising the temperature of the material to a temperature above the melting point of the material, or for a polymer material, raising the temperature to a temperature above the glass transition temperature of the polymer material. Defined as letting In an alternative embodiment, the fiber manufacturing apparatus is not heated. In fact, for any embodiment using a fiber manufacturing apparatus that can be heated, the fiber manufacturing apparatus can be used without heating. In some embodiments, the fiber manufacturing apparatus is heated but the material is not heated. The material will be heated once in contact with the heated fiber production equipment. In some embodiments, the material is heated and the fiber manufacturing equipment is not heated. The fiber manufacturing equipment will be heated once in contact with the heated material.

  A wide range of volume / quantity materials can be used to produce the fibers. Furthermore, a wide range of rotation times can be used. For example, in certain embodiments, at least 5 milliliters (mL) of material is placed in the fiber manufacturing apparatus and the fiber manufacturing apparatus is rotated for at least about 10 seconds. As described above, the rotation can be, for example, a rotation at a speed from about 500 RPM to about 25,000 RPM. The amount of material can range from mL to liters (L), or any range that can be derived therein. For example, in certain embodiments, at least about 50 mL to about 100 mL of material is placed in a fiber manufacturing device, and the fiber manufacturing device is about 300 seconds to about 2, at a rate of about 500 RPM to about 25,000 RPM. Rotate for up to 000 seconds. In certain embodiments, at least about 5 mL to about 100 mL of material is placed in the fiber manufacturing apparatus and the fiber manufacturing apparatus is rotated for 10 to 500 seconds at a speed of 500 RPM to about 25,000 RPM. In certain embodiments, at least about 100 mL to about 1,000 mL of material is placed in the fiber maker, and the fiber maker is at a rate of 500 RPM to about 25,000 RPM for about 100 seconds to about 5,000. Rotate for up to seconds. Other combinations of material quantity, RPM and seconds are contemplated as well.

  Typical dimensions for fiber production equipment range from a few inches in diameter and height. In some embodiments, the fiber manufacturing apparatus has a diameter from 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 manufacturing equipment can range from about 1 inch to about 10 inches, from about 2 inches to about 8 inches, or from about 3 inches to about 5 inches.

  In certain embodiments, the fiber manufacturing device has at least one opening through which material is extruded to create nanofibers. In certain embodiments, the fiber manufacturing device has a plurality of openings, and the material is extruded through the plurality of openings to create nanofibers. These openings can be of various shapes (eg, circular, oval, rectangular, square) and of various diameters (eg, 0.01-0.80 mm). If multiple openings are used, not all openings need be identical to another opening, but in certain embodiments all openings are of the same configuration. Some openings include a divider that divides the material as it passes through the opening. The divided material can form multiple lumen fibers.

  In one embodiment, an exit element having two or more coaxial conduits can be used to form a coaxial fiber. FIG. 5 shows an outlet element 3200 having an outer conduit 3210 and an inner conduit 3220. Inner conduit 3220 is sized and positioned within outer conduit 3210 such that, during use, material flows through the inner and outer conduits. The outlet element 3200 shown in FIG. 5 is a portion of a needle or nozzle (eg, a nozzle tip). The use of an outlet element 3200 having a coaxial conduit allows the formation of coaxial fibers. Different materials are passed through each of the conduits 3210/3220 to form mixed-material fibers in which the inner fibers (generated from the inner conduit) are at least partially surrounded by outer fibers (generated from the outer conduit). Coaxial fiber formation allows the formation of fibers having different properties that can be selected based on the materials used to form the fibers. Alternatively, the same material can be passed through each of the conduits 3210/3220 to form coaxial fibers formed from the same material.

  In one embodiment, the material is placed in a reservoir of a fiber manufacturing device. The reservoir can be defined, for example, by a concave cavity in the structure to be heated. In certain embodiments, the heated structure includes one or more openings in communication with the concave cavity. The fiber is pushed out of the opening while the fiber manufacturing device rotates around the spin axis. One or more apertures have an aperture axis that is non-parallel to the spin axis. The fiber manufacturing apparatus includes a body including a concave cavity and a lid disposed on the body.

  Another variable of the fiber production equipment includes the materials used to make the fiber production equipment. The fiber manufacturing equipment can be made of various materials including metals (eg, brass, aluminum, stainless steel) and / or polymers. The choice of material depends, for example, on the temperature at which the material is heated, or whether sterility is desired.

  Any of the methods described herein can further include collecting at least a portion of the created microfibers and / or nanofibers. As used herein, “collecting” a fiber refers to the fiber being supported and stationary by a fiber collection device. After the fibers are collected, the fibers are removed from the fiber collection device by a human or robot. Fibers can be collected using various methods and fiber (eg, nanofiber) collection devices.

  With respect to the collected fibers, in certain embodiments, at least a portion of the collected fibers are continuous, discontinuous, matte, woven, non-woven, or a mixture of these configurations. In some embodiments, the fibers are not bundled into a cone after production. In some embodiments, the fibers are not bundled into a cone during production. In certain embodiments, the fibers are not formed into a particular shape, such as a cone, using a gas such as ambient air that is blown onto the fibers when and / or after the fibers are created.

  The method can further include introducing gas, for example, through the inlet and into at least the enclosure surrounding the heating structure. The gas can be, for example, nitrogen, helium, argon, or oxygen. In certain embodiments, a mixture of gases can be used.

  The environment in which the fibers are made includes various conditions. For example, any of the fibers discussed herein are made in a sterile environment. As used herein, the term “sterile environment” refers to an environment in which more than 99% of live bacteria and / or microorganisms have been removed. In certain embodiments, a “sterile environment” refers to an environment that is substantially free of live bacteria and / or microorganisms. The fiber is prepared in a vacuum, for example. For example, the pressure in the fiber manufacturing system can be lower than the ambient pressure. In some embodiments, the pressure in the fiber manufacturing system ranges from about 1 millimeter (mm) mercury (Hg) to about 700 mmHg. In other embodiments, the pressure in the fiber manufacturing system is at or near ambient pressure. In other embodiments, the pressure in the fiber manufacturing system can be higher than the ambient pressure. For example, the pressure in the fiber manufacturing system can range from about 800 mmHg to about 4 atmospheres (atm), or any range that can be derived therein.

  In certain embodiments, the fibers are made in an environment of 0-100% humidity, or any range that can be derived therein. The temperature of the environment in which the fibers are created can vary widely. In certain embodiments, the temperature of the environment in which the fibers are made is adjusted prior to operation (eg, before rotation) using a heat source and / or a cooling source. Furthermore, the temperature of the environment in which the fibers are made is adjusted during operation using a heat source and / or a cooling source. The temperature of the environment can be set to a temperature below freezing, for example, −20 ° C. or lower. The temperature of the environment can be as high as 2500 ° C., for example.

  The material used can include one or more components. The material can be a single phase (eg, solid or liquid) or a mixture of phases (eg, solid particles in a liquid). In some embodiments, the material comprises a solid and the material is heated. The material can become liquid upon heating. In other embodiments, the material can be mixed with a solvent. As used herein, a “solvent” is a liquid that at least partially dissolves a material. Examples of solvents include, but are not limited to water and organic solvents. Examples of organic solvents include, but are not limited to, hexane, ether, ethyl acetate, acetone, dichloromethane, chloroform, toluene, xylene, petroleum ether, dimethyl sulfoxide, dimethylformamide, or mixtures thereof. Additives may also be present. Examples of additives include, but are not limited to, thinners, surfactants, plasticizers, or combinations thereof.

  The material used to form the fibers can include at least one polymer. Polymers that can be used include conjugated polymers, biopolymers, water-soluble polymers, and polymers with incorporated particles. Examples of polymers that can be used include polypropylene, polyethylene, polyolefin, polystyrene, polyester, fluorinated polymer (fluoropolymer), polyamide, polyaramid, acrylonitrile butadiene styrene, nylon, polycarbonate, beta-lactam, block copolymer, or any combination thereof. For example, but not limited to. The polymer can be a synthetic (artificial) polymer or a natural polymer. The material used to form the fibers can be a complex of different polymers or a complex of drugs bound to a polymer carrier. Specific polymers that can be used include chitosan, nylon, nylon-6, polybutylene terephthalate (PBT), polyacrylonitrile (PAN), poly (lactic acid) (PLA), poly (lactic acid-co-glycolic acid) (PLGA). ), Polyglycolic acid (PGA), polyglactin, polycaprolactone (PCL), silk, collagen, poly (methyl methacrylate) (PMMA), polydioxanone, polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polytetrafluoroethylene ( PTFE), polyvinylidene fluoride (PVDF), polypropylene (PP), polyethylene oxide (PEO), acrylonitrile butadiene styrene (ABS), and polyvinyl pyrrolidone (PVP). Not a constant

  In other embodiments, the material used to form the fibers can be a metal, ceramic, or carbon-based material. Metals used to make the fibers include, but are not limited to, bismuth, tin, zinc, silver, gold, nickel, aluminum, or combinations thereof. The material used to form the fibers can be, for example, ceramics such as alumina, titania, silica, zirconia, or combinations thereof. The materials used to form the fibers can be composites of different metals (eg, alloys such as nitonol), metal / ceramic composites, or ceramic oxides (eg, PVP and germanium / palladium / platinum). can do.

  The fibers produced can be, for example, 1 micron or longer in length. For example, the fibers made can be of a length ranging from about 1 μm to about 50 cm, from about 100 μm to about 10 cm, or from about 1 mm to about 1 cm. In some embodiments, the fibers can have a narrow length distribution. For example, the length of the fiber can be between about 1 μm and about 9 μm, between about 1 mm and about 9 mm, or between about 1 cm and about 9 cm. In some embodiments, when a continuous process is performed, fibers up to about 10 meters, up to about 5 meters, or up to about 1 meter in length can be formed.

  In certain embodiments, the fiber cross-section can be circular, elliptical, or rectangular. Other shapes are possible. The fibers can be single lumen fibers or multiple lumen fibers.

  In another embodiment of the method of making the fiber, the method includes spinning the material to make the fiber, where the fiber is made from an externally applied electric field or external when the fiber is made. The fiber does not fall into the liquid after it has been created.

  The fibers discussed herein are a class of materials that exhibit an aspect ratio of at least 100 or greater. The term “microfiber” refers to a fiber having a minimum diameter ranging from 10 microns to 700 nanometers, or from 5 microns to 800 nanometers, or from 1 micron to 700 nanometers. The term “nanofiber” refers to a fiber having a minimum diameter ranging from 500 nanometers to 1 nanometer, or from 250 nanometers to 10 nanometers, or from 100 nanometers to 20 nanometers.

  The typical cross section of the fiber is essentially circular or elliptical, but can be formed in other shapes by controlling the shape and size of the openings in the fiber manufacturing equipment (described below). The fiber can include a blend of multiple materials. The fibers can also include holes (eg, lumens or multiple lumens) or pores. Multiple lumen fibers can be realized, for example, by designing one or more outlet openings to have coaxial openings. In certain embodiments, such openings are divided openings (ie, two or more openings are adjacent to each other, or in other words, the openings have one or more dividers). 2 or more small openings). This feature can be used to obtain certain physical properties, such as thermal insulation or shock absorption (elasticity). Nanotubes can also be made using the methods and apparatus discussed herein.

  The fibers can be analyzed by any means known to those skilled in the art. For example, scanning electron microscopy (SEM) can be used to measure the dimensions of a given fiber. Techniques such as differential scanning calorimetry (DSC), thermal analysis (TA) and chromatography can be used for physical and material characterization.

  In certain embodiments, one fiber of the fiber of the present invention is not a lyocell fiber. Lyocell fibers are described, for example, in documents such as Patent Document 15, Patent Document 16, Patent Document 17, Patent Document 18, and Patent Document 19, each of which is incorporated herein by reference.

  In one embodiment, microfibers and nanofibers can be generated substantially simultaneously. Any of the fiber manufacturing devices described herein have a diameter and / or shape in which one or more openings produce nanofibers in use, and one or more openings are micro in use. It can be modified to have a diameter and / or shape that produces a fiber. Therefore, when the fiber manufacturing apparatus is rotating, the material is ejected to generate both microfibers and nanofibers. In some embodiments, the nozzle can be coupled to one or more openings. Different nozzles can be coupled to different apertures such that nozzles designed to create microfibers and nozzles designed to create nanofibers are coupled to the apertures. In alternative embodiments, the needle can be coupled (directly to the opening or via the needle port). Different needles can be coupled to different apertures such that needles designed to create microfibers and needles designed to create nanofibers are coupled to the apertures. By producing microfibers and nanofibers substantially simultaneously, a controlled distribution of fiber sizes can be achieved and substantial control of the properties of the final product produced from the microfiber / nanofiber mixture. Is possible.

  Another embodiment of the fiber manufacturing system is shown in FIG. The fiber manufacturing system 3300 includes a fiber manufacturing apparatus 3310. The fiber manufacturing apparatus includes a body 3312 and a coupling member 3314. In this embodiment, body 3312 includes a first member 3314 and a second member 3316 that are coupled together. Alternatively, the body 3312 can be a single integral 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 within the body passes during use. One or more outlet elements (eg, nozzles, needles, needle ports or outlet conduits) can be coupled to one or more openings 3320. As previously described, the body's internal cavity includes an angled or rounded wall to help guide material disposed within the internal cavity 3318 of the body 3312 toward the opening 3320.

  The coupling member 3330 is an elongated member extending from the body. In one embodiment, the coupling member 3330 is coupled to the second member 3316 of the body 3312 and extends through the internal cavity 3318 in a direction away from the second member. The coupling member 3330 is used to couple the fiber manufacturing apparatus 3310 to a coupling element 3342 of the drive unit 3340 (eg, a chuck coupler or a universal threaded joint of the drive unit). Alternatively, the coupling member can be a receptacle that will receive an elongate member from the drive (eg, the coupling member may be a chuck or a universal thread joint). The coupling element 3342 of the drive unit interacts with the coupling member 3330 of the fiber production device, and the coupling member can be adjusted within the coupling element so that the distance between the fiber production device and the drive unit can be changed. It can be arranged in the. This is useful for applications in which the produced fiber is delivered to a substrate positioned below the fiber production equipment. Assuming that the substrate and the drive are at a certain distance from each other, changing the vertical distance between the fiber production device and the drive is the vertical direction between the underlying substrate and the fiber production device. The distance will also change. If the distance between the underlying substrate and the fiber manufacturing equipment can be changed, the fiber deposition pattern can be changed and customized for different substrates.

  The fiber manufacturing system 3300 includes a drive unit 3340 coupled to the coupling member 3330. The drive unit 3340 is disposed above the fiber manufacturing device 3330 when the fiber manufacturing device is coupled to the drive unit. During use, the drive unit 3330 rotates the fiber manufacturing apparatus 3310. Suitable drive units include commercially available variable electric motors such as brushless DC motors.

  The fiber manufacturing system 3330 further includes a material delivery system 3350. The material delivery system 3350 includes a material storage container 3352, a pump 3354, and a conduit 3356 for directing the liquid mixture to the fiber production device 3310. A liquid material mixture is stored in storage container 3352. A liquid material mixture is formed by dissolving the material in a suitable solvent to form a solution of the material. The liquid material mixture is transferred to the fiber production device 3352 using a pump 3354 coupled to the storage container 3352. Pump 3352 collects the liquid mixture and generates a flow of liquid material through conduit 3356. The liquid mixture enters the fiber manufacturing equipment from conduit 3356 through openings 3313 formed in the fiber manufacturing equipment 3310. A liquid level sensor 3358 is optically coupled to a liquid mixture disposed in the fiber manufacturing apparatus. The liquid level sensor 3358 provides a measurement of the amount of fluid placed in the fiber manufacturing apparatus. The flow rate of the pump during use can be adjusted based on the amount of fluid in the fiber production apparatus. In one embodiment, the material delivery system 3350 delivers material to the fiber production device substantially continuously while the fiber production device 3310 is rotating. Placing conduit 3356 outside of the fiber manufacturing device allows continuous delivery of material while the fiber manufacturing device is rotating.

  Drive unit 3340 is attached to arm 3360. In one embodiment, arm 3360 is coupled to a support (not shown). The arm 3360 can be coupled to the support so that the arm is movable relative to the support. For example, the arm 3360 can move (eg, swing) the drive 3340 and the combined fiber manufacturing device 3310 (referred to as a “drive / fiber manufacturing assembly”) away from the substrate. The maintenance of the fiber manufacturing apparatus (for example, replacement of the fiber manufacturing apparatus, purging of the fiber manufacturing apparatus, etc.) can be performed. The arm 3360 can also allow the horizontal position of the drive / textile production assembly to be changed. In one embodiment, the arm 3360 allows the drive / fiber maker assembly to be moved along a horizontal fixed path. This makes it possible to change the arrangement of the drive / fabric production assembly relative to the underlying substrate. In some embodiments, a motor can be coupled to the drive / fiber maker assembly to allow automated movement of the drive / fiber maker assembly relative to the substrate.

  In one embodiment, the pattern of fibers deposited by the fiber manufacturing apparatus 3310 in the inverted configuration described in connection with FIG. 6 is not sufficient to provide a uniform coating of the underlying substrate. There is. To improve the coating, the drive / fiber maker assembly can be moved horizontally relative to the substrate to provide a more uniform coating of the underlying substrate. For example, the arm can allow the drive / fabric assembly assembly to move along a certain horizontal path. When the substrate is located below the fiber production equipment, fiber production can begin and the drive / fiber production equipment assembly is moved horizontally to provide a more uniform deposition of fibers on the substrate. Bring. The horizontal movement of the drive / fiber maker assembly can be coordinated with the movement of the underlying substrate within the fiber deposition system. In an alternative embodiment, the arm can be configured to rotate the drive / fiber maker assembly relative to the substrate. Rotation of the drive / fiber maker assembly allows for a more uniform distribution of the fibers in the substrate.

  In some embodiments, the fiber manufacturing apparatus can be heated. One or more heating devices 3370 and 3372 are thermally coupled to the fiber production device 3310. In some embodiments, the heating device 3370 can be an annular heating device to allow the coupling member to extend through the heating device. The heating device 3372 may be a flat substrate disposed under the fiber manufacturing device or may be ring-shaped. In some embodiments, heating devices 3370 and 3372 have a diameter that is smaller than the diameter of fiber manufacturing device 3310. During fiber production, it has been generally found that the produced fiber is attracted to the heat from the heating device as it approaches the heating device. By making the diameter of the heating device smaller than the diameter of the fiber production device, fiber loss due to contact with the heating device is minimized.

  Another embodiment of the fiber manufacturing system is shown in FIG. The fiber manufacturing system shown in FIG. 7 is similar to the system shown in FIG. However, the system of FIG. 7 is configured for use in melt spinning, while the system shown in FIG. 6 is configured for use in solution spinning. In order to accommodate the melt spinning process, the material delivery system 3350 includes a material storage vessel 3380 and an extruder 3382. Solid material is stored in a material storage container 3380 and transferred to an extruder 3382. The extruder 3382 receives the material from the material storage container 3380 and melts the material to generate a melt. The melt is transferred to a metered melt pump 3385, which meteres the molten material and feeds it through a conduit 3386 to the fiber production equipment. Conduit 3386 is formed of a material that transfers the heated material from the extruder to the fiber production equipment. In some embodiments, the conduit 3386 is at least partially surrounded by thermal insulation 3384 to prevent cooling of the heated material as it is transferred to the fiber manufacturing apparatus. Heating devices 3370 and 3372 are used to keep the fiber production equipment at a temperature sufficient to maintain the material in a molten state.

  In an alternative embodiment, the extruder 3382 can be replaced with a material feed hopper. The material supply hopper is used to send the solid material placed in the material storage container 3380 directly into the fiber production equipment. The fiber manufacturing device can be heated to melt at least a portion of the solid material transferred from the material storage container to the fiber manufacturing device. The heating device is used to heat the fiber manufacturing device before or after the solid material is placed in the fiber manufacturing device, as described above. By doing so, the use of extruders and insulated conduits can be avoided and the energy requirements of the system can be reduced.

  Top driven fiber manufacturing systems are particularly useful for depositing fibers on a substrate. One embodiment of a system for depositing fibers on a substrate is shown in FIG. The substrate deposition system 3500 includes a deposition system 3600 and a substrate transfer system 3550. The deposition system 3600 includes a fiber manufacturing system 3610 as described herein. The deposition system guides the fibers produced by the fiber manufacturing device in use in the direction of the substrate 3520 disposed below the fiber manufacturing device. The substrate transfer system 3350 moves a continuous sheet of substrate material through the deposition system.

  The deposition system 3600, in one embodiment, includes a fiber manufacturing device 3610 attached to the top. In use, the fibers produced by the fiber production device 3610 are deposited on the substrate 3520. A schematic diagram of the deposition system 3600 is shown in FIG. The fiber deposition system includes one or more of a vacuum system 3620, an electrostatic plate 3630, and a gas flow system 3640. The vacuum system 3620 is configured such that a reduced pressure region is created below the substrate 3520, and the fibers generated by the fiber manufacturing device 3610 are attracted toward the substrate by the reduced pressure. Alternatively, one or more fans can be placed below the substrate to create an air flow through the substrate. The gas flow system 3640 generates a gas flow 3642 that guides the fibers formed by the fiber manufacturing apparatus toward the substrate. The gas flow system can be a source of compressed air or one or more fans that generate a flow of air (or other gas). Using a combination of vacuum and airflow system, forced air (fan, compressed air) and exhaust (fan, to create outward flow) are used to balance and guide the airflow toward the underlying substrate By creating a fiber deposition zone, a “balanced air flow” is created from the top of the deposition chamber through the substrate to the exhaust system. The deposition system 3600 includes a substrate inlet 3614 and a substrate outlet 3612.

  An electrostatic plate 3630 is also disposed below the substrate 3520. The electrostatic plate is a plate that can be charged to a predetermined polarity. Usually, the fibers produced by the fiber production equipment have a net charge. The net charge of the fiber can be positive or negative depending on the type of material used. In order to improve the deposition of charged fibers, an electrostatic plate is placed under the substrate 3520 and charged to the opposite polarity as the fibers produced. In doing so, the fibers are attracted to the electrostatic plate due to electrostatic attraction between the opposite charges. As the fibers move toward the electrostatic plate, the fibers are embedded in the substrate.

  A compressed gas generation and distribution system can be used to control the flow of fibers toward a substrate located below the fiber production equipment. In use, the fibers produced by the fiber production equipment are dispersed within the deposition system. Since the fibers are mainly composed of microfibers and / or nanofibers, the fibers are easy to disperse in the deposition system. The use of a compressed gas generation and distribution system helps guide the fibers toward the substrate. In one embodiment, the compressed gas generation 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 at the same height as the fiber production device to facilitate uniform fiber movement toward the substrate. One or more lateral gas flow devices 3645 are oriented perpendicularly or downwardly with respect to the fiber production device. In some embodiments, the lateral gas flow device 3645 has an exit width that is the same as the width of the substrate to facilitate uniform fiber deposition on the substrate. In some embodiments, the angle of the exit of one or more lateral gas flow devices 3645 can be varied to allow better control of fiber deposition on the substrate. Each lateral gas flow device 3645 can be operated independently.

  During use of the deposition system, the fiber production device 3610 may generate various gases due to solvent evaporation (during solution spinning) and material vaporization (during melt spinning). As such gases accumulate in the deposition system, they can begin to affect the quality of the fibers produced. In some embodiments, the deposition system includes an exhaust fan 3650 for removing gas generated during fiber manufacture from the deposition system.

  The substrate transfer system 3550, in one embodiment, moves a continuous sheet of substrate material through the deposition system. In other embodiments, the substrate transfer system 3550 includes a substrate reel 3552 and a substrate take-up reel system 3554. In use, a roll of substrate material is placed on substrate reel 3552 and passed through deposition system 3600 to substrate take-up reel system 3554. In use, the substrate take-up reel system 3554 rotates to draw the substrate through the deposition system at a predetermined speed. In this way, the continuously wound substrate material is drawn through the fiber deposition system.

  In some embodiments, it may be difficult to produce a sufficient amount of fibers to supply the desired level of fibers throughout the substrate with a single fiber production device. In order to ensure proper and uniform coating of the fibers on the substrate, the substrate deposition system can be provided with two or more fiber manufacturing equipment as shown in FIG. The fiber deposition system 3700 can include two or more fiber production devices 3710 coupled to the drive unit 3720. The drive unit is coupled to the fiber manufacturing device 3710. In one embodiment, the drive unit 3720 includes a plurality of drive units, each of which is coupled to the fiber manufacturing device 3710. The drive unit includes a controller that allows each drive unit to operate independently so that two or more fiber production devices produce fibers substantially simultaneously. In an alternative embodiment, the drive unit includes a single drive that operates all of the fiber manufacturing devices coupled to the drive unit simultaneously. In such an embodiment, all fiber production devices produce fibers substantially simultaneously, ensuring complete coverage of the underlying substrate 3730.

  Microfibers and nanofibers produced using any of the devices and methods described herein can be used in a variety of applications. Some common areas of use include food, materials, electricity, defense, tissue engineering, biotechnology, medical devices, energy, alternative energy (eg solar, wind, nuclear and hydro energy), therapeutics, drugs Delivery (eg, improved drug solubility, drug encapsulation, etc.), textiles / textiles, nonwoven materials, filtration (eg, air, water, fuel, semiconductor, biomedical, etc.), automotive, sports, aeronautics, space, Examples include, but are not limited to, energy transfer, paper, substrate, hygiene, cosmetics, architecture, clothing, packaging, geotextile, thermal insulation and sound insulation.

  Some products that can be formed using microfibers and / or nanofibers include filters for purifying fluids using charged nanofibers and / or microfibers; ceramic nanofibers ("NF") Catalyst filters used; nanofibers with carbon nanotubes (“CNT”) for storing energy; NF for CNT-introduced / coated electromagnetic shielding; microfibers and NF for filters and other applications Polyesters introduced into cotton for denim and other textiles; metal nanoparticles or other antibacterial materials introduced / coated on NF for filters; wound dressings, cell growth substrates or scaffolds; Battery separator; charged polymer or other material for solar energy; NF for use in environmental cleanup; piezoelectric fiber; suture thread; chemical sensor; And textile / woven fabrics with stain resistance, odor resistance, insulation, self-cleaning, penetration resistance, antibacterial, porous / breathable, tear resistant, and abrasion resistant; Force energy absorbers, building reinforcement materials (eg concrete and plastic); carbon fibers; fibers used to reinforce skins for aerospace applications; tissue engineering substrates utilizing aligned or irregular fibers Petri dishes for tissue engineering with aligned or irregular nanofibers; Filters used in drug production; Filters combining microfibers and nanofibers for deep filter functions; Hydrophobic materials such as textiles; Oil fences, etc. Selective absorbent material; continuous nanofibers (aspect ratio greater than 1,000 to 1); paint / colorant; durability, fire resistance, color retention, porosity, flexibility, antibacterial, pest resistance, airtightness Enhance building products; adhesive; tape; epoxy; paste; adsorbent; diaper medium; mattress cover; acoustic material; and a liquid, a gas, although chemical or air filter include, but are not limited to.

  The fibers can be coated after formation. In one embodiment, the microfibers and / or nanofibers can be coated with a polymer or metal coating. The polymer coating can be formed by spraying the manufactured fibers or by any other known method for forming a polymer coating. The metal coating can be formed using a metal deposition process (eg, CVD).

  This patent incorporates by reference certain US patents, US patent applications, and other materials (eg, articles). However, the texts of those U.S. patents, U.S. patent applications, and other materials are incorporated by reference to the extent that there is no inconsistency between those texts and other statements and drawings described herein. Where there is such a conflict, any conflicting text in US patents, US patent applications, and other materials incorporated by reference is not expressly incorporated by reference into this patent.

  In view of this description, further modifications and variations of various aspects of the invention will become apparent to those skilled in the art. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It should be understood that the forms of the invention shown and described herein are to be construed as examples of embodiments. All of the elements and materials shown and described herein can be replaced, and the parts and processes reversed, as will be apparent to those skilled in the art after gaining the benefit of this description of the invention. Yes, certain features of the invention can be utilized independently. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the appended claims.

1900, 2100, 3300: Textile manufacturing system 1910, 1000, 2110, 3310, 3610, 3710: Textile manufacturing apparatus 1912, 1010, 3312: Body 1914, 1030, 3330: Coupling members 1916, 1011, 1013, 1015, 3320: Opening 1918, 3200: outlet element 1920, 1040, 3340: drive 1930: collection system 1012, 3318: internal cavity 1042, 3342: coupling element 2000, 3600: deposition system 2010: inlet conduit 2020: substrate support 2022, 3620: Vacuum system (vacuum equipment)
2025: Upper chamber 2030, 2130, 3520, 3730: Base material 2040, 3640, 3645: Gas flow generator (gas flow device)
2045: Lower chamber 3350: Material delivery system 3352, 3380: Material storage container 3354: Pump 3360: Arm 3370, 3372: Heating device 3382: Extruder 3500: Substrate deposition system 3550: Substrate transfer system 3552: Substrate reel 3554 : Substrate take-up reel system 3630: electrostatic plate 3700: fiber deposition system 3720: drive unit

Claims (17)

A microfiber and / or nanofiber manufacturing system,
A fiber manufacturing apparatus comprising a body having a plurality of openings and a coupling member, wherein the body is configured to receive a material produced as a fiber;
A drive unit that rotates the body and couples the body through the coupling member;
A deposition system that collects the fibers produced by the fiber manufacturing device during use and directs the collected fibers toward a substrate disposed therein during use;
With
The body comprises a plurality of chambers each having one or more openings;
One or more outlet elements are coupled to the one or more openings;
The one or more outlet elements are outlet orifices;
In use, rotation of the body coupled to the drive causes material in the body to be ejected through the one or more openings to produce microfibers and / or nanofibers, the fibers being at least Partially transferred to the deposition system;
A system characterized by that. Wherein the plurality of chambers, characterized Rukoto the Ki de be removably coupled to each other, according to claim 1 system.   The deposition system comprises a substrate support that places the substrate in a series of microfiber and / or nanofiber streams generated by the fiber manufacturing device during use. Item 3. The system according to Item 1 or 2.   The substrate support comprises one or more openings that penetrate at least a portion of the substrate support, the one or more openings being connected to a vacuum system, The system according to claim 3.   4. The system of claim 3, further comprising a substrate transfer system that moves a continuous sheet of substrate material along the substrate support in the deposition system. 6. System according to claims 1-5, characterized in that the outlet element can be removably coupled to the body. A microfiber and / or nanofiber manufacturing system,
A fiber manufacturing apparatus comprising a body having a plurality of openings and a coupling member, wherein the body is configured to receive a material produced as a fiber;
A drive unit that rotates the body and couples the body through the coupling member;
A deposition system that collects the fibers produced by the fiber manufacturing device during use and directs the collected fibers toward a substrate disposed therein during use;
With
The body comprises a plurality of chambers each having one or more openings;
  Further comprising one or more needle ports coupled to one or more of the openings;
In use, one or more needles can be removably coupled to the needle port, and rotation of the body coupled to the drive causes the material in the body to move to the one or more. Ejected through these openings to produce microfibers and / or nanofibers, which are at least partially transferred to the deposition system;
A system characterized by that. The system of claim 7, wherein the plurality of chambers can be removably coupled to each other.   The drive unit includes a coupling element coupled to the coupling member, and the coupling member is arranged to be adjustable in the coupling element so that a distance between the fiber manufacturing apparatus and the drive unit can be changed. It forms so that it can do, The system as described in any one of Claims 1-8 characterized by the above-mentioned.   10. The vacuum system according to any one of claims 1 to 9, further comprising a vacuum system that creates a reduced pressure region under the substrate that causes a flow of generated fibers toward the substrate. The system described in.   11. The system according to any one of claims 1 to 10, further comprising a gas flow system that generates a gas flow that causes a flow of generated fibers toward the substrate. One or more additional fiber manufacturing devices each including a body having one or more openings and a coupling member, the body configured to receive material produced as fibers;
One or more additional drives disposed above the one or more additional fiber production devices and rotating one or more of the additional fiber production devices;
Further comprising
In use, rotation of the one or more fiber manufacturing devices causes material in the body to be ejected through one or more openings to produce microfibers and / or nanofibers.
The system according to claim 1, wherein: A method for producing microfibers and / or nanofibers,
Disposing a material in the fiber manufacturing apparatus according to any one of claims 1 to 12,
Rotating the fiber manufacturing device at a speed of at least 1000 rpm, and rotation of the fiber manufacturing device causes material in the body to be ejected through one or more openings to produce microfibers and / or nanofibers; ,
Depositing at least a portion of the generated microfibers and / or nanofibers on a substrate;
Including the method.   14. The method according to claim 13, characterized in that the microfibers and / or nanofibers are produced without exposing the fibers to an externally applied electric field during their production. Heating the material to a temperature sufficient to at least partially melt the material;
Heating the fiber production device to or near a temperature sufficient to at least partially melt the material;
Placing the heated material in the heated fiber production apparatus;
14. The method of claim 13, further comprising: Placing the material in a fiber manufacturing device;
Heating the fiber manufacturing apparatus to or near a temperature sufficient to at least partially melt the material disposed in the fiber manufacturing apparatus;
14. The method of claim 13, further comprising: 14. The method of claim 13, further comprising: mixing the material with a solvent to produce a mixture of the material in a solvent; and placing the mixture in the fiber manufacturing apparatus.

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