System and method for automating production of electrospun textile products

Abstract

A system and method for producing a textile product which includes an insulated enclosure; an electrospinning dispensing system positioned along at least one face of the insulated enclosure; a solution supply system with a solution transport connection to the electrospinning dispensing system; a mold structure; a cyclical mold actuator mechanically coupled to the mold structure; and a charge unit electrically connected to the electrospinning dispensing system and the mold structure.

We claim: 
     
         1 . A system for producing a textile product comprising:
 an insulated enclosure;   an electrospinning dispensing system positioned along at least one face of the insulated enclosure;   a solution supply system with a solution transport connection to the electrospinning dispensing system;   a mold structure;   a cyclical mold actuator mechanically coupled to the mold structure; and   a charge unit electrically connected to the electrospinning dispensing system and the mold structure.   
     
     
         2 . The system of  claim 1 , wherein the mold structure comprises a mold fixture base that is interchangeably connectable to a mold collector. 
     
     
         3 . The system of  claim 2 , wherein the mold structure further comprises a first mold collector that is a two-dimensional projection mold and that is connectable to the mold fixture base. 
     
     
         4 . The system of  claim 3 , wherein the two-dimensional projection mold comprises convex and concave edges. 
     
     
         5 . The system of  claim 3 , wherein the two-dimensional projection mold comprises at least one surface feature. 
     
     
         6 . The method of  claim 5 , wherein the at least one surface feature is a feature cutout. 
     
     
         7 . The system of  claim 5 , wherein the at least one surface feature is a textured pattern on the surface of the two-dimensional projection mold. 
     
     
         8 . The system of  claim 2 , wherein the mold structure comprises a three-dimensional mold connectable to the mold fixture base. 
     
     
         9 . The system of  claim 1 , wherein the mold fixture base is interchangeably connectable to a two-dimensional projection mold; and wherein the electrospinning dispensing system comprises a first dispensing area directed at a first face of a connected two-dimensional projection mold and a second dispensing area is directed to a second face of the connected two-dimensional projection mold. 
     
     
         10 . The system of  claim 9 , wherein the cyclical mold actuator is a linear actuator with an oscillating motion along a defined axis in a plane defined by the first face. 
     
     
         11 . The system of  claim 1 , wherein the electrospinning dispensing system comprises an array of electrospinning dispensing nozzles 
     
     
         12 . The system of  claim 1 , wherein the solution supply system includes a solution cartridge system. 
     
     
         13 . The system of  claim 12 , wherein the solution cartridge system includes a solution cartridge with a first type of solution and a second solution cartridge with a second type of solution, wherein electrospun fiber produced from the first type of solution possess different fiber properties from electrospun fiber produced from the second type of solution. 
     
     
         14 . The system of  claim 1 , wherein the solution supply system includes a colorant system. 
     
     
         15 . A method for producing a textile product comprising:
 fixing a mold structure to a textile production system;   actuating the mold structure; and   executing an electrospinning process across at least one dispensing region onto the two-dimensional projection mold.   
     
     
         16 . The method of  claim 15 , wherein the mold structure is a two-dimensional projection mold. 
     
     
         17 . The method of  claim 16 , wherein executing the electrospinning process across at least one dispensing area comprises executing the electrospinning from a first array of nozzles that is arranged across a first dispensing region and from a second array of nozzles that is arranged across a second dispensing region, wherein electrospun fiber from the first array of nozzles is drawn towards a first face of the two-dimensional projection mold, and wherein electrospun fiber from the second array of nozzles is drawn towards a second face of the two-dimensional projection mold; and wherein at least one edge of the two-dimensional projection mold is a transition edge. 
     
     
         18 . The method of  claim 15 , wherein the mold structure is a three-dimensional mold. 
     
     
         19 . The method of  claim 15 , wherein executing an electrospinning process comprises controlling the electrospinning process in a fabric property transition mode, wherein the electrospinning process in the fabric property transition mode is applied to a defined region of the two dimensional projection mold. 
     
     
         20 . The method of  claim 19 , wherein the fabric property transition mode is configured for a transition of fabric type. 
     
     
         21 . The method of  claim 19 , wherein the fabric property transition mode is configured for a transition of fabric color. 
     
     
         22 . The method of  claim 19 , wherein the fabric property transition mode is a gradient transition mode. 
     
     
         23 . The method of  claim 19 , wherein the fabric property transition mode is a discrete transition mode.