Advances in Polymer Melt Differential Electrospinning · MD-ESP NANOStruc 2014 International...
Transcript of Advances in Polymer Melt Differential Electrospinning · MD-ESP NANOStruc 2014 International...
MD-ESP
NANOStruc 2014
International Conference on Structural Nano Composites,20-21 May 2014 in Madrid, Spain
(Email:[email protected])
Advances in Polymer Melt
Differential Electrospinning
Yinglan Laboratory
Beijing University of Chemical Technology
李好义(Haoyi Li)
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MD-ESP
1. Research Background
2. Electrospinning
3. New Solution: Melt Differential Electrospinning
4. Recent Results in Pilot Line
5. Applications and Future Prospects
Content
MD-ESP Polymer Nanofiber
comparison between electrospun
fibers and traditional fibers. selectrospun fabirc-oriented . electrospun fabric-
nonwoven.
MD-ESP Applications of Polymer Nanofiber
Air Filtration Water Treatment Lithium Battery
Membrane
Nonwoven with
Special Functionalities Tissue Engineering Catalyst Loading Material
MD-ESP Electrospinning and Nanofiber
Comparison on Existing Preparation
Technology of Polymer Nanofibers
MD-ESP
1 Solvent-free, environmental-friendly, simple.
Polymers such as PP, PE, PPS which can not
find solvent at room temperature is spinnable .
2 No evaporation of solvent, 100% conversion
rate. Productivity of MESP is one order of
magnitude higher than that of SESP at the
same condition.
3 No defects are left because of the evaporation
of solvents, fiber surface is smooth and exhibit
higher mechanical strength.
Comparison between MESP and SESP
Melt Electrospinning Solution Electrospinning
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MD-ESP
1. Research Background
2. Electrospinning
3. Melt Differential Electrospinning
4. Recent Results in Pilot Line
5. Application and Future Prospects
Report content
MD-ESP
Basic Principle of
Electrspinning
Introduction into Electrospinning
Polymer
Solution/Melt Polarization
of Molecular
Chains
Overcome
Surface
Tension
Solvent
Evaporatin
g, Melt
Solidifying
High-
Voltage
Electric
Field
Collected
Indirectly or
by Electrode
Common View in Academia:
the road to industrialized
production of nanofibers:
electrospinning
MD-ESP Popularity of Electrosinning
2 4 3 3 17 6 12 13 24 28 3289277 320
492770969
14301769
2431
28503041
0
500
1000
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2000
2500
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35002002
2003
2004
2005
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2008
2009
2010
2011
2012
熔体静电纺丝文献数量
溶液静电纺丝文献数量
1
6758
6 51118 17
32
0
15
30
45
60
75
2004
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Image on the left is based on SciFinder, showing the number of published papers (until 2012), image on the right is based on Dingxianghua Foundation Searching Platform, showing the number of NSFC programs (until 2012).
The number of published papers on solution electrospinning is
100 times that on melt electrospinning.
number of papers on melt
electrospinning
number of papers on solution
electrospinning
MD-ESP Progress in Solution Electrospinning
Multi-needle Needleless
Participators: DuPont's facility in South Korea; NFTC - Nanofibre Future Technologies Corporation; NanoStatics Corporation & Texas Tech University; Donalson CO; KX Industries; Hills Inc; Rieter; Fanacaran nano-meghyas, Iran; Xiaohong Qin Team, Donghua University; Haoqing Hou team, Jiangxi Xiancai Nanofiber Technology Ltd.
Participator: Czech Elmarco (100 sold out, sales volume billion)
Low productivity
Easy to be blocked
Hard to maintain
No Blockage
Discontinuous solution supply
Limited mechanical strength
of nonwoven
MD-ESP Progress in Melt Electrospinning
In 1981, Larrondo and Manley firstly fabricate PP, PE nanofibers with hundreds of microns in diameter using melt elecrospinning.
In 2001, Reneker and Rangkupan reported the melt electrospinning of PP, PE, PET and PEN in a container in their review.
A large part of research is based on electrospinning device with a single needle as its nozzle.
Syringe-type Electrospinning Device:
Needle Based Melt Electrospinning Device Multi-needle Based Melt Electrospinning Device Manufactured by ITAAachen in Germany
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MD-ESP
Naoki Shimada et al put a polymer sheet under the adjusted laser beam and melt the polymer sheet along its length, then several Taylor cons will be formed along a single line with interjet distance of 4-6 mm. But this method still faces the issues of high cost and low production and its safety has to be assessed, so mass production of nanofibers by this method still doom.
Schematic of slit-type electrospinning device, Analysis on electric field distribution, Flying jets in experiment
Czech Republic University proposed an idea of cleft-type electrospinning device, melt didn't distributed uniformly along the cleft. Furthermore, the number of Taylor cones were not enough to be applied into mass production.
Needleless electrospinning device:
Progress in melt electrospinning
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When free surface electrospinning method was applied to melt electrospinning, problems such as high threshod voltage, easy degradability of melt, poor continuous production are emerging.
NEEDLE or Capillary to
NEEDLELESSS NOZZLE
Method
MD-ESP
High dielectric properties
of polymer melts;
High viscosity;
Safety issues associated
with high voltage;
Hard to control micro-flow rate precisely during mass production
Solution Electrospinning
0.8-4Pa.s 40-200Pa.s
10-6-10-2S/cm
10-11-10-13S/cm
Less than 20kv,
40-100kv,
0.1-1g/h*needle
0.01-10g/h*needle
Technical Difficulties in Melt Electrospinning
Melt Electrospinning
MD-ESP
Realize the mass-production of polymer superfine fibers
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MD-ESP
1. Research Background
2. Electrospinning
3. New solution: Melt Differential Electrospinning
4. Recent Results in Pilot Line
5. Application and Future Prospects
Report Content
MD-ESP
Miniature extruder
Schematic of Melt Differential Electrospinning
Melt Differential Electrospinning
TPU
Connical surface of nozzle
multiple taylor cones
collector
MD-ESP Designing
Split-flow and Multi-flow of Melt Differential Technique (The Idea of Calculus)
Solution: Peculiar Structure of Spinning Die Head Assembly
First Split-flow on the runner of Injection Moulding Machine
Second Split-flow on Inner Connical Surface
of the Nozzle
Hot air has a Thinning Effect on the Melt
+ Assisted by Hot Air
Smallest Inter-jet Distance Can Reach 1.1 mm
MD-ESP
High voltage is applied to nozzle, which makes heating of polymer melts complicated and restricts the research on industrialization.
Japan academic magzine Molding Processing highlights the importance of electrode inversion in their overview on electrospinning.
Designing
MD-ESP
PP Processing Using MD-ESP
Experimental Prototype of MD-ESP
Designing
MD-ESP Experimental
Inter-jet distance --productivity
MD-ESP Experimental
Interpjet distance --productivity
Li H, Chen H, Zhong X, et al. Journal of Applied Polymer Science, 2014, 131(15).
MD-ESP Experimental
Hot air assistance--finner fiber
Without hot air: 5.6 μm
Hot air assisted: 1.4μm Hot air assisted: 2.4μm
MD-ESP Experimental
Hyperbranched polyester as viscosity-reducing modifiers:
Absence of hyperbranched resin PP 5-6μm
Presence of hyperbranched resin PP 1-2μm
MD-ESP Experimental
Stearic acid viscosity-reducing modifiers:
Presence of 8% Stearic acid PP 1.65μm
Zhiyuan C, He J, Fengwen Z, et al Journal of
the Serbian Chemical Society, 2013 (00): 150-
150.
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MD-ESP
1. Research Background
2. Electrospinning
3. New solution: Melt Differential Electrospinning
4. Results in Pilot Line
5. Application and Future Prospects
Report Content
MD-ESP
Basic Features: 32 Melt-differential Nozzles are integrated; Breadth: 0.8 m, output:300- 600g/h; Average Fiber Diameter: 500-800nm; Nonwoven Thickness: 10-1000μm (controllable)
Operating Speed: 1-10 m/min; Continuous Supply of the Melt; Electrospinning of Polymer blending; Modularly extendable
Pilot Prototype of MD-ESP
MD-ESP Pilot Prototype of MD-ESP in Operation
MD-ESP
Pilot Prototype of MD-ESP in Running Microphotograph of MD-ESP Fibers SEM Images of MD-ESP Fibers: D=645nm
Electrospinning Process of Nanospiders
Microphotograph of S-ESP Fibers by Reneker
SEM Images of Respirator by 3M
MD-ESP
S-ESP
Spinning Effects of MD-ESP
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MD-ESP
1. Research Background
2. Electrospinning
3. New solution: Melt Differential Electrospinning
4. Recent Results in Pilot Line
5. Application and Future Prospects
Report Content
M-ESP
PM2.5 Shelter Easy for rechange; Low pressure drop; Efficient isolation of outdoor tiny particles; Highly recycable.
Applications
High efficient PP oil sorbent Reused for over a hundred times.High oil sorption capacity (129 g/g, 6 to 7 times that of traditional melt blown fabirc); Reused for over a hundred times.
MD-ESP
Lithium Battery Membrane PP superfine fibrous membrane; Membrane thickness: 20-60μm; Melting point: 160℃; Porosity > 80%.
Thermal Insulation Material Dust absorption and thermal insulation; Acid and alkali resistant; Ventilated and and hydrophobic; Soft and light.
Medical Dressing Bio-compatible material like PlA and PCL; No toxic solvent residue; soft and comfortable; recycable and bio-degradable.
Filtration membrane for water treatment Operating
Temperature: 5-80 ℃;
Filtration Efficiency
for 0.3μm particles:
99.9%;
Acid and Alkali
Resistant(ph:1-14),Ethanol Resistant.
Potencial applications
J Appl Polym Sci, Vol.125,2012 J Mater Sci, Vol. 46, 2011
Polym Engine Sci, Vol.50, 2010
J Non-Newtonian Fluid Mech,Vol.202, 2013 J Appl Polym Sci, Vol.131, 2014
MD-ESP Published Papers
J Appl Polym Sci, Vol.131,2014 Desalination, Vol.344,2014
J Appl Polym Sci, Vol.114,2009
MD-ESP
Multi-layer nowoven mebrane combining s-ESP and m-ESP
What we are doing
3D-Printing using m-ESP head.
3D multi-level structure built using m-ESPUN fiber(micro scale) twined by s-ESPUN
MD-ESP
Thanks for Your Participation!
Questions or Suggestions are
welcome!
(Email:[email protected])