Patent Grant
10513800
An embodiment of the invention relates to an electrospinning apparatus and a method of manufacturing deposited body.
There exists an electrospinning apparatus for forming a deposited body by depositing a microscopic fiber on a member using an electrospinning method.
The deposited body formed by the electrospinning apparatus is used after exfoliated from the surface of the member in some cases.
Therefore, it is necessary for the deposited body to be exfoliated from the member without a damage.
According to one embodiment, an electrospinning apparatus is adapted to deposit fibers on a member to form a deposited body. The apparatus includes a processing section. The processing section is capable of forming a mixture section in the deposited body. A first fiber part of the deposited body, and a second fiber part of the deposited body are mixed with each other in the mixture section. The first fiber part is located on the member. The second fiber part is located on the first fiber part.
Embodiments will now be illustrated with reference to the drawings. Similar components in the drawings are marked with the same reference numerals; and a detailed description is omitted as appropriate.
As shown in
It should be noted that in the embodiment, the collection section 5 corresponds to the member on which the fiber 100 is deposited.
The nozzle head 2 has a nozzle 20, a connection section 21, and a main body section 22.
The nozzle 20 exhibits a needle shape. Inside the nozzle 20, there is provided a hole for discharging the raw liquid. The hole for discharging the raw liquid penetrates between an end part on the connection section 21 side of the nozzle 20 and an end part (tip) on the collection section 5 side of the nozzle 20. An opening on the collection section 5 side of the hole for discharging the raw liquid acts as a discharge port 20a.
Although there is no limitation on the outer diameter (the diameter in the case in which the nozzle 20 has a cylindrical shape) of the nozzle 20, the smaller the outer diameter is, the more preferable. If the outer diameter is made smaller, the electric field concentration becomes apt to occur in the vicinity of the discharge port 20a of the nozzle 20. If the electric field concentration occurs in the vicinity of the discharge port 20a of the nozzle 20, it is possible to increase the intensity of the electric field generated between the nozzle 20 and the collection section 5. Therefore, it is possible to lower the voltage applied by the power supply 5. In other words, it is possible to reduce the drive voltage. In this case, the outer diameter of the nozzle 20 can be set in a range of, for example, about 0.3 mm through 1.3 mm.
The dimension (the diameter in the case in which the discharge port 20a has a circular shape) of the discharge port 20a is not particularly limited. The dimension of the discharge port 20a can arbitrarily be changed in accordance with the desired cross-sectional dimension of the fiber 100 to be formed. The dimension (the inner diameter of the nozzle 20) of the discharge port 20a can be set in a range of, for example, about 0.1 mm through 1 mm.
The nozzle 20 is formed of a conductive material. It is preferable for the material of the nozzle 20 to have conductivity and a resistance property with respect to the raw liquid described later. The nozzle 20 can be formed from, for example, stainless steel.
The number of the nozzles is not particularly limited, and can arbitrarily be changed in accordance with the size of the collection section 5 and so on. It is sufficient to provide at least one nozzle 20.
In the case of providing a plurality of nozzles 20, the nozzles 20 are provided side by side with predetermined intervals. It should be noted that the arrangement of the nozzles 20 is not particularly limited. For example, in the embodiment, the nozzles 20 can be provided in a line, or provided in a circle, or in a concentric manner, or provided in a zigzag manner or in a matrix.
The connection section 21 is provided between the nozzle 20 and the main body section 22. The connection section 21 is not necessarily required, and it is also possible to arrange that the nozzle 20 is directly provided to the main body section 22. Inside the connection section 21, there is provided a hole for supplying the raw liquid from the main body section 22 to the nozzle 20. The hole provided inside the connection section 21 is communicated with the hole provided inside the nozzle 20, and a space provided inside the main body section 22.
The connection section 21 is formed of a conductive material. It is preferable for the material of the connection section 21 to have conductivity and a resistance property with respect to the raw liquid. The connection section 21 can be formed from, for example, stainless steel.
The main body section 22 exhibits a plate shape. Inside the main body section 22, there is provided the space in which the raw liquid is contained.
Further, the main body section 22 is provided with a supply port 22a. The raw liquid supplied from the raw liquid supply section 3 is introduced into the main body section 22 via the supply port 22a. The number and the arrangement of the supply ports 22a are not particularly limited. The supply port 22a can be provided, for example, on the opposite side to the side, on which the nozzle 20 is provided, of the main body section 22.
It is preferable for the material of the main body section 22 to have conductivity and a resistance property with respect to the raw liquid. The main body section 22 can be formed from, for example, stainless steel.
It should be noted that although the nozzle head 2 illustrated in
The raw liquid supply section 3 includes a housing section 31, a supply section 32, a raw liquid control section 33, and piping 34.
The housing section 31 houses the raw liquid. The housing section 31 is formed of a material having a resistance property with respect to the raw liquid. The housing section 31 can be formed from, for example, stainless steel.
The raw liquid obtained by dissolving a polymer substance in a solvent.
The polymer substance is not particularly limited, but can arbitrarily be changed in accordance with the material of the fiber 100 to be formed.
It is sufficient for the solvent to be able to dissolve the polymer substance. The solvent can arbitrarily be changed in accordance with the polymer substance to be dissolved.
As described later, the raw liquid is arranged to remain in the vicinity of the discharge port 20a due to the surface tension. Therefore, the viscosity of the raw liquid can arbitrarily be changed in accordance with the dimension of the discharge port 20a. The viscosity of the raw liquid can be obtained by performing an experiment or a simulation. Further, the viscosity of the raw liquid can be controlled by the mixture ratio between the solvent and the polymer substance.
The supply section 32 supplies the main body section 22 with the raw liquid contained in the housing section 31. As the supply section 32, there can be used, for example, a pump having a resistance property with respect to the raw liquid. Further, the supply section 32 can also be defined as, for example, a section for supplying the housing section 31 with a gas to pressure feed the raw liquid contained in the housing section 31.
The raw liquid control section 33 controls the flow rate, the pressure, and so on of the raw liquid supplied to the main body section 22 to prevent the raw liquid located inside the main body section 22 from being pushed out from the discharge port 20a when the new raw liquid is supplied inside the main body section 22. It should be noted that the control amount to the raw liquid control section 33 can arbitrarily be changed in accordance with the dimension of the discharge port 20a, the viscosity of the raw liquid, and so on. The control amount to the raw liquid control section 33 can be obtained by performing an experiment or a simulation.
Further, the raw liquid control section 33 can also be arranged to switch between start and stop of the supply of the raw liquid.
It should be noted that the supply section 32 and the raw liquid control section 33 are not necessarily required. For example, if it is arranged that the housing section 31 is provided at a position higher than the position of the main body section 22, the raw liquid can be supplied to the main body section 22 using the gravitational force. Further, by arbitrarily setting the height position of the housing section 31, it is possible to prevent the raw liquid located inside the main body section 22 from being pushed out from the discharge port 20a when the new raw liquid is supplied inside the main body section 22. On this occasion, the height position of the housing section 31 can arbitrarily be changed in accordance with the dimension of the discharge port 20a, the viscosity of the raw liquid, and so on. The height position of the housing section 31 can be obtained by performing an experiment or a simulation.
The piping 34 is provided between the housing section 31 and supply section 32, between the supply section 32 and the raw liquid control section 33, and between the raw liquid control section 33 and the main body section 22. The piping 34 forms a flow channel of the raw liquid. The piping 34 is formed of a material having a resistance property with respect to the raw liquid.
The power supply 4 applies a voltage to the nozzle 20 via the main body section 22 and the connection section 21. It should be noted that it is also possible to arrange that a terminal not shown electrically connected to the nozzle 20 is provided. In this case, the power supply 4 applies the voltage to the nozzle 20 via the terminal not shown. Therefore, it is sufficient to arrange that the voltage can be applied by the power supply 4 to the nozzle 20.
The polarity of the voltage to be applied to the nozzle 20 can be set to plus, or can also be set to minus. It should be noted that the power supply 4 illustrated in
The voltage applied to the nozzle 20 can arbitrarily be changed in accordance with the type of the polymer substance included in the raw liquid, the distance between the nozzle 20 and the collection section 5, and so on. For example, the power supply 4 can be arranged to apply the voltage to the nozzle 20 so that the potential difference between the nozzle 20 and the collection section 5 becomes not lower than 10 kV.
As the power supply 4, there can be used, for example, a direct-current high-voltage power supply. The power supply 4 can be arranged to output, for example, a direct-current voltage not lower than 10 kV and not higher than 100 kV.
The collection section 5 is provided on the side, on which the raw liquid is discharged, of the nozzle 20. The collection section 5 is grounded. It is also possible to arrange that the voltage having an opposite polarity to the voltage applied to the nozzle 20 is applied to the collection section 5. The collection section 5 can be formed of a conductive material. It is preferable for the material of the collection section 5 to have conductivity and a resistance property with respect to the raw liquid. As the material of the collection section 5, there can be used, for example, stainless steel.
The collection section 5 can be arranged to exhibit, for example, a plate shape or a sheet shape. In the case of the collection section 5 exhibiting the sheet shape, it is also possible to arrange that the fiber 100 is deposited on the collection section 5 wound around a roll or the like.
The deposited body 110 formed on the collection section 5 is exfoliated from the collection section 5. The deposited body 110 is used as, for example, a nonwoven cloth or a filter. It should be noted that the application of the deposited body 110 is not limited to those illustrated above.
Here, when the fiber 100 charged is deposited on the collection section 5, the potential of the surface of the deposited body 110 rises as the thickness of the deposited body 110 increases. Therefore, as the thickness of the deposited body 110 increases, the fibers 100 become to repel each other on the surface of the deposited body 110. As a result, as shown in
When exfoliating the deposited body 110 from the collection section 5, the obverse side of the deposited body 110 is pulled upward.
However, the bonding force between the region 110a high in density of the fiber 100 and the region 110b low in density of the fiber 100 is weaker than the bonding force between the region 110a high in density of the fiber 100 and the collection section 5.
Therefore, as shown in
As described above, when forming the deposited body using the electrospinning method, in the thickness direction of the deposited body, the region high in density of the fiber occurs in a part closer to the member, and on the region high in density of the fiber, there occurs the region lower in density of the fiber than the region high in density of the fiber. In this case, when exfoliating the deposited body from the member, the exfoliation does not occur between the region high in density of the fiber and the member, but the exfoliation is apt to occur between the region low in density of the fiber and the region high in density of the fiber.
Therefore, the electrospinning apparatus 1 according to the embodiment is provided with the processing section 6.
The processing section 6 processes the deposited body 110 to form a mixture section 110c, in which the fiber 100 located in the region 110a high in density of the fiber 100 and the fiber 100 located in the region 110b low in density of the fiber 100 are mixed with each other, in the deposited body 110.
In other words, the processing section 6 forms the mixture section 110c, in which the fiber 100 located on the collection section 5 side of the deposited body 100 and the fiber 100 located on the opposite side to the collection section 5 side of the deposited body 110 are mixed with each other, in the deposited body 110.
As shown in
The contact section 60 has contact with the deposited body 110. The contact section 60 scrapes the deposited body 110 upward to thereby form the mixture section 110c in the deposited body 110.
As the contact section 60, there can be used a rotating body such as a roller or a brush. In this case, the larger the friction coefficient of the surface of the contact section 60 is, the more preferable. Further, it is preferable to make the contact section 60 have elasticity. As the contact section 60, there can be used, for example, a roller obtained by lining a metal shaft with resin such as rubber. The type of the resin is not particularly limited, but it is possible to use, for example, polyurethane rubber as the resin.
The moving section 61 rotatably holds the contact section 60, and at the same time, moves the contact section 60 to an end part of the deposited body 110. Then, the contact section 60 is pressed against to have contact with the end part of the deposited body 110, and the contact section 60 is rotated in a predetermined direction in that state. Specifically, the moving section 61 presses the contact section 60 against the end part of the deposited body 110 to make the contact section 60 have contact with the end part of the deposited body 110, and rotates the contact section 60 in the direction of scraping the both fibers 100 upward so as to be mixed with each other from the region 110a high in density of the fiber 100 to the region 110b low in density of the fiber 100 in the deposited body 110.
The moving section 61 is configured so as to move the contact section 60 in the direction of making the contact section 60 come closer to the deposited body 110, and in the direction of getting away from the deposited body 110.
Further, the moving section 61 controls the force (pressing force) when pressing the contact section 60 against the deposited body 110.
The moving section 61 can be made to be provided with, for example, a control motor such as a servomotor, or an air cylinder.
The guide section 62 defines the moving direction of the moving section 61. As the guide section 62, there can be used, for example, a linear motion bearing.
The control section 7 controls the operations of the supply section 32, the raw liquid control section 33, the power supply 4, and the moving section 61.
As the control section 7, there is used a computer provided with, for example, a CPU (Central Processing Unit) and a memory.
Then, an operation of the electrospinning apparatus 1 will be described.
The raw liquid is retained in the vicinity of the discharge port 20a of the nozzle 20 due to the surface tension.
The power supply 4 applies the voltage to the nozzle 20. Then, the raw liquid located in the vicinity of the discharge port 20a is charged to have a predetermined polarity. In the case of the apparatus illustrated in
Since the collection section 5 is grounded, an electric field is generated between the nozzle 20 and the collection section 5. Then, when the electrostatic force acting along the line of electric force becomes stronger than the surface tension, the raw liquid located in the vicinity of the discharge port 20a is drawn toward the collection section 5 due to the electrostatic force. The raw liquid thus drawn is stretched, and the solvent included in the raw liquid evaporates to thereby form the fiber 100. The fiber 100 thus formed is deposited on the collection section 5 to thereby form the deposited body 110.
Then, the mixture section 110c is formed in the deposited body 110.
As shown in
In the mixture section 110c, since the fiber 100 located in the region 110a high in density of the fiber 100 and the fiber 100 located in the region 110b low in density of the fiber 100 are entwined with each other, the region 110a high in density of the fiber 100 and the region 110b low in density of the fiber 100 are tightly bonded to each other. Further, the mixture section 110c includes the fiber 100 having contact with the collection section 5.
Therefore, if the mixture section 110c is pulled upward, the deposited body 110 can be exfoliated from the collection section 5 without causing the exfoliation between the region 110b low in density of the fiber 100 and the region 110a high in density of the fiber 100.
Therefore, according to the electrospinning apparatus 1 related to the embodiment, the damage of the deposited body 110 can be prevented.
As shown in
The contact section 60a has contact with the deposited body 110. The contact section 60a scrapes aside the deposited body 110 to thereby form the mixture section 110c in the deposited body 110.
As the contact section 60a, there can be used, for example, a plate-like body. In this case, it is preferable for the hardness of the contact section 60a to be made lower than the hardness of the collection section 5. If the hardness of the contact section 60a is lower than the hardness of the collection section 5, it is possible to prevent the damage from occurring in the collection section 5 even if the contact section 60a and the collection section 5 are made to have contact with each other. The contact section 60a can be formed from, for example, resin.
The moving section 61a holds the contact section 60a, and at the same time, makes the tip of the contact section 60a have contact with the surface of the collection section 5 on which the fiber 100 is deposited. Further, the moving section 61a reciprocates the contact section 60a in a direction parallel to the surface of the collection section 5 on which the fiber 100 is deposited.
The moving section 61a can be made to be provided with, for example, a control motor such as a servomotor or, an air cylinder.
Although the processing section 6 described above scrapes the deposited body 110 upward to thereby form the mixture section 110c, the processing section 6a according to the embodiment forms the mixture section 110c by scraping aside the deposited body 110. Therefore, if the mixture section 110c is pulled upward, the deposited body 110 can be exfoliated from the collection section 5 without causing the exfoliation between the region 110b low in density of the fiber 100 and the region 110a high in density of the fiber 100.
Therefore, according to the electrospinning apparatus 1 related to the embodiment, the damage of the deposited body 110 can be prevented.
As described above, the configuration of the processing section is not particularly limited providing the mixture section 110c, in which the fiber 100 located in the region 110a high in density of the fiber 100 and the fiber 100 located in the region 110b low in density of the fiber 100 are mixed with each other, can be formed in the deposited body 110.
However, if the roller is used as the contact section 60, it is possible to prevent the damage from occurring in the collection section 5 or a base member 120 described later.
Further, although there is illustrated the case of forming the mixture section 110c in the vicinity of the end part of the deposited body 110, the formation position of the mixture section 110c is not particularly limited. For example, it is also possible to segmentalize the deposited body 110, and at the same time, form the mixture section 110c. It should be noted that since the mixture section 110c is removed in a later process, if the mixture section 110c is formed in the vicinity of the end part of the deposited body 110, the region of the part to be the product can be made large.
It should be noted that in
As shown in
It should be noted that in the embodiment, the collection section 5a corresponds to the member on which the fiber 100 is deposited.
The collection section 5a is grounded. It is also possible to arrange that the voltage having an opposite polarity to the voltage applied to the nozzle 20 is applied to the collection section 5a. The collection section 5a can be formed of a conductive material. It is preferable for the material of the collection section 5a to have conductivity and a resistance property with respect to the raw liquid. As the material of the collection section 5a, there can be used, for example, stainless steel.
The collection section 5a is a rotatable roller. The collection section 5a is arranged to rotate due to a drive section not shown.
A tension section 8 is provided between the collection section 5a and a wind-up roller 9.
The tension section 8 has a pair of support rollers 80 and a dancer roller 81.
The pair of support rollers 80 support the deposited body shaped like a strip on a roller 5a described later.
The dancer roller 81 is provided between the support roller 80 and the support roller 80, and applies tension to the deposited body shaped like a strip described later. By applying the tension to the deposited body shaped like a strip described later using the dancer roller 81, the deposited body is exfoliated from the collection section 5a. Further, the deposited body shaped like a strip described later is prevented from being loosened between the collection section 5a and the wind-up roller 9.
The dancer roller 81 can be one for applying the tension to the deposited body described later with the weight, or can also be one for applying the tension to the deposited body with a spring or the like.
The wind-up roller 9 is arranged to rotate due to a drive apparatus not shown.
An exfoliation section 10 holds the mixture section 110c, and moves in a predetermined direction to separate the mixture section 110c from the collection section 5a. Specifically, the exfoliation section 10 exfoliates the deposited body 110 with a predetermined length from the collection section 5a.
The exfoliation section 10 can be made to be provided with an adhesive tape or a mechanical chuck. Further, it is also possible to make the exfoliation section 10 be provided with a moving section for moving the adhesive tape or the mechanical chuck, a guide section for defining the moving direction of the moving section, and so on similarly to the processing section 6.
Then, an operation of the electrospinning apparatus 1a will be described.
Firstly, as shown in
Then, as shown in
Then, as shown in
Then, as shown in
Then, as shown in
Subsequently, in substantially the same manner as in the electrospinning apparatus 1, the deposited body 110 is formed on the collection section 5a. Further, by rotating the collection section 5a and the wind-up roller 9, the deposited body 110 shaped like a strip is formed continuously. On this occasion, by applying the tension to the deposited body 110 shaped like a strip using the dancer roller 81, the deposited body 110 is exfoliated from the collection section 5a. Further, the deposited body 110 shaped like a strip is prevented from being loosened between the collection section 5a and the wind-up roller 9.
It should be noted that in
Further, in the embodiment, the base member 120 corresponds to the member on which the fiber 100 is deposited.
As shown in
The wind-up roller 11b takes up the base member 120 from which the deposited body 110 has been exfoliated.
The roller 11a and the wind-up roller 11b regionrranged to be rotated by the drive apparatus not shown.
Support rollers 12 are provided on a conveying path of the base member 120 between the roller 11a and the wind-up roller 11b. The number and the arrangement of the support rollers 12 can arbitrarily be changed in accordance with the conveying path of the base member 120.
A charge neutralizer 13 can be provided in the vicinity of the position where the deposited body 110 is exfoliated from the base member 120. The deposited body 110 is electrically charged. Therefore, there is a possibility that it becomes difficult to exfoliate the deposited body 110 from the base member 120, or the deposited body 110 once exfoliated is adsorbed to the dancer roller 81 or the support rollers 80. Therefore, it is arranged that the charge neutralizer 13 is provided to thereby reduce the charge amount of the deposited body 110.
A receiving platform 63 is provided at a position opposed to the contact section 60. It is arranged that the base member 120 passes through the contact section 60 side of the receiving platform 63.
Then, an operation of the electrospinning apparatus 1b will be described.
Firstly, as shown in
Then, as shown in
Then, as shown in
Then, as shown in
Then, as shown in
Subsequently, in substantially the same manner as in the electrospinning apparatus 1, the deposited body 110 is formed on the base member 120. Further, by rotating the roller 11a and the wind-up roller 11b, the deposited body 110 shaped like a strip is formed continuously. On this occasion, by applying the tension to the deposited body 110 shaped like a strip using the dancer roller 81, the deposited body 110 is exfoliated from the base member 120. Further, the deposited body 110 shaped like a strip is prevented from being loosened.
As described hereinabove, the method of manufacturing the deposited body 110 according to the embodiment can be provided with the following processes:
a process of forming the deposited body 100 by depositing the fiber 100 on the member using the electrospinning method; and
a process of forming the mixture section 110c, in which the fiber 100 located on the member side of the deposited body 110 and the fiber 100 located on the opposite side to the member side of the deposited body 110 are mixed with each other, in the deposited body 110.
In this case, the fiber 100 located on the member side of the deposited body 110 can be arranged to have contact with the deposited body 110.
Further, in the process of forming the mixture section 110c, it is possible to arrange that the mixture section 110c is formed by scraping the deposited body 110 upward.
Alternatively, in the process of forming the mixture section 110c, it is possible to arrange that the mixture section 110c is formed by scraping aside the deposited body 110.
Further, it is possible to further providing a process of making the mixture section 110c get away from the member by holding the mixture section 110c and moving the mixture section 110c in a predetermined direction.
It should be noted that the content of each of the processes can be made substantially the same as described above, and therefore, the detailed description will be omitted.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. Moreover, above-mentioned embodiments can be combined mutually and can be carried out.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-054826 | Mar 2016 | JP | national |
This is a continuation application of International Application PCT/JP2016/075679, filed on Sep. 1, 2016. This application also claims priority to Japanese Application No. 2016-054826, filed on Mar. 18, 2016. The entire contents of each are incorporated herein by reference.
| Number | Name | Date | Kind |
|---|---|---|---|
| 20090031691 | Tajima | Feb 2009 | A1 |
| Number | Date | Country |
|---|---|---|
| 3-220305 | Sep 1991 | JP |
| 2006-169644 | Jun 2006 | JP |
| 2015-214161 | Dec 2015 | JP |
| Entry |
|---|
| International Search Report dated Nov. 8, 2016 in PCT/JP2016/075679, filed on Sep. 1, 2016 (with English Translation of Categories of cited documents). |
| Written Opinion dated Nov. 8, 2016 in PCT/JP2016/075679, filed on Sep. 1, 2016. |
| Number | Date | Country | |
|---|---|---|---|
| 20170362741 A1 | Dec 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2016/075679 | Sep 2016 | US |
| Child | 15696935 | US |
