A novel method to investigate the polystyrene nanofiber formation during electrospinning process

In this study, the formation of polystyrene (PS) nanofibers during electrospinning process was investigated using a simple coagulation method. The fiber diameter, bead size and bead density of the PS nanofibers electrospun from the solutions with three different PS concentrations were studied. It revealed that the initial stage of electrospinning was responsible for fiber thinning, while the later stage is responsible for improving the fiber uniformity.

Polyacrylonitrile nanofibre yarn; electrospinning and their post-drawing behaviour

Polyacrylontrile nanofibre yarns have been successfully produced from an electrospinning setup composing positively and negatively charged spinnerets, a rotating funnel and a yarn winder. Through hot drawing, yarns show compact morphology and improved uniformity and have a significant decrease in both yarn and fibre diameters. The hot drawing has improved the molecular orientation and crystallinity of the fibres. The yarn drawn to 5 times of its original length has been found to have the highest tensile strength and modulus.

Ultrafine PDMS fibers: Preparation from in situ curing-electrospinning and mechanical characterization

Polydimethylsiloxane (PDMS) fibers with unexpected elasticity were prepared by a modified core-shell electrospinning method using a commercially-available liquid PDMS precursor (Sylgard 184) and polyvinylpyrrolidone (PVP) as core and sheath materials, respectively. The liquid PDMS precursor was crosslinked in situ to form a solid core when the newly-electrospun core-sheath nanofibers were deposited onto a hot-plate electrode collector. After dissolving the PVP sheath layer off the fibers, net PDMS fibers showed larger average diameter than core-sheath fibers, with an average diameter around 1.35 μm. The tensile properties of both single fibers and fibrous mats were measured. Single PDMS fibers had a tensile strength and elongation at break of 6.0 MPa and 212%, respectively, which were higher than those of PDMS cast film (4.9 MPa, 93%). The PDMS fiber mat had larger elongation at break than the single PDMS fibers, which can be drawn up to 403% their original length. Cyclic loading tests indicated a Mullin effect on the PDMS fiber mats. Such a superior elastic feature was attributed to the PDMS molecular orientation within fibers and the randomly-orientated fibrous structure. Highly-elastic, ultrafine PDMS fibers may find applications in strain sensors, biomedical engineering, wound healing, filtration, catalysis, and functional textiles. © The Royal Society of Chemistry 2014.

Scaling up the production rate of nanofibers by needleless electrospinning from multiple ring

Mass production of nanofibers is crucial in both laboratory research and industry application of nanofibers. In this study, multiple ring spinnerets have been used to generate needleless electrospinning. Multiple polymer jets were produced from the top of each ring in the spinning process, resulting in thin and uniform nanofibers. Production rate of nanofibers increased gradually with the increase of the number of rings in the spinneret. Spinning performance of multiple ring electrospinning, namely the quality and production rate of the as-spun nanofibers, was dependent on experimental parameters like applied voltage and polymer concentration. Electric field analysis of multiple ring showed that high concentrated electric field was formed on the surface of each ring. Fiber diameter together with production rate of needleless electrospinning was dependent on the strength and distribution of the electric field of the spinneret. Needleless electrospinning from multiple ring can be further applied in both laboratory research and industry where large amount of nanofibers must be employed simultaneously. © 2014 The Korean Fiber Society and Springer Science+Business Media Dordrecht.

Recent developments in electrospinning of nanofiber yarns

Nanofibers possess high surface area and excellent porosity. Though nanofibers can be produced by a variety of techniques, electrospinning stands distinct because of its simplicity and flexibility in processing different polymer materials, and ability to control fiber diameter, morphology, orientation, and chemical component. Nonetheless, electrospun nanofibers are predominantly produced in the form of randomly oriented fiber webs, which restrict their wide use. Converting nanofibers into twisted continuous bundles, i.e., nanofiber yarns, can improve their strength and facilitate their subsequent processes, but remains challenging to make. Nanofiber yarns also create enormous opportunities to develop well-defined three-dimensional nanofibrous architectures. This review article gives an overview of the state-of-the-art techniques for electrospinning of nanofiber yarns and control of nanofiber alignment. A detailed account on techniques to produce twisted/non-twisted short bundles and continuous yarns are discussed.

Electrospinning of nanofibre yarns using rotating ring collector

 In this project, a novel ring collector was used to convert newly electrospun nanofibres into yarn. This setup has been designed to separate electrospinning from yarn drafting/twisting in two distinct zones. Three different types of electrospinning systems, i.e. needle, needleless, and needle/needleless hybrid, were utilized to produce nanofibre yarns.

Direct electrospinning of nanofibre yarns using a rotating ring collector

Nanofibres prepared by electrospinning typically have randomly oriented fibrous structure. They have large surface-to-volume (or weight) ratio and excellent porous characteristic, which have shown enormous potential in diverse applications. However, electrospun nanofibres are often prepared in the form of randomly orientated fibrous web, which are fragile and difficult to be tailored in fibrous structures. Herein, we demonstrate a novel yarn electrospinning method which uses a rotating ring collector to convert newly electrospun nanofibres directly into a continuous yarn. The use of ring collector separates the yarn formation from the electrospinning zone. The deposition of later-spun nanofibres to the inner surface of fibrous cone eliminates hooked or curled nanofibres in the final yarn. The effects of polymer concentration and operating parameters on nanofibre and yarn morphology, diameter and the ring collector on yarn twist feature were examined. The nanofibre yarns had a surface twist angle up to 54.4°, and tensile strength as high as 93.6 MPa (elongation at break 242.6%). Increasing twist levels improves tensile strength and strain values.

Effect of electrospinning parameters and polymer concentrations on mechanical-to-electrical energy conversion of randomly-oriented electrospun poly(vinylidene fluoride) nanofiber mats

Poly(vinylidene fluoride) (PVDF) nanofiber mats prepared by an electrospinning technique were used as an active layer for making mechanical-to-electric energy conversion devices. The effects of PVDF concentration and electrospinning parameters (e.g. applied voltage, spinning distance), as well as nanofiber mat thickness on the fiber diameter, PVDF β crystal phase content, and mechanical-to-electrical energy conversion properties of the electrospun PVDF nanofiber mats were examined. It was interesting to find that finer uniform PVDF fibers showed higher β crystal phase content and hence, the energy harvesting devices had higher electrical outputs, regardless of changing the electrospinning parameters and PVDF concentration. The voltage output always changed in the same trend to the change of current output whatever the change trend was caused by the operating parameters or polymer concentration. Both voltage and current output changes followed a similar trend to the change of the β crystal phase content in the nanofibers. The nanofiber mat thickness influenced the device electrical output, and the maximum output was found on the 70 μm thick nanofiber mat. These results suggest that uniform PVDF nanofibers with smaller diameters and high β crystal phase content facilitate mechanical-to-electric energy conversion. The understanding obtained from this study may benefit the development of novel piezoelectric nanofibrous materials and devices for various energy uses.

Highly-twisted, continuous nanofibre yarns prepared by a hybrid needle-needleless electrospinning technique

Nanofibres prepared by electrospinning have shown enormous potential for various applications. They are obtained predominantly in the form of nonwoven fibre webs. The 2-dimensional nonwoven feature and fragility have considerably confined their further processing into fabrics through knitting or weaving. Nanofibre yarns, which are nanofibre bundles with continuous length and a twist feature, show improved tensile strength, offering opportunities for making 3-dimensional fibrous materials with precisely controlled fibrous architecture, porous features and fabric dimensions. Despite a few techniques having been developed for electrospinning nanofibre yarns, they are chiefly based on the needle electrospinning technique, which often has low nanofibre productivity. In this study, we for the first time report a nanofibre yarn electrospinning technique which combines both needle and needleless electrospinning. A rotating intermediate ring collector was employed to directly collect freshly-electrospun nanofibres into a fibrous cone, which was further drawn and twisted into a nanofibre yarn. This novel system was able to produce high tenacity yarn (tensile strength 128.9 MPa and max strain 222.1%) at a production rate of 240 m h^-1, with a twist level up to 4700 twists per metre. The effects of various parameters, e.g. position of the electrospinning units, operating conditions and polymer concentration, on nanofibre and yarn production were examined.

Use of airflow to improve the nanofibrous structure and quality of nanofibers from needleless electrospinning

Mass production of nanofibers from needleless electrospinning shows great potential in research and development of nanofibers. However, how to improve the electrospinning performance so as to achieve high quality nanofibers is still of great challenge. In this study, airflow has been applied to optimize upward needleless electrospinning from ring spinneret. Effects of airflow speed and the position of airflow on the nanofiber quality and production rate have been investigated. It has been found that thinner and more uniform nanofibers were produced when airflow was applied to needleless electrospinning system. It also improved the collected nonwoven membrane, resulting in better nanofibrous structure of the as-spun nanofibers. Application of airflow on needleless electrospinning would further benefit the development of mass production of nanofibers from needleless electrospinning.