Multiple passage extrusion apparatus

Abstract

The application relates to an extrusion apparatus which comprises at least one first reservoir connected at a first end to a first opening of a plurality of regulatory modules. The regulatory modules or spinnerets contain tubular passages through which dope material is extrudable. The extrusion apparatus has at least 1,000 of the tubular passages per square metre cross-section.

What is claimed is:  
     
         1 . Extrusion apparatus comprising at least one first reservoir fluidly connected at a first end to a first opening of a plurality of regulatory modules having passages, through which material is extrudable, wherein the extrusion apparatus has at least 1,000 passages per square meter cross-section.  
     
     
         2 . Extrusion apparatus according to  claim 1 , wherein the extrusion apparatus is a spinning apparatus.  
     
     
         3 . Extrusion apparatus according to  claim 2  wherein said apparatus is an electrospinning apparatus.  
     
     
         4 . Extrusion apparatus according to  claim 1 , wherein said passages are tubular.  
     
     
         5 . Extrusion apparatus according to  claim 1 , wherein at least one second reservoir is connected to the plurality of regulatory modules  
     
     
         6 . Extrusion apparatus according to  claim 5 , wherein the second reservoir is fluidly connected to at least one opening in at least one of the passages.  
     
     
         7 . Extrusion apparatus according to  claim 1 , further comprising one or more sensors.  
     
     
         8 . Extrusion apparatus according to  claim 7 , comprising at least one sensor selected from the following group of sensors: pressure sensors, temperature sensors, thermal conductivity sensors, thermal absorption sensors, molecular size sensors, viscosity sensors, rheology sensors, anisotropy sensors, mechanical modulus sensors, mechanical toughness sensors, ultrasound sensors, chemical sensors, pH sensors, electrical conductivity sensors, light-absorption sensors, refractive index sensors, sensors for measuring light-scattering, morphological sensors, infra-red absorption sensors and rapid Fourier Transform Infra Red sensors.  
     
     
         9 . Extrusion apparatus according to  claim 7 , wherein one or more of said regulatory modules comprise at least one sensor.  
     
     
         10 . Extrusion apparatus according to  claim 9 , wherein said sensor is integral to said one or more of said regulatory modules.  
     
     
         11 . Extrusion apparatus according to  claim 1 , wherein the regulatory modules additionally comprise one or more pumps.  
     
     
         12 . Extrusion apparatus according to  claim 11 , wherein said one or more pumps comprise a pump selected from the group of pumps consisting of piezo-electric pumps, peristaltic pumps and vibration pumps.  
     
     
         13 . Extrusion apparatus according to  claim 1 , wherein said passages further comprise flow inlets.  
     
     
         14 . Extrusion apparatus according to  claim 13 , said one or more flow inlets comprise at least one concentrically arranged flow inlet.  
     
     
         15 . Extrusion apparatus according to  claim 1 , wherein at least part of one wall of each of said passages is permeable.  
     
     
         16 . Extrusion apparatus according to  claim 1 , wherein at least part of one wall of each of said passages is semipermeable.  
     
     
         17 . Extrusion apparatus according to  claim 1 , wherein the regulatory modules are at least partly formed by injection molding.  
     
     
         18 . Extrusion apparatus according to  claim 1 , wherein the regulatory modules are at least partly formed by ablasion.  
     
     
         19 . Extrusion apparatus according to  claim 1 , wherein the regulatory modules are at least partly formed by a lost wax process.  
     
     
         20 . Extrusion apparatus according to  claim 1 , wherein, in operation, said material is drawn down within the individual passages at a first distance that is at least 0.05 mm from an outer exit opening.  
     
     
         21 . Extrusion apparatus according to  claim 20 , wherein said first distance is at least 0.5 mm from an outer exit opening.  
     
     
         22 . Extrusion apparatus according to  claim 1 , wherein a component of said material in an initial zone of one of the said passages forms rod-shaped units that are substantially perpendicular to at least one wall of said one of the passages.  
     
     
         23 . Extrusion apparatus according to  claim 1 , wherein a component of said material in a subsequent zone of one of the said passages has rod-shaped units which tumble as said material flows within the one of the said passages.  
     
     
         24 . Extrusion apparatus according to  claim 1 , further comprising a ridged surface having a plurality of ridges on at least one wall of one of the passages.  
     
     
         25 . Extrusion apparatus according to  claim 24 , wherein the height of the ridges is less than 10% of the broadest cross-sectional dimension of said one of the passages.  
     
     
         26 . Extrusion apparatus according to  claim 24 , wherein the surface energy of the ridged surface is lower than the surface energy of said material.  
     
     
         27 . Extrusion apparatus according to  claim 24 , wherein said ridges are substantially oriented along a long axis of said one of the passages.  
     
     
         28 . Extrusion apparatus according to  claim 24 , wherein said ridges comprise hydrophobic material.  
     
     
         29 . Extrusion apparatus according to  claim 24 , wherein said ridges are coated with hydrophobic material.  
     
     
         30 . Extrusion apparatus according to  claim 24 , wherein, in operation, said material is drawn down substantially adjacent to the ridged surface.  
     
     
         31 . Extrusion apparatus according to  claim 1 , wherein said material is a liquid crystalline polymer.  
     
     
         32 . Extrusion apparatus according to  claim 1 , further comprising cleaning apparatus.  
     
     
         33 . Extrusion apparatus according to  claim 32 , wherein said cleaning apparatus comprises a permeable wall of the passage, through which cleaning agents are introduced.  
     
     
         34 . Extrusion apparatus according to  claim 33 , wherein the cleaning agents are alkaline fluids.  
     
     
         35 . Extrusion apparatus according to  claim 1 , wherein said first reservoir is capable of containing a dope that provides material to be extruded.  
     
     
         36 . Extrusion apparatus according to  claim 35 , wherein said dope comprises a protein solution.  
     
     
         37 . Extrusion apparatus according to  claim 36 , wherein the protein of said protein solution is selected from the following group: 
 (a) recombinant spider silk proteins;    (b) analogs of recombinant spider silk proteins;    (c) recombinant silk-worm silk proteins;    (d) analogs of recombinant silk-worm silk proteins;    (e) regenerated silk solution from silk-worm silk; and    (f) mixtures of (a) to (e).    
     
     
         38 . Extrusion apparatus according to  claim 37 , wherein said dope in said first reservoir is stored in said first reservoir at a pH value above the gelling pH of said protein.  
     
     
         39 . Extrusion apparatus according to  claim 7 , further comprising a microprocessor connected to said sensor.  
     
     
         40 . Extrusion apparatus according to  claim 39 , wherein the microprocessor has an output for sending signals to regulate at least one parameter of the extrusion apparatus.  
     
     
         41 . Extrusion apparatus according to  claim 39 , wherein said microprocessor is integral to the plurality regulatory modules.  
     
     
         42 . Extrusion apparatus according to  claim 1 , wherein said apparatus is produced by a process comprising the following steps: 
 (a) covering an electrically-conductive base plate with a layer of resist;    (b) forming a resist pattern in the resist by means selected from lithographic processes and radiation ablation processes;    (c) placing a layer of metal over the resist pattern using an electroformation means;    (d) removing said base plate and dissolving the remaining resist pattern to produce a mold insert; and    (e) filling the mold insert with plastic molding compound to mold the extrusion apparatus.    
     
     
         43 . Object formed from the material extruded by the extrusion apparatus according to  claim 1.