纺织学报 ›› 2025, Vol. 46 ›› Issue (08): 217-225.doi: 10.13475/j.fzxb.20250100101

• 机械与设备 • 上一篇    下一篇

多尖端锯齿状静电纺丝喷头的设计及优化

刘健1,2(), 潘山山1, 刘泳汝2, 尹兆松1, 任康佳1, 赵庆浩1   

  1. 1.天津工业大学 机械工程学院, 天津 300387
    2.天津工业大学 工程教学实习训练中心, 天津 300387
  • 收稿日期:2025-01-02 修回日期:2025-05-26 出版日期:2025-08-15 发布日期:2025-08-15
  • 作者简介:刘健(1985—),男,高级实验师,博士。主要研究方向为新型纺织机械设计及自动化、机电一体化技术。E-mail:liujian3286@tiangong.edu.cn。
  • 基金资助:
    天津市技术创新引导专项基金企业科技特派员项目(23YDTPJC00280);天津市自然科学基金面上项目(22JCYBJC01470)

Design and optimization of multi-tip serrated electrospinning nozzle

LIU Jian1,2(), PAN Shanshan1, LIU Yongru2, YIN Zhaosong1, REN Kangjia1, ZHAO Qinghao1   

  1. 1. School of Mechanical Engineering, Tiangong University, Tianjin 300387, China
    2. Center of Engineering Practice Training, Tiangong University, Tianjin 300387, China
  • Received:2025-01-02 Revised:2025-05-26 Published:2025-08-15 Online:2025-08-15

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摘要：

为解决传统针头式静电纺丝易堵塞、无针头式静电纺丝泰勒锥形成位置不稳定等问题,设计一种锯齿状静电纺丝喷头,其锯齿尖端能够精准激发泰勒锥,解决了泰勒锥形成位置不稳定的问题,通过增加尖端数量激发产生更多的纺丝射流从而提高纺丝效率。利用COMSOL软件对锯齿状静电纺丝系统进行电场仿真发现,直线式排列的锯齿尖端场强值存在两边高、中间低的现象,即边缘效应问题。通过对锯齿尖端按圆弧排列优化各个尖端的高度,其场强变异系数(CV值)比直线排列锯齿的普遍低2%~4%。为得到最优的锯齿圆弧排列方式,设计不同参数的多尖端锯齿模型并进行电场仿真,得出在弧高为13 mm、齿数为11、齿宽为15 mm时,场强CV值最小,为6.09%,此时的场强分布较均匀,边缘效应问题得到改善。最后搭建实验台进行纺丝实验对比,该喷头射流形成数量较多且形态均匀稳定,纺丝效率为1.18 g/h,验证了新型锯齿状静电纺丝喷头在提高纺丝效率的同时能够保证纳米纤维质量,为静电纺丝规模化生产提供技术参考。

关键词: 静电纺丝, 锯齿状喷嘴, 边缘效应, 尖端圆弧排列, 电场仿真, 规模化生产

Abstract:

Objective A serrated electrostatic spinning jet exciter has been developed to overcome the problems of easy clogging in conventional electrostatic spinning tips and unstable position of the Taylor cone formation. By increasing the number of tips to excite more spinning jets, this research aims to increase the electrospinning rate to industrial production levels. The sawtooth shape is to be optimized to improve the uniformity of the electric field to ensure stability of the spinning process and uniformity of fiber quality.

Method The study is based on the theory of jets originating from wave crests and the theory of tip-collected charge, combined with the existing spinning methods. The serrated jet exciter is designed and 3-D models were established using SolidWorks software and electric field simulation using COMSOL software. The effect on the uniformity of the electric field was analyzed by changing the shape and size of the sawtooth. Laser cutting was used to fabricate the serrated nozzle and the spinning solution was formulated using polyacrylonitrile (PAN) powder and N,N-dimethylformamide (DMF) solvent for spinning experiments to verify the spinning.

Results The electric field simulation results showed that there is a significant ‘End-effect’ in the distribution of electric field intensity in the straight-toothed saw nozzle. Specifically, the electric field intensity was higher at the tips of both sides of the saw and relatively lower in the middle region, and this uneven electric field distribution can lead to resulted in instability in the spinning process and variability in fiber quality. The initial electric field distribution of the nozzle shows a trend of being high at both ends and low in the middle. To make the electric field uniform, the height of the middle sawtooth was increased while reducing the height of the sawtooth at both ends. By using the principle of a circle formation using three points, an arc was drawn through the outer endpoints of the sawtooth at both ends and the tip vertex of the middle sawtooth. The field strength at the tips was reduced by optimizing the design of the circular arc serrated nozzle. The optimized circular-arc serrated nozzles showed generally 2% to 4% lower CV value than that of straight serrated nozzles. Simulation was carried out for different parameters to find the arc model with the best CV value performance, i.e. when the arc height S=13 mm, the number of teeth n=11 and the tooth width c=15 mm, the CV value of the electric field was 6.09% and the electric field intensity was more uniform. Experimental comparison made by observing the jet morphology verified that the number of straight teeth sawtooth for 5 mm jet was less. However, with the ‘end-effect’ fiber whipping entanglement, the phenomenon of flying silk was obvious. The optimized nozzle jet morphology was better and the edge effect problem was greatly improved, evidenced by no flying silk phenomenon and high fiber quality. The Phenom Pure Plus desktop scanning electron microscope was used to observe the appearance of the fibers, and it was found that the fibers were distributed relatively uniformly. Image processing software was used to randomly select fibers for diameter analysis, which showed that the average diameter of the spun fibers was 163 nm with smooth fiber surface, and the diameter of the distribution area is more concentrated. The experimental and simulation results agree to each other, and the simulation data and experimental phenomena have high accuracy and consistency.

Conclusion In this study, a multi-tip serrated electrostatic spinning nozzle was successfully designed and optimized to improve spinning efficiency and fiber quality by improving electric field uniformity. The optimized circular-arc serrated nozzle has better electric field uniformity compared to the straight-arc serrated nozzle, solves the problem of easy clogging in conventional needles, the jet position is fixed and the shape is more uniform, which provides strong support for large-scale production of electrostatic spinning.

Key words: electrospinning, serrated nozzle, edge-effect, circularly arranged tip, electric field simulation, large-scale production

中图分类号: 

  • TS174.8

图1

锯齿模型示意图 注:L为踞齿总长,mm。"

图2

COMSOL仿真模型"

图3

不同齿高的场强变化"

图4

直线排列射流激发器电场云图"

图5

直线排列与圆弧排列射流激发器的变化"

图6

圆弧排列射流激发器电场云图"

表1

圆弧排列射流激发器电场强度表"

编号
i		 电场强度/(106 V·m-1) 编号
i		 电场强度/(106 V·m-1) 编号
i		 电场强度/(106 V·m-1)
5 mm 10 mm 15 mm 20 mm 5 mm 10 mm 15 mm 20 mm 5 mm 10 mm 15 mm 20 mm
1 前
后		 2.14
2.12		 2.28
2.27		 2.32
2.21		 2.18
2.01		 8 前
后		 2.13
2.08		 2.27
2.48		 2.90
2.84		 2.63
2.68		 15 前
后		 1.95
1.74		 2.17
2.37		 2.43
2.39		 2.63
2.82
2 前
后		 1.88
2.04		 2.16
2.11		 2.42
2.73		 2.16
2.45		 9 前
后		 2.01
2.23		 2.65
2.44		 2.94
2.58		 2.39
2.38		 16 前
后		 2.09
1.99		 2.35
2.19		 2.59
2.70		 2.60
2.72
3 前
后		 2.07
2.07		 2.23
2.20		 2.08
2.33		 2.45
2.16		 10 前
后		 2.23
2.06		 2.27
2.23		 2.37
2.55		 2.57
2.35		 17 前
后		 2.00
1.81		 2.12
2.03		 2.31
2.54		 2.13
2.29
4 前
后		 2.17
2.01		 3.37
2.41		 2.54
2.27		 2.23
2.52		 11 前
后		 2.29
2.25		 2.52
2.66		 2.66
2.58		 2.89
2.84		 18 前
后		 2.09
2.04		 2.12
2.02		 2.32
2.77		 2.28
2.32
5 前
后		 2.33
2.09		 2.17
2.31		 2.30
2.72		 2.51
2.58		 12 前
后		 2.59
2.13		 3.62
3.42		 2.56
2.29		 2.47
2.76		 19 前
后		 2.11
2.13		 2.19
2.01		 2.06
2.03		 2.09
2.03
6 前
后		 2.20
2.21		 2.28
2.16		 2.39
2.34		 2.54
2.26		 13 前
后		 2.28
2.06		 2.21
2.08		 2.54
2.33		 2.47
2.52		 平均值
标准差		 2.12
1.50		 2.30
2.42		 2.46
2.17		 2.45
2.29
7 前
后		 2.26
2.29		 2.43
2.38		 2.44
2.42		 2.70
2.71		 14 前
后		 2.20
2.25		 2.19
2.13		 2.39
2.38		 2.50
2.35

图7

直线排列与圆弧排列场强CV值对比"

图8

圆弧锯齿电场强度与CV值折线图"

图9

齿数对电场强度的影响"

图10

不同齿数电场云图"

图11

齿宽对电场强度的影响"

图12

不同齿宽电场云图"

图13

实验设备"

图14

直线形锯齿射流形态"

图15

最优圆弧锯齿射流形态"

图16

纤维膜成品图"

图17

纤维直径分析"

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