Electrospinning apparatuses & processes

Abstract

Provided herein are electrospinning systems, apparatuses, components, and processes for the preparation of nanofibers, including high throughput systems, apparatuses, and processes for producing high performance nanofibers.

We claim: 
     
         1 . A system comprising a plurality of electrospinning nozzle components, each of the plurality of electrospinning nozzle components comprising:
 a. a first conduit, the first conduit being enclosed along the length of the conduit by a first wall having an interior surface and an exterior surface, the first conduit having a first inlet end and a first outlet end, and the first conduit having a first diameter; and   b. a second conduit, the second conduit being enclosed along the length of the conduit by a second wall having an interior surface, the second conduit having a second inlet end and a second outlet end, and the second conduit having a second diameter;   the first and second conduit having a conduit overlap length, wherein the first conduit is positioned inside the second conduit, the exterior surface of the first wall and the interior surface of the second wall being separated by a conduit gap, the first outlet end protruding beyond the second outlet end by a protrusion length, and wherein:
 i. the ratio of the conduit overlap length-to-second diameter is about 10 or more, and/or 
 ii. the ratio of the average conduit gap-to-second diameter about 0.25 or less, and/or 
 iii. the ratio of the protrusion length-to-second diameter is about 0.3 or less. 
   
     
     
         2 . The system of  claim 1 , wherein each of the plurality of electrospinning nozzle components therein comprises at least two of the groups consisting of:
 a. a ratio of the conduit overlap length-to-second diameter of about 10 or more,   b. a ratio of the average conduit gap-to-second diameter of about 0.2 or less, and   c. a ratio of the protrusion length-to-second diameter of about 0.3 or less.   
     
     
         3 . The system of  claim 1 , wherein each of the plurality of electrospinning nozzle components thereof comprises:
 i. a ratio of the conduit overlap length-to-second diameter is about 10 or more,   ii. a ratio of the average conduit gap-to-second diameter about 0.2 or less, and   iii. a ratio of the protrusion length-to-second diameter is about 0.3 or less.   
     
     
         4 . The system of  claim 1 , wherein the ratio of the distance between adjacent nozzles-to-second diameter is about 0.5 to about 10. 
     
     
         5 . The system of  claim 2 , wherein the ratio of the distance between adjacent nozzles-to-second diameter is about 0.5 to about 10. 
     
     
         6 . The system of  claim 3 , wherein the ratio of the distance between adjacent nozzles-to-second diameter is about 0.5 to about 10. 
     
     
         7 . The system of  claim 1 , wherein the first conduit is configured to receive liquid polymer. 
     
     
         8 . The system of  claim 2 , wherein the first conduit is configured to receive liquid polymer. 
     
     
         9 . The system of  claim 3 , wherein the first conduit is configured to receive liquid polymer. 
     
     
         10 . The system of  claim 7 , wherein the second conduit is configured to receive a pressurized gas. 
     
     
         11 . The system of  claim 8 , wherein the second conduit is configured to receive a pressurized gas. 
     
     
         12 . The system of  claim 9 , wherein the second conduit is configured to receive a pressurized gas. 
     
     
         13 . The system of  claim 1 , wherein the ratio of the conduit overlap length-to-second diameter is about 13 or more. 
     
     
         14 . The system of  claim 2 , wherein the ratio of the conduit overlap length-to-second diameter is about 13 or more. 
     
     
         15 . The system of  claim 3 , wherein the ratio of the conduit overlap length-to-second diameter is about 13 or more. 
     
     
         16 . The system of  claim 1 , wherein the ratio of the average conduit gap-to-second diameter about 0.1 or less. 
     
     
         17 . The system of  claim 2 , wherein the ratio of the average conduit gap-to-second diameter about 0.1 or less. 
     
     
         18 . The system of  claim 3 , wherein the ratio of the average conduit gap-to-second diameter about 0.1 or less. 
     
     
         19 . The system of  claim 3 , wherein the ratio of the conduit overlap length-to-second diameter is about 18 or more, the ratio of the average conduit gap-to-second diameter about 0.05 or less, and the ratio of the protrusion length-to-second diameter is about 0.3 or less. 
     
     
         20 . The system of  claim 6 , wherein the ratio of the conduit overlap length-to-second diameter is about 18 or more, the ratio of the average conduit gap-to-second diameter about 0.05 or less, and the ratio of the protrusion length-to-second diameter is about 0.3 or less. 
     
     
         21 . The system of  claim 1 , wherein the first and second conduits are cylindrical. 
     
     
         22 . The system of  claim 21 , wherein the first conduit and the first wall, taken together, form a first needle, and the second conduit and the second wall, taken together, form a second needle. 
     
     
         23 . The system of  claim 1 , wherein the first diameter being about 0.05 mm to about 3 mm and the second diameter being about 0.1 mm to about 5 mm. 
     
     
         24 . The system of  claim 2 , wherein the first diameter being about 0.05 mm to about 3 mm and the second diameter being about 0.1 mm to about 5 mm. 
     
     
         25 . The system of  claim 3 , wherein the first diameter being about 0.05 mm to about 3 mm and the second diameter being about 0.1 mm to about 5 mm. 
     
     
         26 . The system of  claim 1 , wherein the conduit gap is on average 0.5 mm or less. 
     
     
         27 . The system of  claim 2 , wherein the conduit gap is on average 0.5 mm or less. 
     
     
         28 . The system of  claim 25 , wherein the conduit gap is on average 0.5 mm or less. 
     
     
         29 . The system of  claim 12 , wherein the nozzle is configured to receive a voltage. 
     
     
         30 . A process for electrospinning a nanofiber, the process comprising:
 a. providing a liquid polymer composition to a system comprising a plurality of electrospinning nozzle components, each of the plurality of electrospinning nozzle components comprising:
 a first conduit, the first conduit being enclosed along the length of the conduit by a first wall having an interior surface and an exterior surface, the first conduit having a first inlet end and a first outlet end, and the first conduit having a first diameter, and 
 a second conduit, the second conduit being enclosed along the length of the conduit by a second wall having an interior surface, the second conduit having a second inlet end and a second outlet end, and the second conduit having a second diameter; 
 the first and second conduit having a conduit overlap length, wherein the first conduit is positioned inside the second conduit, the exterior surface of the first wall and the interior surface of the second wall being separated by a conduit gap, the first outlet end protruding beyond the second outlet end by a protrusion length, and wherein (i) the ratio of the conduit overlap length-to-second diameter is about 10 or more, and the ratio of the average conduit gap-to-second diameter about 0.2 or less; 
    the liquid polymer being provided to the first inlet end of at least one nozzle component of the system;   b. providing a pressurized gas to the second inlet end of the at least one nozzle component; and   c. applying a voltage to the at least one nozzle component.