Journal of Textile Research ›› 2024, Vol. 45 ›› Issue (11): 215-225.doi: 10.13475/j.fzxb.20230806101

• Machinery & Equipment • Previous Articles     Next Articles

Design and optimization of semi-enclosed free-surface electrospinning nozzle

LIU Jian1,2(), WANG Chenghao1, DONG Shoujun1, LIU Yongru2   

  1. 1. School of Mechanical Engineering, Tiangong University, Tianjin 300387, China
    2. Center of Engineering Practice Training, Tiangong University, Tianjin 300387, China
  • Received:2023-08-28 Revised:2024-08-15 Online:2024-11-15 Published:2024-12-30

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Abstract:

Objective In the process of electrospinning, the yield of capillary needle spinning is low and the free-surface electrospinning solution system is unstable. Therefore, it is necessary to design a new type of nozzle to ensure the stability, high efficiency and controllable preparation of electrospinning nanofibers. Aiming at the problems of multi-needle electrospinning and needle-free electrospinning, a multi-blade semi-enclosed free-surface electrospinning nozzle is proposed.

Method The multi-blade semi-enclosed free-surface nozzle was primarily divided into the straight pipe section and the blade section. The straight pipe section was first designed based on the uniformity of solution distribution. Next, the blade part was modeled according to the shape and distribution characteristics of a lotus petal, with the inner and outer layers of the blade clips determined using a neural network (BP) combined with a simulated annealing algorithm. The model was then set up to verify the accuracy of the algorithm, and theoretical calculations of droplet holding time were performed for the designed model. Finally, the model's validity was confirmed through experiments.

Results A multi-blade semi-enclosed free surface nozzle was designed. The straight pipe part of the nozzle adopted the method of multi-channel uniform distribution. The blade section was simulated by the lotus petal section curve. The angle between the inner and outer layers of the blade layer was calculated by combining BP and simulated annealing algorithm, and the angle between the inner and outer layers was determined to be 27° and 50°, respectively. Fluent software was adopted to simulate the final model of the above design. At this time, the pressure ratio between the inner wall and the outlet of the inner and outer layer solution in the process of electrostatic spinning was 0.45, which was close to the theoretical calculation and verified the accuracy of the theoretical model. On the basis of calculating the tension coefficient, a formula for calculating the droplet retention time of the nozzle blade was derived, and the nozzle parameters involved were included in the calculation. The results showed that the droplet holding time of the inner and outer blades was 21.89 s and 17.80 s, respectively, which is sufficient for the droplet to complete the electrospinning process and stabilize the electrospinning solution system. The identified model was 3D printed with stainless steel and electrospinning experiment was carried out. In the experiment, it was found that 12 blade tips would form a stable jet, and the efficiency was about 12 times higher than that of a single needle jet. In addition, because of the angle between the inner and outer layers in the nozzle blade, the angle between the inner and outer layers of the nozzle blades ensures that the pressure of the solution on the inner wall is the same for both layers, resulting in equal outflow speeds. The spinning area was large, and the measured fiber membrane area in this experiment was in the range of 1 140-1 440 cm2. Because the liquid supply rate was higher than the spinning rate during electrostatic spinning, the liquid droplets would not overflow on the nozzle surface or drop on the nozzle surface, and would not affect the quality of the fiber membrane. Finally, the film generated by the semi-closed free-surface nozzle with 10 mL/h supply rate and 15 min spinning time was observed by electron microscopy. The average fiber diameter was 275 nm and the CV value was 17.49%.

Conclusion Combining the advantages of single-needle and free-surface nozzle in electrospinning, a semi-enclosed free-surface nozzle with multiple blades is proposed and designed. It has the advantages of multi-jet formation, long droplet holding time and no solution volatization. Compared with conventional single needle electrospinning, the efficiency is improved and the spinning area is enlarged. Compared with electrospinning without needles, the solution utilization rate and stability of electrospinning solution are improved. Through the electrospinning experiment and the electron microscopy of the fiber membrane, the average diameter of the fiber film produced by the nozzle is 275 nm, with a diameter coefficient of variation (CV) of 17.49%, indicating excellent fiber characteristics, and this study has certain reference significance for the development of stable, efficient and controllable electrospinning nanofibers preparation method.

Key words: electrospinning, semi-enclosed free surface, neural network, simulated annealing algorithm, fluent simulation, holding time, multiple jet

CLC Number: 

  • TS174.8

Tab.1

Lotus petal longitudinal section curve coordinates"

组数 坐标1 坐标2 坐标3 坐标4 坐标5
1 (0,0.00) (0,0.00) (0,0.00) (0,0.00) (0,0.00)
2 (1,-0.16) (1,-0.17) (1,-0.16) (1,-0.15) (1,-0.15)
3 (2,-0.35) (2,-0.34) (2,-0.35) (2,-0.36) (2,-0.33)
4 (3,-0.64) (3,-0.65) (3,-0.64) (3,-0.64) (3,-0.65)
5 (4,-1.06) (4,-1.05) (4,-1.06) (4,-1.07) (4,-1.07)
6 (5,-1.50) (4,-1.49) (4,-1.48) (4,-1.51) (4,-1.50)
7 (6,-1.80) (6,-1.79) (6,-1.81) (6,-1.80) (6,-1.78)
8 (7,-1.78) (7,-1.81) (7,-1.80) (7,-1.79) (7,-1.80)
9 (8,-1.59) (7,-1.58) (7,-1.59) (7,-1.58) (7,-1.57)
10 (9,-0.92) (9,-0.91) (9,-0.91) (9,-0.90) (9,-0.92)
11 (10,0.00) (10,0.00) (10,0.00) (10,0.00) (10,0.00)

Fig.1

Nozzle straight pipe flow channel distribution"

Fig.2

Nozzle parameters"

Fig.3

Neural network model"

Fig.4

Experiments for blade opening angle and droplet holding time"

Tab.2

Fit table of angles between inner and outer layer blades and center line"

内层角度/(°) 外层角度/(°)
25 25 30 35 40 45 50 55 60
30 - 30 35 40 45 50 55 60
35 - - 35 40 45 50 55 60
40 - - - 40 45 50 55 60
45 - - - - 45 50 55 60
50 - - - - - 50 55 60
55 - - - - - - 55 60
60 - - - - - - - 60

Fig.5

Boundary division"

Tab.3

Experimental data of pressure ratio of solution to inner wall and outlet of inner and outer layer of nozzle"

序号 溶液对内外层
内壁压力比		 溶液对内外层
出口压力比		 角度/(°) 序号 溶液对内外层
内壁压力比		 溶液对内外层
出口压力比		 角度/(°)
内层 外层 内层 外层
1 0.15 0.09 25 25 19 0.25 0.30 35 50
2 0.18 0.17 25 30 20 0.28 0.43 35 55
3 0.22 0.25 25 35 21 0.35 0.52 35 60
4 0.25 0.35 25 40 22 0.13 0.06 40 40
5 0.30 0.45 25 45 23 0.16 0.10 40 45
6 0.34 0.56 25 50 24 0.20 0.20 40 50
7 0.39 0.70 25 55 25 0.24 0.29 40 55
8 0.48 0.86 25 60 26 0.30 0.40 40 60
9 0.15 0.08 30 30 27 0.12 0.05 45 45
10 0.18 0.15 30 35 28 0.16 0.12 45 50
11 0.21 0.23 30 40 29 0.20 0.16 45 55
12 0.25 0.32 30 45 30 0.25 0.29 45 60
13 0.29 0.42 30 50 31 0.13 0.06 50 50
14 0.34 0.54 30 55 32 0.16 0.12 50 55
15 0.39 0.67 30 60 33 0.20 0.20 50 60
16 0.14 0.07 35 35 34 0.11 0.05 55 55
17 0.17 0.14 35 40 35 0.16 0.12 55 60
18 0.20 0.21 35 45 36 0.11 0.04 60 60

Tab.4

Weight and threshold value of solution to inner wall pressure ratio and outlet pressure ratio of inner and outer layers of nozzle"

参数 内壁压力比 出口压力比
w11 0.172 7 -1.398 4
w12 0.355 5 0.262 0
w21 -0.194 5 -1.460 9
w22 -1.613 0 -0.307 6
w1 -3.636 6 -0.039 8
w2 -1.747 4 -6.274 7
b1 0.379 1 1.764 6
b2 2.894 4 1.172 2
b 2.304 7 2.304 7

Fig.6

Simulated annealing logic block diagram"

Fig.7

Cloud images of fluid simulation pressure (a) and velocity (b)"

Fig.8

Semi-enclosed free surface nozzle model parameters"

Fig.9

Cross-sectional pressure cloud map"

Fig.10

Semi-enclosed free surface hozzle"

Fig.11

Semi-enclosed free-surface nozzle electrospinning"

Fig.12

Semi-enclosed free surface nozzle fiber film"

Fig.13

Surface morphology (a) and diameter distribution (b) of nanofibers"

Fig.14

Conventional capillary needle electrospinning"

Fig.15

Convenitional free surface electrospinning"

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