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US20060012084A1 - Electroblowing web formation process - Google Patents

Electroblowing web formation process Download PDF

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Publication number
US20060012084A1
US20060012084A1 US10/890,358 US89035804A US2006012084A1 US 20060012084 A1 US20060012084 A1 US 20060012084A1 US 89035804 A US89035804 A US 89035804A US 2006012084 A1 US2006012084 A1 US 2006012084A1
Authority
US
United States
Prior art keywords
collection
spinneret
collection means
voltage
polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/890,358
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English (en)
Inventor
Jack Armantrout
Michael Bryner
Michael Davis
Yong Kim
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US10/890,358 priority Critical patent/US20060012084A1/en
Assigned to E. I. DU PONT DE NEMOURS AND COMPANY reassignment E. I. DU PONT DE NEMOURS AND COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAVIS, MICHAEL C., KIM, YONG MIN, BRYNER, MICHAEL ALLEN, ARMANTROUT, JACK EUGENE
Priority to BRPI0513127-8A priority patent/BRPI0513127A/pt
Priority to KR1020077000765A priority patent/KR20070047282A/ko
Priority to JP2007521643A priority patent/JP2008506864A/ja
Priority to CNA2005800232116A priority patent/CN1985030A/zh
Priority to PCT/US2005/025008 priority patent/WO2006017360A1/fr
Priority to EP05771691A priority patent/EP1766110A1/fr
Publication of US20060012084A1 publication Critical patent/US20060012084A1/en
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
    • D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
    • D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
    • D01D5/0069—Electro-spinning characterised by the electro-spinning apparatus characterised by the spinning section, e.g. capillary tube, protrusion or pin
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00—Manufacture or treatment of nanostructures

Definitions

  • the present invention relates to a process for forming a fibrous web wherein a polymer stream is spun through a spinning nozzle into an electric field of sufficient strength to impart electrical charge on the polymer and wherein a forwarding gas stream aids in transporting the polymer away from the spinning nozzle.
  • PCT publication no. WO 03/080905A discloses an apparatus and method for producing a nanofiber web.
  • the method comprises feeding a polymeric solution to a spinning nozzle to which a high voltage is applied while compressed gas is used to envelop the polymer solution in a forwarding gas stream as it exits the nozzle, and collecting the resulting nanofiber web on a grounded suction collector.
  • the high voltage introduces a hazard to those persons providing routine maintenance to electrified equipment in support of an on-going manufacturing process.
  • the polymeric solutions and solvents being processed are often flammable, creating a further potential danger exacerbated by the presence of the high voltage.
  • the invention relates to an electroblowing process for forming a fibrous web comprising:
  • a voltage is applied to the collection means, the voltage having a polarity opposite that of the fibrous web, and wherein the spinneret is substantially grounded, such that an electric field is generated between the spinneret and the collection means of sufficient strength to impart an electrical charge on the polymer stream as it issues from the spinning nozzle.
  • electro-blown spinning refer interchangeably to a process for forming a fibrous web by which a forwarding gas stream is directed generally towards a collection means, into which gas stream a polymer stream is injected from a spinning nozzle, thereby forming a fibrous web which is collected on the collection means, wherein a voltage differential is maintained between the spinning nozzle and the collection means and the voltage differential is of sufficient strength to impart charge on the polymer as it issues from the spinning nozzle.
  • nanofibers refers to fibers having diameters of less than 1,000 nanometers.
  • FIG. 1 is an illustration of the prior art.
  • FIG. 2 is a schematic of a process according to the present invention.
  • FIG. 3A is a schematic of an alternative process according to the present invention.
  • FIG. 3B is a detail from FIG. 3A of the collection means.
  • a polymer stream comprising a polymer and a solvent, or a polymer melt
  • a spinning nozzle 104 also referred to as a “die” located in a spinneret 102 through which the polymer stream is discharged.
  • Compressed gas which may optionally be heated or cooled in a gas temperature controller 108 , is issued from gas nozzles 106 disposed adjacent to or peripherally to the spinning nozzle 104 .
  • the gas is directed generally downward in a forwarding gas stream which forwards the newly issued polymer stream and aids in the formation of the fibrous web.
  • the forwarding gas stream provides the majority of the forwarding forces in the initial stages of drawing of the fibers from the issued polymer stream and in the case of polymer solution, simultaneously strips away the mass boundary layer along the individual fiber surface thereby greatly increasing the diffusion rate of solvent from the polymeric solution in the form of gas during the formation of the fibrous web.
  • the local electric field around individual fibers is of sufficient strength that the electrical force becomes the dominant drawing force which ultimately draws the individual fibers to diameters measured in the hundreds of nanometers or less.
  • the geometry of the tip of the spinning nozzle also referred to as the “die tip,” creates an intense electric field in the three-dimensional space surrounding the tip which causes charge to be imparted to the web.
  • the die tip may be in the form of a cylindrical capillary or in the form of a linear array of cylindrical capillaries.
  • the forwarding gas stream is issued from gas nozzles 106 on each side of the spinneret 102 .
  • the gas nozzles are in the form of slots formed between elongated knife edges, one on each side of the spinneret, along the length of the linear array, and the spinneret.
  • the gas nozzle 106 may be in the form of a circumferential slot surrounding the spinneret 102 . It is believed that the electric field combined with the charge on the fibrous web provides spreading forces which act on the fibers and fibrils of the web, causing the web to be better dispersed and providing for very uniform web laydown on the collection surface of the collection means.
  • the velocity of the compressed gas issued from gas nozzles 106 is advantageously between about 10 m/min and about 20,000 m/min, and more advantageously between about 100 and about 3000 m/min.
  • the polymeric solution is electrically conductive.
  • polymers for use in the invention may include polyimide, nylon, polyaramide, polybenzimidazole, polyetherimide, polyacrylonitrile, PET (polyethylene terephthalate), polypropylene, polyaniline, polyethylene oxide, PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), SBR (styrene butadiene rubber), polystyrene, PVC (polyvinyl chloride), polyvinyl alcohol, PVDF (polyvinylidene fluoride), polyvinyl butylene and copolymer or derivative compound thereof.
  • the polymer solution is prepared by selecting a solvent suitable to dissolve the polymer.
  • the polymer solution can be mixed with additives including any resin compatible with an associated polymer, plasticizer, ultraviolet ray stabilizer, crosslink agent, curing agent, reaction initiator, etc. Any polymer solution known to be suitable for use in a conventional electrospinning process may be used in the process of the invention.
  • the polymer stream fed to the spin pack and discharged through the nozzle in the spinneret is a polymer melt.
  • Any polymer known to be suitable for use in a melt spinning process may be used in the process in the form of a polymer melt.
  • the collection means comprises a moving conductive belt 110 connected to high voltage onto which the fibrous web is collected.
  • the belt 110 is advantageously made from a porous conductive material such as a metal screen so that a vacuum can be drawn from beneath the belt through gas collecting tube 114 by blower 112 .
  • the collection belt must be isolated from ground by any known means. The collected fibrous web of nanofibers is sent to a wind-up roll, not shown.
  • the moving collection substrate 118 ( FIG. 3B ) is a nonconductive substrate superposed over a conductive element 120 connected to high voltage, itself superposed on a nonconductive support material 122 .
  • the conductive element 120 and/or the nonconductive support material 122 can be stationary.
  • the moving collection substrate 118 is supplied from a supply roll 124 and the combined collected fibrous nanofiber web and collection substrate 118 are sent to a wind-up roll 126 .
  • nanofibers and the forwarding gas stream are directed toward the collection substrate 118 , where the nanofibers are deposited and collected into a fibrous nanofiber web superposed on the nonconductive collection substrate 118 .
  • the collection substrate 118 , conductive element 120 and support material 122 are each highly breathable, so that the gas from the forwarding gas stream as it impinges the collection substrate may be exhausted through the collection substrate 118 , conductive element 120 and support material 122 using vacuum.
  • the vacuum can be drawn from beneath the support material 122 through gas collecting tube 114 by blower 112 .
  • the collection substrate 118 can be any of a number of substantially nonconductive breathable materials such as woven fabrics, nonwoven fabrics, scrims, etc.
  • the conductive element 120 is a porous material, and more advantageously a metal screen, for example a fine mesh screen having a mesh greater than about 50 .
  • the high voltage conductive screen 120 must be isolated from ground by any known means.
  • a nonconductive moving collection substrate 118 according to FIG. 3B can be supplied from a supply roll and fed over the moving conductive belt 110 of FIG. 2 .
  • a fibrous web containing nanofibers is deposited onto the collection substrate, the combination of nanofiber web and nonconductive moving collection substrate are separated from the moving conductive belt by conventional means and are forwarded to a wind-up roll.
  • the distance between the spinneret and the collection surface (also referred to as the “die to collector distance” or “DCD”; illustrated in FIGS. 2 and 3 A) is in the range of about 1 to about 200 cm, and more advantageously in the range of about 10 to about 50 cm.
  • the voltage applied to the collection means is in the range of about 1 to about 500 kV, and more advantageously about 10 to about 100 kV.
  • the process of the invention avoids the necessity of maintaining the spin pack including the spinneret, as well as all other upstream equipment, at high voltage, as described in the Background of the Invention.
  • the pack, the spinneret and all upstream equipment may be grounded or substantially grounded.
  • substantially grounded is meant that the spinneret may be held at a low voltage level, i.e., between ⁇ 100 V and +100 V.
  • the polymer discharge pressure is in the range of about 0.01 kg/cm 2 to about 200 kg/cm 2 , more advantageously in the range of about 0.1 kg/cm 2 to about 20 kg/cm 2 , and the polymer solution throughput per hole is in the range of about 0.1 cc/min to about 15 cc/min.
  • the collector consisted of a rectangular metal screen supported by a frame. The collector was stationary and electrically insulated from ground with the use of Teflon® supports. A voltage of ⁇ 60 kV was applied to the collector and the spin pack was connected to ground.
  • a 22 wt % solution of nylon 6 (type BS400N obtained from BASF Corporation, Mount Olive, N.J.) in formic acid (obtained from Kemira Industrial Chemicals, Helsinki, Finland) was electroblown through a spinneret of 100 mm wide, having 11 nozzles at a throughput rate of 1.5 cc/hole.
  • a forwarding air stream was introduced through air nozzles at a flow rate of 4 scfm (2 liters per second). The air was heated to about 70° C.
  • the distance from the spinneret to the upper surface of the collector was approximately 300 mm. The process ran for about 1 minute.
  • the average fiber size of the Comparative Example was 511 nm with a standard deviation of 115.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Nonwoven Fabrics (AREA)
US10/890,358 2004-07-13 2004-07-13 Electroblowing web formation process Abandoned US20060012084A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US10/890,358 US20060012084A1 (en) 2004-07-13 2004-07-13 Electroblowing web formation process
BRPI0513127-8A BRPI0513127A (pt) 2004-07-13 2005-07-13 processo de sopro elétrico
KR1020077000765A KR20070047282A (ko) 2004-07-13 2005-07-13 개량된 일렉트로블로잉 웹 형성 방법
JP2007521643A JP2008506864A (ja) 2004-07-13 2005-07-13 改善されたエレクトロブローウェブ形成法
CNA2005800232116A CN1985030A (zh) 2004-07-13 2005-07-13 改进的电吹纤维网形成工艺
PCT/US2005/025008 WO2006017360A1 (fr) 2004-07-13 2005-07-13 Procede ameliore de formation d'une bande par electrosoufflage
EP05771691A EP1766110A1 (fr) 2004-07-13 2005-07-13 Procede ameliore de formation d'une bande par electrosoufflage

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/890,358 US20060012084A1 (en) 2004-07-13 2004-07-13 Electroblowing web formation process

Publications (1)

Publication Number Publication Date
US20060012084A1 true US20060012084A1 (en) 2006-01-19

Family

ID=34979561

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/890,358 Abandoned US20060012084A1 (en) 2004-07-13 2004-07-13 Electroblowing web formation process

Country Status (7)

Country Link
US (1) US20060012084A1 (fr)
EP (1) EP1766110A1 (fr)
JP (1) JP2008506864A (fr)
KR (1) KR20070047282A (fr)
CN (1) CN1985030A (fr)
BR (1) BRPI0513127A (fr)
WO (1) WO2006017360A1 (fr)

Cited By (20)

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US20060138710A1 (en) * 2004-12-27 2006-06-29 Bryner Michael A Electroblowing web formation process
US20080242171A1 (en) * 2007-03-29 2008-10-02 Tao Huang Production of nanofibers by melt spinning
US20090102100A1 (en) * 2007-10-23 2009-04-23 Ppg Industries Ohio, Inc. Fiber formation by electrical-mechanical spinning
US20090160099A1 (en) * 2007-12-17 2009-06-25 Tao Huang Centrifugal solution spun nanofiber process
WO2009049563A3 (fr) * 2007-10-18 2009-10-29 Elmarco, S.R.O. Dispositif de production d'une couche de nanofibres par filage électrostatique de matrices de polymères
US20100187729A1 (en) * 2007-07-11 2010-07-29 Mitsuhiro Takahashi Method for manufacturing fine polymer, and fine polymer manufacturing apparatus
US20110148006A1 (en) * 2008-08-11 2011-06-23 Jfe Chemical Corporation Fibre-production device and fibre-production method
WO2012003349A2 (fr) 2010-07-02 2012-01-05 The Procter & Gamble Company Article présentant une structure en tissu fibreux soluble et contenant des agents actifs
US8496088B2 (en) 2011-11-09 2013-07-30 Milliken & Company Acoustic composite
CN103484956A (zh) * 2013-10-12 2014-01-01 厦门大学 电纺纳米纤维气浮传输收集装置
CZ304742B6 (cs) * 2006-07-24 2014-09-17 Elmarco S.R.O. Sběrná elektroda zařízení pro výrobu nanovláken elektrostatickým zvlákňováním polymerních roztoků
WO2014169239A1 (fr) * 2013-04-12 2014-10-16 Donaldson Company, Inc. Procédés de filage électrostatique centrifuge
WO2015004291A1 (fr) * 2013-07-11 2015-01-15 Universitat Politécnica de Catalunya Système et procédé de production de fibres par filage électrostatique
WO2015164227A2 (fr) 2014-04-22 2015-10-29 The Procter & Gamble Company Compositions se présentant sous la forme de structures solides solubles
US9186608B2 (en) 2012-09-26 2015-11-17 Milliken & Company Process for forming a high efficiency nanofiber filter
US20160047061A1 (en) * 2011-12-21 2016-02-18 E I Du Pont De Nemours And Company Process for laying fibrous webs from a centrifugal spinning process
WO2017147444A1 (fr) 2016-02-25 2017-08-31 Avintiv Specialty Materials Inc. Tissus non-tissés dotés d'un additif améliorant les propriétés de barrière
US9816214B2 (en) * 2009-11-10 2017-11-14 Stc.Unm Electrospun fiber mats from polymers having a low Tm, Tg, or molecular weight
US20180215132A1 (en) * 2017-01-26 2018-08-02 The North Face Apparel Corp. Garment or substrate and systems and methods for creation thereof
US10240257B2 (en) * 2014-09-15 2019-03-26 Clarcor Inc. Systems and methods for controlled laydown of materials in a fiber production system

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US7846374B2 (en) * 2004-11-05 2010-12-07 E. I. Du Pont De Nemours And Company Blowing gases in electroblowing process
JP4876252B2 (ja) * 2006-02-28 2012-02-15 国立大学法人信州大学 極細繊維の製造方法
JP4848970B2 (ja) * 2007-02-07 2011-12-28 パナソニック株式会社 高分子ウェブの製造方法及び装置
JP4915258B2 (ja) * 2007-03-14 2012-04-11 パナソニック株式会社 高分子ウェブの製造装置
KR100843266B1 (ko) * 2007-05-07 2008-07-02 박종철 보조 기재를 가진 전기방사장치의 컬렉터
KR100890192B1 (ko) * 2007-07-10 2009-03-25 한국기계연구원 나노섬유 제조장치
CA2705957A1 (fr) 2007-11-20 2009-05-28 Dow Corning Corporation Article et son procede de fabrication
JP4864915B2 (ja) * 2008-02-26 2012-02-01 Ｊｆｅケミカル株式会社 繊維製造装置及び繊維製造方法
CZ301226B6 (cs) * 2008-04-09 2009-12-16 Elmarco S.R.O. Zarízení pro výrobu nanovláken elektrostatickým zvláknováním polymerní matrice
CN102197093B (zh) 2008-08-29 2014-07-16 陶氏康宁公司 从分散体形成的金属化的颗粒
US20100059906A1 (en) * 2008-09-05 2010-03-11 E. I. Du Pont De Nemours And Company High throughput electroblowing process
US8211353B2 (en) * 2008-09-05 2012-07-03 E. I. Du Pont De Nemours And Company Fiber spinning process using a weakly interacting polymer
CN101892527B (zh) * 2010-06-30 2015-05-13 江苏丽洋新材料股份有限公司 微纤维包裹细小气穴形成的纤维集聚材料及其生产工艺
JP5698507B2 (ja) * 2010-12-06 2015-04-08 トップテック・カンパニー・リミテッドＴＯＰＴＥＣ Ｃｏ．， Ｌｔｄ． 電界紡糸装置及びナノ繊維製造装置
US9090996B2 (en) * 2012-08-15 2015-07-28 E I Du Pont De Nemours And Company Multizone electroblowing process
JP2017075407A (ja) * 2015-10-12 2017-04-20 康次 市原 加熱溶融静電紡糸による微細繊維集合体の生産方法
CN105350098A (zh) * 2015-11-13 2016-02-24 广东工业大学 一种具有三维结构的纳米纤维支架制备装置及方法
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KR102317136B1 (ko) * 2020-03-19 2021-10-22 충남대학교산학협력단 고분자 마이크로 섬유 번들 제조 및 이를 위한 역전압 전기수력학적 제팅 방법
EP3954811A1 (fr) * 2020-08-13 2022-02-16 Gelatex Technologies OÜ Dispositif et procédé de production de fibres polymère et leurs utilisations
CN115976660A (zh) * 2022-12-19 2023-04-18 佛山轻子精密测控技术有限公司 一种静电纺丝系统

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US3319309A (en) * 1964-06-04 1967-05-16 Du Pont Charged web collecting apparatus
US3387326A (en) * 1964-06-04 1968-06-11 Du Pont Apparatus for charging and spreading a web
US3490115A (en) * 1967-04-06 1970-01-20 Du Pont Apparatus for collecting charged fibrous material in sheet form
US4043331A (en) * 1974-08-05 1977-08-23 Imperial Chemical Industries Limited Fibrillar product of electrostatically spun organic material
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US4655757A (en) * 1984-04-23 1987-04-07 Kimberly-Clark Corporation Selective layering of superabsorbents in meltblown substrates
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JP2008506864A (ja) 2008-03-06
KR20070047282A (ko) 2007-05-04
BRPI0513127A (pt) 2008-04-29
WO2006017360A1 (fr) 2006-02-16
EP1766110A1 (fr) 2007-03-28

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