JP2006524739A - Apparatus and method for electrostatic processing of polymer blends - Google Patents

Abstract

Apparatus and methods are provided that are useful for continuously electrostatically processing polymer blends. The apparatus includes an input stage operable to continuously eject electrostatically processed material and an integration stage on which the ejected material is accumulated. The apparatus includes a device for continuously removing deposited electrostatic processing material from the integration stage. The apparatus can optionally include a pick-up stage operable to wind up the removed electrostatic processing material. A processing stage can be provided for applying a substance to the material to change the properties of the electromechanical material and / or physically processing the material, such as rolling or heating. The electrostatic processing material can have microscale or nanoscale dimensions.

Description

  Electrostatic processing techniques use electrostatic forces to draw a charged polymer formulation from a source to a collector. The electrostatic force functions to accelerate the liquid from the source to the collector where the electrostatic processing material is integrated.

Larondo, L .; And S. John Manley, J "Electrospinning with polymer melt, I. Experimental observation of fiber formation and properties", Journal of Polymer Science, Polymer Phisics Ed. , Vol. 19, (1981) 909-920

Apparatus and methods are provided for electrostatic processing polymer blends. The apparatus and method can perform continuous production of electrostatically processed materials.
A preferred embodiment of an apparatus for electrostatically processing a polymer formulation includes an input stage operable to continuously eject an electrostatically processed material containing the polymer compound and an integration spaced from the input stage. A stage, a power supply operable to generate an electric field for depositing the electrostatic processing material ejected from the input stage on the integration stage, and an extraction device arranged to continuously extract the electrostatic processing material from the integration stage And a pickup stage.

  Polymer formulations that can be electrostatically processed using the preferred embodiments of the apparatus and method of the present invention include polymer solutions, dispersions, suspensions, emulsions, mixtures thereof, and polymer melts. The electromechanical material can have a variety of forms including fibers, droplets, beads, thin films, dry porous thin films, webs, mats and / or combinations thereof. The electrostatic processing material preferably has at least one microscale or nanoscale dimension.

  Another preferred embodiment of the apparatus of the present invention comprises a processing stage operable to process the electromechanical material at and / or after being removed from the integration stage. For example, the material can be heated, cured, rolled, cut, stretched, and / or treated to change the chemical structure of the surface. The processing stage can also be operable to apply one or more substances to the electrostatic processing material.

  Another preferred embodiment of the apparatus comprises at least one thickness sensor and / or a looseness sensor that detects the thickness and / or amount of looseness of the electromechanical material. The apparatus can include a controller operable to receive a signal from the sensor to adjust the integration stage and / or the pickup stage and maintain a required thickness and / or amount of slack as needed.

  A preferred embodiment of a method for electrostatically processing a polymer formulation includes the steps of generating an electric field, supplying a polymer formulation to the input stage, and continuously supplying the electrostatically processed material from the input stage via the electric field. The step of ejecting, the step of accumulating the electrostatic machining material at the accumulation stage, and the step of continuously removing the electrostatic machining material from the accumulation stage are included.

  Preferred embodiments of the apparatus and method for electrostatic processing of polymer blends can provide continuous production of electrostatic processed materials. The electroprocessed material can be in various forms including, but not limited to, fibers, droplets, beads, thin films, dry porous films, webs, mats, and / or combinations thereof.

  The electrostatic processing material can be a microscale or nanoscale material. The terms “microscale” and “nanoscale” as used herein refer to materials having at least one microscale dimension or at least one nanoscale dimension, respectively. The dimensions can be, for example, diameter, maximum lateral dimension, length, width, and / or height. The electrostatic processing material can also have a composition, structure and properties that can be varied by selecting starting materials and / or processing conditions.

  As used herein, the term “electrostatic machining” means an electrostatic spinning (electrospinning) method and an electrostatic spraying (electrospray) method. Electrospinning produces fibers and electrostatic spraying produces droplets or clusters of droplets. Such fibers accumulate continuously on the accumulation stage, while droplets or clusters of droplets accumulate in individual droplets on the accumulation stage.

  Electrostatically processed materials allow polymer formulations to be electrostatically modified by adjusting the constituents of the polymer system and / or changing various processing parameters such as applied voltage, distance from input stage to integration stage, volume flow rate, etc. It can be formed by spinning or electrostatic spraying. In addition, either electrospinning or spraying of the polymer formulation can be controlled by changing the physical properties of the polymer formulation, such as concentration changes, solvent selection, polymer molecular weight, polymer branching, and the like.

  A preferred embodiment of an apparatus 20 for electrostatic processing polymer blends is shown in FIG. The apparatus 20 includes an input stage 30 and an accumulation stage 40. The apparatus 20 also preferably includes a pick-up stage as will be described below. The apparatus 20 can also optionally include an integrated post-processing stage as described below.

  The input stage 30 operates to continuously eject the polymer blend 45 to be electrostatically processed. As will be described below, the input stage 30 may comprise a single input device or alternatively multiple input devices. The electrostatic processing material 72 is deposited on the integration stage and is preferably continuously removed from the stage. The polymer blend can be a polymer solution, dispersion, suspension, emulsion, mixture thereof, or polymer melt. The polymer blend can include a one-phase system or a two-phase system. Exemplary polymer formulations include, but are not limited to, acetylcellulose, poly (ethylene-co-vinyl acetate), polylactic acid, and blends thereof, polyacrylonitrile, polyaniline-sulfonated styrene, polyaniline, polyester, polyethylene terephthalate. , Polypropylene, polyethylene and blends thereof. Exemplary suitable solvents for polymer formulations include, but are not limited to, water for aqueous solvent based polymer formulations and organic solvents such as acetone and alcohol for organic solvent based polymer formulations. Including.

  The polymer melt can be prepared and electrostatically processed by techniques known to those skilled in the art. Preparation techniques can include premixing and melting the polymer components, such as by melt mixing in a heated extrusion apparatus. Electrostatic machining techniques are described in, for example, Larondo, L .; And S. John Manley, J "Electrospinning with polymer melt, I. Experimental observation of fiber formation and properties", Journal of Polymer Science, Polymer Phisics Ed. , Vol. 19, (1981) 909-920, which is incorporated herein by reference in its entirety.

  In this embodiment, the making stage 30 is electrically connected to a power supply device 50 that applies a voltage to the making stage. The power supply 50 can be a DC or AC power supply. In this embodiment, the integration stage 40 is at ground potential. An electric field can be generated in the space between the input stage and the integrated stage by applying a sufficiently high voltage to the input stage 30 with the integrated stage 40 at the ground potential. The input stage 30 and the integration stage 40 are sufficiently close to each other to generate sufficient electric field strength to initiate electrostatic processing of the polymer blend. The input stage 30 operates to introduce the polymer blend 45 into the electric field. The electric field produces an electrostatic force that draws the polymer formulation through the space from the input stage 30 to the integration stage 40, especially when the transition from electrostatic spraying to electrostatic spinning occurs during processing of the polymer formulation. The polymer blend is deposited at the accumulation stage to form a structure composed of fibers, droplets, and / or fibers and / or droplets. Depending on the polymer formulation, the transition from electrostatic spraying to electrospinning may or may not occur as the polymer concentration in the polymer formulation increases.

  A preferred embodiment of the input stage 30 is shown in FIG. The input stage 30 includes an input device 130 that includes a channel 132 in fluid communication with a manifold 134. Manifold 134 may include a single nozzle, or preferably a plurality of nozzles, as shown. The nozzles 136 can be arranged parallel to each other as shown, or can have other desired orientations. The nozzles 136 can be arranged in a horizontal plane as shown, or alternatively can be arranged at various angles relative to the horizontal to change the direction of impact of the electrostatic processing material on the integration stage 40.

  The number of nozzles 136 in the manifold 134 can be selected based on various factors such as the required throughput of fibers from the input device 130 or the dimensions of the integration surface of the integration stage on which the polymer is deposited. The number of nozzles 136 in the manifold 134 and / or the number of manifolds 134 that include the nozzle 136 can be increased in the apparatus to increase the throughput of the electrostatically processed material.

  In addition, the dimensions of the nozzle 136 openings in the manifold 134 can be the same as each other, or two or more nozzles can have different sized openings. The nozzle 136 can have a suitable nozzle opening size and length that produces a jet or spray of polymer blend with the required properties.

  The polymer blend is supplied from the source 138 to the input device flow path 132 in fluid communication with the flow path 132. The source 138 preferably has a volume of polymer blend that is sufficiently large to allow the required amount of electrostatic processing material to be continuously produced by operation of the apparatus.

  The input stage 30 preferably includes at least one pump 137 between the source 138 and the flow path 132. The pump 137 is preferably operated to supply the polymer blend to the manifold 134 at a controlled rate, thereby controlling the rate of ejection of the polymer blend from the nozzle 136. Pump 137 can be used to feed a single manifold or alternatively two or more manifolds.

  In another preferred embodiment, the polymer blend is fed through one or more nozzles 136 of the manifold 134 using a variety of alternative feeding techniques including, for example, gravity, compressed air, piston motion, and the like. it can.

  FIG. 3 represents an input device 230 according to another preferred embodiment. The input device 230 is in fluid communication with a first source 238 of polymer blend, solvent, at least one optional active ingredient, or a mixture of solvent and at least one optional active ingredient. Second flow path in fluid communication with flow path 233 and a second source 239 of polymer blend, solvent, at least one optional active ingredient, or a mixture of solvent and at least one optional active ingredient. 235. The first and second polymer blends can be the same blend or different blends. The active ingredient can be, for example, at least one crosslinker, photoinitiator, thermal initiator or the like.

  The first flow path 233 and the second flow path 235 are in fluid communication with the flow path 232. The input device 230 operates to produce the electromechanical material from a single polymer blend or a two-component polymer blend. In particular, the same or different formulations can be introduced via the first flow path 233 and the second flow path 235, where the polymer formulations are mixed together to form a mixed polymer formulation. This is ejected from the nozzle 236. Alternatively, the polymer blend is supplied from the first source 238 or the second source 239 and the solvent or active ingredient is supplied from the other of the first source 238 or the second source 239, The polymer blend composition that affects the composition and / or processing characteristics of the polymer blend can be varied.

  In an embodiment, the input device 230 preferably includes a first pump 237 and a first valve 241, a second source 239 and a flow path 232 between the first source 238 and the flow path 232. With a second pump 240 and a second valve 243 to supply the contents of the first supply source 238 and the second supply source 239 to the manifold 234, preferably at a controlled flow rate, thereby charging Control the ejection rate of the polymer blend from one or more nozzles 236 of the device 230.

  If necessary, only solvent can flow from the first source 238 or the second source 239 to the manifold 234 to clean the nozzle.

  In a preferred embodiment, an in-line mixer 244 can be provided along the flow path 232 to facilitate mixing of the polymer blend prior to ejection from the nozzle 236.

  FIG. 4 represents an input device 330 according to another preferred embodiment. The dosing device 330 includes an open container 332 and a brush 340 that contain a polymer blend. The input device 330 also includes a polymer formulation delivery system 344 as shown in FIG. 3 that replenishes the polymer formulation in the container 332 as the polymer formulation is consumed during electrostatic processing.

  The brush 340 includes a plurality of bristles 342 made of a conductive material such as a metal or alloy. The brush 340 can be connected to a suitable drive source 345 such as a variable speed motor operable to rotate the brush 340 at the required speed as indicated by arrow A. The power supply device 346 can be electrically connected to the brush 340 such as the shaft portion 347. The power supply 346 can be either a DC or AC power supply. During rotation of the brush 340, the bristol 342 is wetted in contact with the polymer blend in the container 332, causing the polymer blend 45 to be ejected into the electric field.

  FIG. 5 shows an input device 430 according to another preferred embodiment. The dosing device 430 includes an alternative brush 440 and a container 430 that contains the polymer blend 45. The brush 440 includes a main body 442 and a bristol-like extending portion 444 extending outward from the main body 442. The brush 440 is made of a conductive metal or alloy. During the rotation of the brush 440 represented by arrow B, the stretch 444 is wetted in contact with the polymer blend 45 in the container 432 so that the polymer blend 45 is ejected into the electric field toward the accumulation stage. Attracted.

  An input device 530 according to another preferred embodiment is shown in FIG. The dosing device 530 includes a polymer formulation flow path 560, a cleaning liquid flow path 570, and a plurality of nozzles 581-588 extending outwardly from the surface 552. The number of nozzles of dosing device 530 can be variable to provide the required ejection pattern and throughput of the polymer blend. The polymer blend is supplied to the polymer blend flow path 560 from a source of the polymer blend. The cleaning liquid is supplied to the cleaning liquid flow path 570 from the supply source of the cleaning liquid.

  The dosing device 530 is rotatable as represented by arrow C so that the nozzles 581-588 are in sequential fluid communication with the polymer blend flow path 560 containing the polymer blend. As shown, when a dosing device 530 is in a particular angular orientation, a nozzle, such as nozzle 581, is in fluid communication with the polymer blend flow path 560, which allows the polymer blend to be ejected from the nozzle.

  The input device 530 includes a fixed mask 590 having an opening 591. The mask 590 is provided to cover the inlet end portions of the nozzles 581 to 588. In the illustrated position of the dosing device 530, the mask 590 covers the inlets of the nozzles 582-588 and prevents cleaning liquid from flowing into these nozzles. As the nozzle rotates over the location of the opening 591, the opening 591 supplies cleaning liquid to the nozzle. The cleaning liquid can flow into a nozzle 585 that is in fluid communication with the opening 591 of the mask 590 at the illustrated location of the dosing device 530. Accordingly, when the nozzles 581 to 588 are sequentially rotated on the mask, the cleaning liquid can be sequentially supplied to the nozzles 581 to 588.

  The cleaning liquid can be any suitable liquid that is effective to remove polymer material that may accumulate in the flow path of nozzles 581-588 during operation of dosing device 530. For example, the cleaning liquid can be water in a water-based polymer formulation, or it can be acetone, alcohol, or other organic solvent in a solvent-based polymer formulation. The cleaning liquid is flowed through the nozzles 581-588, preferably at high pressure, to facilitate removal of the deposited polymer material from the nozzle flow path. Accordingly, the nozzles 581-588 can be cleaned during operation of the dosing device 530 to more stably and homogeneously eject the polymer blend from the nozzle.

  The input stage 30 allows for the production of electrostatically engineered material structures such as mats or webs composed of different polymer materials, or to produce structures with different composition and / or density characteristics. One or more input devices such as the input devices 130, 230, 330, 430, and 530 described above may be included. The relative spatial arrangement of the different input devices of the input stage 30 can be selected to produce fibrous structures having different densities, configurations, or other characteristics relative to each other and the integration stage 40.

  The electric field can be generated between the input stage 30 and the integration stage 40 according to various preferred configurations. For example, a polymer formulation loading device can include a conductive portion that is electrically connected to an electrode of a power supply. The conductive portion can be, for example, the manifolds 134 (FIG. 2) and 234 (FIG. 3) of the input devices 130 and 230, respectively, or the brushes 340 (FIG. 4) and brush 440 (of the input devices 330 and 430, respectively. FIG. 5). Alternatively, the polymer formulation can be charged by placing electrodes within the polymer formulation flow path 560 of the input device 530.

  However, those skilled in the art will appreciate that, alternatively, the integration stage 40 can be charged with the input stage grounded to generate an electric field between the input stage and the integration stage. .

  A preferred embodiment of the device 100 is shown in FIG. The apparatus 100 includes an input device, such as the input device 230 described above, an integration stage 40, and a post-integration stage 60 downstream from the integration stage 40. As shown, the polymer blend 45 is ejected from the input device 230 onto the target 70 of the integrated device 40 and an electrostatic processing material 72 is formed on the outer surface 74 of the target 70 so that the electrostatic processing material is Accumulated at the pickup stage.

  The target 70 includes a body 76 that can have various shapes and dimensions. As shown, the body 76 can be a cylindrical roll having a cylindrical outer surface 74. Alternatively, the outer surface 74 of the body 76 can have other shapes, such as an ellipse. The outer surface 74 can include one or more flat and / or undulating portions (eg, including ridges and depressions, grooves, paths, etc.). The shape and / or surface structure of the outer surface 74 can be selected based on factors such as the required shape of the deposited polymer material.

  The body 76 of the target 70 can be solid, or alternatively it can be hollow to reduce the weight of the target 70. The body 76 can comprise a suitable conductive material such as aluminum, aluminum alloy, or similar metal. The target 70 can be made entirely of a conductive material, or alternatively can include an outer portion such as a conductive coating formed on the body 76 and including an outer surface.

  Another preferred embodiment of target 70 can be made of a non-conductive material. In such an embodiment, a conductive material that is connected to the electrode of the power supply, which can be either a DC or AC power supply, or alternatively grounded with the voltage applied to the input stage. The target 70 is placed sufficiently close to the member to generate an electric field. The polymer blend is ejected from the input stage 30, drawn toward the conductive member, and deposited on the target 70.

  The apparatus 100 can include one input stage and one target 70, or alternatively can include one or more input stages and two or more targets. By incorporating more than one target, apparatus 100 can produce different electromechanical material structures having the same or different polymer compositions and / or structures on different targets. Different structures can be fabricated on different targets in any required order, either simultaneously or sequentially.

Target 70 is selectively rotatable (as indicated by arrow D) and / or x, y and / or to change the position of the target that the polymer blend impinges upon operation of apparatus 100. Or it is preferable that it can translate in az direction. To provide a rotational function, the target 70 can be attached to a shaft 78 that is operable to rotate the target 70 in one direction or in a rocking rotation during setup and / or operation of the apparatus 100. Operatively connected to a (preferably variable speed motor) to control the formation of the electrostatically processed material on the target.
For example, the target 70 is preferably fully and / or partially counter-rotating and selectively rotatable.

  To provide a translation function, the target 70 can be attached to a translatable target support that can translate in the x, y, and / or z directions.

  In order to control the thickness of the electrostatic processing material deposited on the target 70, the target 70 is preferably rotatable and / or translatable at different speeds during electrostatic processing.

  The pick-up stage 60 of the apparatus 100 operates to remove the electrostatic processing material 72 from the target 70. The pick-up stage 60 is preferably operated to continuously remove the electrostatic processing material 72 from the target 70 to enable continuous production by operation of the apparatus 100. Preferably, the pick-up stage 60 also accumulates the extracted electrostatic processing material 72. The integrated electrostatic processing material 72 can be subjected to one or more post-processing treatments to change its structure and / or properties.

  The pick-up stage 60 includes a suitable device for removing the electrostatic machining material 72 from the target. For example, the pick-up stage 60 may include one or more doctor blades that are positioned relative to the target 70 to operably interact with the target 70 to remove the electrostatic machining material 72 from the target surface 74. Can be included. Alternatively, the pick-up stage can include a mechanical, vacuum, or gas assist device to transfer the removed electroprocessed material 72 from the target 70 to the required location.

  The pick-up stage 60 can comprise one roll, such as roll 64, or alternatively two or more rolls. The roll 64 rotates as indicated by an arrow E, and the electrostatic processing material 72 taken out from the target 70 is wound on the roll. The roll 64 is preferably operatively connected to a motor 68 that operates to rotate the roll 64 during operation of the apparatus 100 to control the winding of the electrostatic work material 72 onto the roll. In addition, the roll 64 is preferably rotatable at different speeds depending on the rotation speed of the target 70.

  In a preferred embodiment of the pick-up stage 60 including a plurality of rolls, for example, the rolls can be stacked vertically and the rolls replaced without interruption during processing.

  The roll 64 is also translatable to follow the translational movement of the target 70. For example, the target 70 and roll can be attached to a common translation support.

  The speed of pick-up of the electrostatic machining material 72 that is removed on the roll 64 may be the same as or different from the speed at which the electrostatic machining material 72 is deposited on the target. In a preferred embodiment of the pick-up stage 60 that includes multiple rolls, preferably the rolls can be operated at different speeds and the electrostatically processed material 72 that is removed can be processed to change properties such as density and / or morphology. .

  The apparatus 100 preferably includes at least one thickness sensor 110 arranged to detect the thickness of the electrostatic machining material 72 on the target 70. The thickness sensor 110 can be, for example, a reflective laser sensor, which emits light on the material. Such a thickness sensor 110 determines the thickness of the electrostatic processing material on the target 70 based on the time required for the light 112 to collide with the electrostatic processing material 72 and be reflected back to the thickness sensor 110. . Other types of sensors, such as optical sensors, can alternatively be used in apparatus 100 to determine the thickness of the electrostatic processing material on target 70.

  The apparatus 100 also preferably includes a controller 115 that operates to receive a signal from the thickness sensor 110 to determine the thickness of the electrostatic workpiece 72. When the controller determines whether the thickness of the electrostatically processed material 72 is above or below the required thickness, the controller 115 sends a signal to the motor 80 to adjust the rotation and / or translation speed of the target 70 so that the deposition range. The residence time on the deposition surface of the target 70 can be increased or decreased. Accordingly, the apparatus 100 can control the thickness of the deposited electrostatic processing material on the target 70. In this way, the rotation and / or translational speed of the target 70 can be adjusted to control the rate of production of the electrostatically processed material by the apparatus.

  The apparatus 100 is also preferably at least one slack positioned to detect the amount of slack in the electroprocessed material 72 at one or more selected locations between the target 70 and the roll 64. A sensor 120 is included. The slack sensor 120 can also be a reflective laser sensor as described above, which sensor 122 is at the time required for the light 122 to impinge on the electrostatic process material 72 and reflect back to the slack sensor 120. Based on this, the amount of looseness of the electrostatic processing material is obtained.

  The slack sensor 120 is also electrically connected to the controller 115. The slack sensor 10 sends a signal to the controller 115, which then determines the amount of slack in the electromechanical material 72. If the amount of looseness is different from the required value, the controller 115 sends a signal to the motor 68 to maintain the required level of looseness in the electromechanical material 72 and the rotational and / or translational speed of the target 70. Accordingly, the rotation and / or translation speed of the roll 64 is adjusted.

  The electromechanical material 72 that is removed from the target 70 can pass through the air or alternatively can be transported to the pick-up stage 60 through another fluid medium. For example, the removed electromechanical material can be transported through one or more liquids to process the polymer material. For example, the liquid can be an adhesive formulation (eg, PVA adhesive, polyacrylate adhesive, or the like), or a solvent that is effective in forming interfiber bonds in the electroprocessed material 72.

  As shown in FIG. 8, an apparatus 200 according to another preferred embodiment includes a post-integration processing stage 125 disposed between the integration stage 40 and the pickup stage 60. The processing stage 125 operates to provide the required physical, chemical and / or electrical properties to the polymer material. For example, the electrostatic processing material can be heated, cured, or corona treated.

  For example, the processing stage 125 can include a radiation device that operates to heat the material to the required temperature. The radiation irradiation device can be, for example, a heater such as a general heater or an infrared heater, or a heating furnace. The heater can heat the material to a suitable high temperature, for example, to dry or cure the electrostatically processed material 72. If the electrostatic process material 72 has already been transferred through the liquid as described above, drying can be performed. The processing stage 125 can include an ultraviolet (UV) light source or an electron beam source, which can be used to cure some polymer formulations. If it is desired to change to the chemical structure of the electromechanical material, the processing stage 125 can include a corona treatment device that operates to subject the electromechanical material to corona treatment to generate surface functional groups. .

  The processing stage 125 can also or alternatively operate to deposit one or more required substances on the electromechanical material. For example, the processing stage 125 can include a source of one or more dopants and / or catalysts, which can be applied to the electrostatic processing material. Alternatively, the processing stage 125 can include a source of one or more drugs or active ingredients that can be applied to the material.

  Alternatively, the processing stage can apply one or more coating layers on the removed polymer material. For example, a coating having the required chemical and / or physical properties can be deposited on the removed electrostatic processing material.

  One or more substances or coatings may be applied to the electrostatic processing material at the processing stage by a suitable application process such as spraying, dipping, rolling, brushing, deposition processing, or the like, using a suitable applicator device. Can be constructed.

  FIG. 9 represents an apparatus 300 according to another preferred embodiment. The apparatus 300 includes a rolling stand including a roll 65, and the electrostatic processing material 72 is transferred through the roll. The roll 64 can reduce the thickness of the electrostatic processing material 72 to a required thickness. In addition, by changing the rotation speeds of the roll 64 and the roll 65, the electrostatic processing material can be stretched and directional stress can be applied to the material.

  FIG. 10 represents an apparatus 400 according to another preferred embodiment. Apparatus 400 includes an applicator, such as a roll 67 of release sheet 69, which applies the release sheet to electrostatic processing material 72 at an integration stage to prevent sticking of the wound material and Make separation easier.

  According to another preferred embodiment, the electromechanical material 72 can be cut after being removed from the target 70. For example, the cutting stage may be arranged to cut the removed electrostatic processing material 72 into a required length of mat instead of winding the continuous length of electrostatic processing material 72 onto a roll 64. it can.

  FIG. 11 shows an apparatus 500 according to another preferred embodiment. Apparatus 500 includes an input device 430 shown in FIG. As shown, the apparatus 500 can include a processing stage 225 arranged to process the electromechanical material 72 while on the target 70. For example, one or more substances can be applied to the electrostatic processing material 72 at the target 70 instead of the processing stage 125 as described above, or in addition to the processing stage.

  FIG. 12 shows an apparatus 600 according to another preferred embodiment, including the input device 530 shown in FIG.

  FIG. 13 shows an apparatus 700 according to another preferred embodiment. The apparatus 700 includes an input stage 30 and an accumulation stage 40. The input stage 30 may include a multiple nozzle input device as shown. However, the input stage 30 may alternatively include an input device 330, 430 or 530 as described above, for example.

  The accumulation stage 40 includes a target 70 and a container 90 of liquid 92. As the target 70 rotates, a portion of the target 70 comes into contact with the liquid 92 and is wetted. A supply source 91 of liquid 92 is in fluid communication with the container 90 and replenishes the liquid consumed during processing.

  In another preferred embodiment, the apparatus 700 can include a cascaded liquid source for applying liquid to the electromechanical material deposited on the target 70.

  As the target 70 rotates, the electrostatic processing material on the target contacts the liquid. The liquid 92 is preferably a composition effective to provide the required properties, characteristics and / or morphology to the electrostatic processing material, or effective to promote bonding of the electrostatic processing material, such as interfiber bonding. Having a composition. For example, the liquid 92 can be a phase separation forming solution that causes phase separation of the electromechanical material, resulting in a different fiber morphology or liquid absorption. Alternatively, the liquid 92 can be an active agent that is absorbed into the electrostatic processing material, such as a cross-linking agent, catalyst, or the like. As another implementation, the liquid 92 can be a binder, such as a web or mat, that is effective to form a bonded structure from the electrostatic processing material deposited on the target 70.

  FIG. 14 shows an apparatus 800 according to another preferred embodiment. The apparatus 800 includes an input stage 30 and an accumulation stage 40. The input stage 30 may include a multi-orifice type input device as shown. Alternatively, the input stage 30 can include, for example, the input devices 330, 430, or 530 described above.

  The integration stage 40 includes a funnel target 95 that can be fixed or movable. Target 95 includes a conical portion 96 and a channel 97 extending through the target. As shown, the polymer blend 45 is ejected from the dosing device 30 and the electromechanical material 72 is accumulated on the inner surface of the conical portion 96 of the target 95. The accumulated electromechanical material 72 can be removed from the conical portion 96 using a suitable gas release device 98, such as a gas gun or the like. A vacuum is created in the flow path 97 by the vacuum system and the fibers are drawn through the flow path as continuous threads 99. The thread 99 can be accumulated on a spool or the like.

  The above are exemplary forms of implementation of the invention and are not intended to be limiting. Those skilled in the art will recognize that modifications can be made to the present invention without departing from the spirit and scope of the invention as set forth in the appended claims.

It is a figure which shows preferable embodiment of the apparatus for electrostatic processing. It is a figure which shows preferable embodiment of the input device of the apparatus for electrostatic machining containing a several nozzle. FIG. 6 shows another preferred embodiment of a dosing device including a double flow path and multiple nozzles. FIG. 4 shows a preferred embodiment of a dosing device including a brush. FIG. 6 shows another preferred embodiment of a dosing device that includes a brush structure. Figure 5 is another preferred embodiment of a dosing device including a nozzle and a nozzle cleaning structure. It is a figure which shows preferable embodiment of the apparatus for electrostatic processing containing an integration | stacking stage, a post-integration stage, and the sensor which monitors an electrostatic processing material. FIG. 6 is a diagram showing another preferred embodiment of an electrostatic machining apparatus including an integrated post-processing stage. It is a figure which shows another preferable embodiment of the apparatus for electrostatic processing containing a rolling stand. It is a figure which shows another preferable embodiment of the apparatus for electrostatic machining containing the roll for release sheets. It is a figure which shows preferable embodiment of the apparatus for electrostatic machining containing the injection | throwing-in apparatus shown in FIG. It is a figure which shows preferable embodiment of the apparatus for electrostatic machining containing the injection | throwing-in device shown in FIG. FIG. 6 shows another preferred embodiment of an electrostatic machining apparatus that includes a target that rotates in a liquid. FIG. 6 shows another preferred embodiment of an apparatus for electrostatic machining including a funnel target.

Explanation of symbols

DESCRIPTION OF SYMBOLS 20 Electrostatic processing apparatus 30 Input stage 40 Integration stage 45 Polymer compound 50 Power supply apparatus 72 Electrostatic processing material

Claims (55)

An apparatus for electrostatic processing of polymer blends,
An input stage operable to continuously eject electrostatically processed material containing a polymer blend;
An integration stage spaced from the input stage;
A power supply device operable to generate an electric field for depositing the electrostatic processing material ejected from the input stage on the integration stage;
A pick-up stage including a pick-up device arranged to continuously pick up the electrostatic processing material from the integration stage;
A device comprising:   The input stage comprises a source of the polymer blend, wherein the polymer blend is selected from the group consisting of polymer solutions, dispersions, suspensions, emulsions, mixtures thereof, and polymer melts. The apparatus according to claim 1.   The apparatus is operable to continuously process electrostatically processed materials including fibers, droplets, beads, thin films, dry porous thin films, webs, mats and / or combinations thereof. The apparatus according to 1.   The apparatus of claim 1, wherein the apparatus is operable to continuously process electrostatically processed material having at least one microscale or nanoscale dimension. The input stage is
A manifold including at least one nozzle through which the polymer blend is ejected;
A source of polymer blend in fluid communication with the manifold;
The apparatus of claim 1, comprising: The input stage is
A manifold including at least one nozzle through which the polymer blend is ejected;
A first polymer formulation, a first solvent, at least one optional first active ingredient, the first solvent, and the at least one in fluid communication with the manifold via a first flow path. A first source of a first substance selected from the group consisting of a mixture with one optional first active ingredient;
A first valve arranged along the first flow path and operable to control the flow of the first material from the first source to the manifold;
A first pump arranged along the first flow path for pumping the first substance from the first source to the manifold;
A second polymer formulation, a second solvent, at least one optional second active ingredient, the first solvent, and the at least one in fluid communication with the manifold via a second flow path. A second source of a second substance selected from the group consisting of a mixture with one optional second active ingredient;
A second valve arranged along the second flow path and operable to control the flow of the second material from the second source to the manifold;
A second pump arranged along the second flow path to pump the second substance from the second source to the manifold;
The apparatus of claim 1, comprising:   And further comprising a mixer arranged to mix the first material supplied to the first flow path and the second material supplied to the second flow path upstream of the manifold. The device according to claim 6. The input device is
Brush and
A container containing the polymer blend;
A source of the polymer blend in fluid communication with the container;
With
The brush is rotatable relative to the container such that the brush contacts and is wetted by the polymer blend, thereby ejecting the polymer blend from the container. Item 2. The apparatus according to Item 1.   9. The apparatus of claim 8, wherein the brush comprises bristles of a conductive material, and the power supply is electrically connected to the brush. The input device is
A polymer blend flow path through which the polymer blend flows;
A cleaning liquid flow path through which the cleaning liquid flows;
A nozzle including an inlet;
A fixed mask including an opening;
With
In the mask and the polymer blend flow path, the nozzle positions the inlet of the nozzle (i) in fluid communication with the polymer blend flow path and (ii) subsequently in fluid communication with the cleaning liquid flow path. 2. The device according to claim 1, wherein the device is rotatable relative to the device. The integration stage comprises:
At least one target on which the electromechanical material is deposited;
A first variable speed motor is optionally connected to the at least one target to rotate and / or translate the at least one target relative to the input stage and rotate the at least one target. A first mechanism to prepare for,
The apparatus of claim 1, comprising:   The apparatus of claim 11, wherein the at least one target comprises at least one cylindrical roll.   The at least one target comprises (i) a conductive outer portion having an outer surface on which electrostatic processing material is deposited, or (ii) a conductive body having an outer surface on which electrostatic processing material is deposited. The apparatus according to claim 11. The integration stage comprises:
A funnel-shaped target including a conical portion having an inner surface on which the sprayed electromechanical material is deposited and a flow path extending through the target;
A gas release source arranged to release a gas to remove the electrostatic processing material from an inner surface of the conical portion;
A vacuum system arranged to draw the removed electrostatically processed material as a thread through the flow path;
The apparatus of claim 1, comprising: The integration stage comprises:
A target having an outer surface;
A container,
A source for supplying a liquid selected from the group consisting of a phase separation forming liquid, an activator, a binder, and mixtures thereof into the container;
A drive source that rotates the target relative to the container such that an outer surface of the target is wetted in contact with the liquid;
The apparatus of claim 1, comprising:   The apparatus according to claim 1, wherein the removal device comprises at least one doctor blade. The pickup stage is
At least one roll on which the removed electrostatic processing material is wound;
A second variable speed motor operably connected to the at least one roll for rotating and / or translating the at least one roll relative to the integrated stage and optionally rotating the at least one roll. A second mechanism included in
The apparatus of claim 1, comprising:   The apparatus of claim 17, further comprising a release sheet applicator operable to attach a release sheet to the electrostatic processing material at the pickup stage.   The apparatus further comprises at least one radiation irradiation device selected from the group consisting of a heater, a heating furnace, an ultraviolet light source, and an electron beam source, and the at least one radiation irradiation device is disposed between the integration stage and the pickup stage. 2. The apparatus of claim 1, wherein the apparatus is operable to dry and / or cure the electrostatic processing material.   The apparatus of claim 1, further comprising a corona treatment device arranged to subject the electrostatic processing material to a corona treatment.   And further comprising at least one applicator device arranged to apply at least one substance to the electrostatic machining material at (i) the integration stage or (ii) downstream of the integration stage. The device of claim 1, wherein the one material is selected from the group consisting of a dopant, a catalyst, a drug and an activator.   The apparatus of claim 21, wherein the at least one applicator device applies a coating layer comprising the at least one substance to the electrostatic processing material.   The apparatus according to claim 1, further comprising a roll stand disposed between the accumulation stage and the pickup stage.   (I) at least one thickness sensor operable to detect the thickness of the electrostatic processing material deposited on the integration stage; and (ii) the retrieved static between the integration stage and the pickup stage. The apparatus of claim 1, further comprising at least one of at least one slack sensor operable to detect the amount of slack in the electroworking material. (I) the integration stage is
At least one target on which the electromechanical material is deposited;
A first mechanism operably connected to the at least one target for rotating and / or translating the at least one target relative to the input stage;
Including
(Ii) The pickup stage is
At least one roll on which the removed electrostatic processing material is wound;
A second mechanism operably connected to the at least one roll for rotating and / or translating the at least one roll relative to the accumulation stage;
Including
(Iii) the device further comprises:
At least one thickness sensor operable to detect a thickness of the electromechanical material deposited on the at least one target;
At least one slack sensor operable to detect the amount of slack in the removed electromechanical material between the at least one target and the at least one roll;
Electrically connected to the first mechanism, the second mechanism, at least one thickness sensor, and at least one slack sensor, and receiving signals from the at least one thickness sensor and the at least one slack sensor; A controller operable to control operation of the first mechanism and the second mechanism based on the received signal;
The apparatus of claim 1, comprising: A method of electrostatically processing a polymer blend comprising:
Generating an electric field between the input stage of the device and the integration stage;
Supplying a polymer blend to the input stage;
Continuously ejecting electrostatic processing material from the charging stage;
Accumulating the electrostatic processing material at the accumulation stage;
Continuously removing the electrostatic processing material from the integration stage;
Including methods. The polymer blend is selected from the group consisting of polymer solutions, dispersions, suspensions, emulsions, mixtures thereof, and polymer melts;
The electrostatic processing material comprises fibers, droplets, beads, thin films, dry porous thin films, webs, mats and / or combinations thereof;
27. A method according to claim 26.   27. The method of claim 26, wherein the electromechanical material has at least one microscale or nanoscale dimension.   27. The method of claim 26, wherein the electrostatic machining material is continuously ejected through at least one nozzle of the input stage.   27. The method of claim 26, wherein the polymer blend comprises at least two different polymer blends.   The polymer blend includes a first polymer blend, and the method further includes a second polymer blend, a solvent, at least one optional active ingredient, and the solvent and the at least one optional 27. The method of claim 26, comprising mixing at least one substance selected from the group consisting of a mixture with various active ingredients and the first polymer blend at the input stage. The input stage comprises a rotatable brush comprising a conductive material, the method further comprising:
Applying a voltage to the conductive material;
Continuously ejecting the electrostatic processing material at the dosing stage by rotating the brush so that the brush is wetted in contact with the polymer blend;
Removing the polymer blend from the brush by the electric field;
27. The method of claim 26, comprising:   35. The method of claim 32, wherein the polymer blend is contained in an open container and the method further comprises replenishing the polymer blend in the container during electrostatic processing of the polymer blend. The input stage includes a first nozzle and a second nozzle, and the method includes:
Ejecting the electrostatic processing material from the first nozzle;
Supplying a cleaning liquid from the cleaning liquid supply source into the second nozzle;
27. The method of claim 26, further comprising: The integration stage comprises at least one target on which the electromechanical material is deposited, the method further comprising:
Rotating and / or translating at least one target relative to the input stage during the electrostatic processing of the polymer blend;
Optionally changing the rotational speed of the target during the electrostatic processing of the polymer formulation;
27. The method of claim 26, comprising:   36. The method of claim 35, wherein the at least one target comprises a conductive outer portion having an outer surface, and the method further comprises the step of integrating the electromechanical material on the outer surface.   The electric field is generated by applying a voltage to the input stage or to a conductive material that is optionally spaced from the integration stage. 26. The method according to 26. The integration stage comprises a funnel-shaped target that includes a conical portion having an inner surface on which the ejected electrostatic processing material is deposited and a flow path extending through the target, the method further comprising:
Releasing a gas to remove the electrostatic processing material from the inner surface of the conical portion;
Evacuating the inside of the flow path, and drawing out the extracted electrostatically processed material as a thread through the flow path;
27. The method of claim 26, comprising: The integration stage comprises:
A target having an outer surface;
A container containing a liquid selected from the group consisting of a phase separation forming liquid, an activator, and a binder;
27. The method of claim 26, further comprising rotating the target relative to the container such that the target is wetted in contact with the liquid.   27. The method of claim 26, wherein the electrostatic machining material is removed from the integration stage using at least one doctor blade.   27. The method of claim 26, further comprising winding the electrostatically processed material removed from the integration stage with a pick-up stage. The pick-up stage comprises at least one roll on which the taken electrostatic processing material is wound;
42. The method of claim 41, further comprising rotating and / or translating the at least one roll relative to the integration stage during electrostatic processing of the polymer blend. The integration stage comprises at least one target for integrating the electromechanical material, the at least one target being rotatable and / or translatable;
The pick-up stage comprises at least one roll for winding up the removed electrostatically processed material, the at least one roll being rotatable and / or translatable;
27. The method of claim 26, further comprising adjusting rotation of the at least one target and / or the at least one roll and / or translating them during electrostatic processing of the polymer blend. The method described. Determining a thickness of the electrostatic processing material integrated on the at least one target;
Adjusting and / or translating the rotation of the at least one target and / or the at least one roll during electrostatic processing of the polymer blend when the determined thickness is different from the selected thickness. Stages,
44. The method of claim 43, further comprising: Determining the amount of slack in the electromechanical material at one or more locations between the at least one target and the at least one roll;
Adjusting rotation of the at least one target and / or the at least one roll during electrostatic processing of the polymer blend when the determined amount of looseness is different from the selected amount of looseness; and / or Or translating them, and
44. The method of claim 43, further comprising:   27. The method of claim 26, further comprising applying a release sheet to the electrostatic processing material removed from the integration stage.   Curing and / or drying the electrostatic processing material removed from the integration stage using at least one radiation irradiating device selected from the group consisting of a heater, a heating furnace, an ultraviolet light source, and an electron beam source; 27. The method of claim 26, further comprising:   27. The method of claim 26, further comprising subjecting the electrostatic processing material removed from the integration stage to a corona treatment.   Applying at least one substance selected from the group consisting of a dopant, a catalyst, a drug, and an active agent to the electrostatic processing material (i) at the integration stage or (ii) after being removed from the integration stage 27. The method of claim 26 further comprising the step.   50. The method of claim 49, wherein the at least one material is at least one coating layer that includes the at least one material applied to the electrostatic processing material.   27. The method of claim 26, further comprising compressing the electrostatic processing material removed from the integration stage to a required thickness and / or stretching the electrostatic processing material.   27. The method of claim 26, further comprising detecting a thickness of the sensor workpiece material deposited on the integration stage using at least one thickness sensor.   42. The method of claim 41, further comprising detecting an amount of slack in the extracted electrostatically processed material between the integration stage and the pick-up stage using at least one slack sensor. (I) the integration stage is
At least one target on which the electrostatic processing material is deposited;
A first mechanism operably connected to the at least one target for rotating and / or translating the at least one target relative to the input stage;
Including
(Ii) The pickup stage is
At least one roll on which the removed electrostatic processing material is wound;
A second mechanism operably connected to the at least one roll for rotating and / or translating the at least one roll relative to the accumulation stage;
Including
(Iii) The method further comprises:
Detecting the thickness of the electromechanical material deposited on the at least one target using at least one thickness sensor;
Detecting the amount of slack in the removed electromechanical material between the at least one target and the at least one roll using at least one slack sensor;
Using the controller that receives signals from the at least one thickness sensor and the at least one looseness sensor and controls the operation of the first mechanism and the second mechanism based on the received signal, the first mechanism Controlling the operation of the mechanism and the second mechanism;
42. The method of claim 41, further comprising:   27. The method of claim 26, wherein the electrostatically processed material is (i) electrospun or (ii) electrostatic sprayed.

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