Multi-nozzle gas-assisted electrospinning apparatuses

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.

What is claimed is: 
     
         1 . A system comprising a plurality of nozzles, and one or more power source:
 the one or more power source being configured to provide a voltage to each of the plurality of nozzles; and   each of the plurality of nozzles 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, the first inlet end being in fluid contact with a reservoir via a first supply component, 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 diameter (d 2 ), the second conduit having a second inlet end and a second outlet end, and the second inlet end being in fluid contact with a gas pump or a pressurized canister via a second supply component, 
 the exterior surface of the first wall and the interior surface of the second wall being separated by a conduit gap (d 4 ), 
 the first and second conduit having a conduit overlap length, wherein the first conduit is positioned inside the second conduit (l 1 ), 
 wherein the first supply component comprises a wall non-parallel to the first conduit with an angle of greater than 5 degree from parallel; and/or 
 the second supply component comprises a wall non-parallel to the second conduit with an angle of greater than 5 degree from parallel. 
   
     
     
         2 . The system of  claim 1 , wherein d 4 /d 2  is 0.2 or less. 
     
     
         3 . The system of  claim 1 , wherein the first and second conduit having a conduit overlap length, wherein the first conduit is positioned inside the second conduit (l 1 ), and wherein l 1 /d 2  is about 13 or more. 
     
     
         4 . The system of  claim 3 , wherein l 1 /d 2  is about 15 or more. 
     
     
         5 . The system of  claim 1 , wherein the first outlet end protruding beyond the second outlet end by a protrusion length (l 2 ), wherein l 2 /d 2  is about 0.5 or less. 
     
     
         6 . A system comprising a plurality of nozzles, and one or more power source:
 the one or more power source being configured to provide a voltage to each of the plurality of nozzles; and   each of the plurality of nozzles 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, the first inlet end being in fluid contact with a reservoir via a first supply component, 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 diameter (d 2 ), the second conduit having a second inlet end and a second outlet end, and the second inlet end being in fluid contact with a gas tank, a gas pump or a pressurized canister via a second supply component, 
 the exterior surface of the first wall and the interior surface of the second wall being separated by a conduit gap (d 4 ), wherein d 4 /d 2  is 0.2 or less; 
 the first and second conduit having a conduit overlap length, wherein the first conduit is positioned inside the second conduit (l 1 ), wherein l 1 /d 2  is about 10 or more; and the first outlet end protruding beyond the second outlet end, and the first outlet end protruding beyond the second outlet end by a protrusion length (l 2 ), wherein l 2 /d 2  is about 0.5 or less. 
   
     
     
         7 . A system comprising one or more nozzle, one or more power source, and at least two supply chambers:
 the one or more power source being configured to provide a voltage to each of the plurality of nozzles; and   each of the one or more nozzles 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 supply end and a first outlet end, the first supply end is fluidly connected to a first supply chamber of the at least two supply chamber via a first supply component, the first conduit having a diameter (d 1 ); 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 supply end and a second outlet end, the second supply end is fluidly connected to a second supply chamber of the at least two supply chamber via a second supply component, the second conduit having a diameter (d 2 ); 
 wherein the first conduit is positioned inside the second conduit such that the first conduit and the second conduit having a conduit overlap length (l 1 ). 
   
     
     
         8 . The system of  claim 7 , wherein the first conduit and the second conduit are concentrically arranged within 10 degrees of a common axis. 
     
     
         9 . The system of  claim 7 , wherein the first supply component and the second supply component are substantially concentrically arranged. 
     
     
         10 . The system of  claim 7 , wherein at least a portion of the first supply component has a diameter larger than the diameter of the first conduit d 1 , and at least a portion of the second supply component has a diameter larger than the diameter of the second conduit d 2 . 
     
     
         11 . The system of  claim 7 , wherein the first supply component is positioned inside the second supply component with at least a portion overlapped along a common axis. 
     
     
         12 . The system of  claim 7 , wherein the second supply component is positioned under the first supply component with or without overlap. 
     
     
         13 . The system of  claim 7 , wherein the first conduit has substantially parallel walls and the first supply component has substantially non-parallel walls, and/or wherein the second conduit has substantially parallel walls and the second supply component has substantially non-parallel walls. 
     
     
         14 . The system of  claim 7 , wherein the first supply component comprises a wall non-parallel to the first conduit with an angle of greater than 5 degree from parallel; and/or the second supply component comprises a wall non-parallel to the second conduit with an angle of greater than 5 degree from parallel. 
     
     
         15 . The system of  claim 7 , wherein the first supply chamber supplies a liquid polymer composition and wherein the second supply chamber supplies pressurized gas. 
     
     
         16 . The system of  claim 7 , wherein each of the one or more nozzles further comprises a third conduit comprising a third supply end and a third outlet end, and the third supply end is fluidly connected to a third supply chamber via a third supply component. 
     
     
         17 . The system of  claim 16 , wherein the first, second, and third conduits are aligned substantially along a common axis with at least a portion overlapped and wherein the first, second and third supply components are aligned substantially along the common axis without overlap among the first, second and third supply components. 
     
     
         18 . The system of  claim 7 , wherein the first conduit protrudes beyond the end of the second conduit by a protrusion length of 0 mm to about 5 mm. 
     
     
         19 . The system of  claim 7 , further comprising a housing that contains at least two supply chambers including the first supply chamber, the second supply chamber and optionally a third supply chamber. 
     
     
         20 . The system of  claim 7 , wherein a cross-dimensional shape of the first and/or the second conduit is circular, elliptical or polygonal, and optionally different at different points along the first and/or the second conduit.