DEVICE FOR POLYMER MATERIALS FABRICATION USING GAS FLOW AND ELECTROSTATIC FIELDS

Abstract

Electrospinning (ES) produces fibers with small cross-sections and high surface area, making them ideal for a multitude of applications. Structures produced using ES methods exhibit a high surface-to-volume ratio, tunable porosity, and controllable composition. ES involves the delivery of a liquid or solid polymer to a spinneret, whereby, an initiated electric field pulls the polymer into micro to nano-scale fibers. Due to the multitude of applications for which polymer fibers can be used, it is desirable to provide an efficient and portable ES device that allows on-demand deposition of polymer materials. The invention that is subject of this patent application is a portable ES device that allows ideal deposition on a substrate regardless of whether that substrate is attached to high voltage or grounded, and regardless of whether or not there is a charged or grounded substrate behind the desired deposition surface.

Claims

1. A portable ES device comprising: A device barrel, wherein said device barrel is comprised of a first end and a second end; A spinneret encapsulated by said device barrel, wherein said spinneret is located in proximity to said first end of said device barrel; A conductive electrode located in proximity to said second end of said device barrel, wherein an electrostatic field is produced between said spinneret and said conductive electrode; and An air flow means, which directs electrospun material from said spinneret to a surface or substrate for deposition.

2. The portable ES device of claim 1, wherein said conductive electrode is located on the outside of said device barrel to isolate said conductive electrode from electrospun material.

3. The portable ES device of claim 1, wherein said conductive electrode is comprised of a ring electrode.

4. The portable ES device of claim 1, wherein said surface or substrate is ungrounded.

5. The portable ES device of claim 1, wherein said spinneret is connected to a high voltage source.

6. The portable ES device of claim 1, wherein said spinneret is grounded.

7. The portable ES device of claim 1, wherein said conductive electrode is connected to a high voltage source.

8. The portable ES device of claim 1, wherein said conductive electrode is grounded.

9. The portable ES device of claim 1 further comprising mechanically-powered means to deliver polymer to said spinneret.

10. The portable ES device of claim 9, wherein said mechanically-powered means is comprised of a pump.

11. The portable ES device of claim 1 further comprising a thermal system comprising of a controller and heating means to melt solid polymer prior to delivery to said spinneret.

12. The portable ES device of claim 1 further comprising a power supply means used to supply the system with high voltage, wherein said power supply means comprises a EMCO CB 101 device that converts low DC voltage to high DC, a 12 V battery, and a 5V signal controller to vary potential output.

13. The portable ES device of claim 1, wherein said barrel and said airflow means are further comprised of quick connect components to allow for easy connection and disconnection.

14. The portable ES device of claim 1, further comprising a crossflow system comprised of a first perpendicular opening of said device barrel, where said airflow means is connected to direct said airflow stream through the device barrel perpendicular to said electrostatic field, wherein, said airflow stream exits the device barrel through a second perpendicular opening of said device barrel.

15. The portable ES device of claim 14, wherein said second perpendicular opening is selectively fitted with a perpendicular barrel.

16. The portable ES device of claim 1, wherein said airflow means is battery powered.

17. A method of depositing electrospun materials on a substrate or surface comprising: a. providing a portable ES device comprising a device barrel, wherein said device barrel is comprised of a first end and a second end; A spinneret encapsulated by said device barrel, wherein said spinneret is located in proximity to said first end of said device barrel; A conductive electrode located in proximity to said second end of said device barrel, wherein an electrostatic field is produced between said spinneret and said conductive electrode, wherein said conductive electrode is located on the outside of said device barrel to isolate said conductive electrode from electrospun material; and An air flow means, which directs electrospun material from said spinneret to a surface or substrate for deposition; b. Electrospinning a material wherein said material is drawn from said spinneret in the direction of said conductive electrode. c. Depositing said material onto said substance or surface, wherein said material is directed to said surface by said airflow means.

18. The method of depositing electrospun materials on a substrate or surface of claim 17, wherein said portable ES device further comprises a crossflow system comprised of a first perpendicular opening of said device barrel, where said airflow means is connected to direct said airflow stream through the device barrel perpendicular to said electrostatic field, wherein, said airflow stream exits the device barrel through a second perpendicular opening of said device barrel.

19. The method of depositing electrospun materials on a substrate or surface of claim 18, wherein said second perpendicular opening is selectively fitted with a perpendicular barrel.

20. The method of depositing electrospun materials on a substrate or surface of claim 17, wherein said material is comprised of antibiotic-containing polymer fibers.

21. The method of depositing electrospun materials on a substrate or surface of claim 17, wherein said material is comprised of antibiotic-containing fiber mesh.

22. The method of depositing electrospun materials on a substrate or surface of claim 17, wherein said material is comprised of pH sensing materials.

23. The method of depositing electrospun materials on a substrate or surface of claim 17, wherein said material is comprised of polymer containing conductive dopants.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0025] FIG. 1 Conceptual depiction of portable ES devices in the prior art, which utilize a system where a ground or high-voltage substrate or a ground or high-voltage surface behind a non-charged substrate is required. A Portable ES set up that includes a non-charged substrate that must be delivered a high voltage signal to pull polymer from a grounded spinneret tip to substrate. B Portable ES set up that includes a non-charged substrate that must be grounded to pull polymer from charged spinneret tip to substrate. C Portable ES set up that includes a non-charged substrate that must be placed in the electrostatic field between the grounded spinneret and a surface that is supplied with high voltage. D Portable ES set up that includes a non-charged substrate that must be placed in the electrostatic field between the charged spinneret and a surface that is grounded.

[0026] FIG. 2 Depiction of the portable ES device described herein. Electrostatic force pulls polymer from the spinneret toward a ring electrode, at which point, airflow overcomes the electrostatic force and directs polymer through the center of the ring electrode and onto a deposition surface or substrate beyond the end of the ES device, regardless of the charge of the deposition surface or substrate. A. One embodiment of the portable ES device, in which, a grounded spinneret and high voltage conductive ring electrode are used to deposit onto a non-conductive substrate. B. A second embodiment of the portable ES device, in which, a spinneret connected to high voltage and a grounded ring electrode are used to deposit onto a non-conductive substrate.

[0027] FIG. 3 A. Photo of electrospun fibers deposited by the portable ES device onto fetal porcine skin. B. Electrospun fibers deposited by the portable ES device onto an apple. C. Electrospun fibers deposited by the portable ES device onto fabric. D. Electrospun fibers deposited by the portable ES device onto dampened rawhide held at physiological temperature.

[0028] FIG. 4 A. Photo of portable ES device depositing antibiotic-containing polymer fibers directly onto a non-conductive agar plate. B. Antibiotic-containing polymer fiber mesh deposited onto a non-conductive substrate and peeled up before being placed in petri dish. C Antibiotic-containing fiber mesh from B after being dropped onto a bacterial plate and allowed to dissolve, thereby releasing the antibiotics. Di. Streak plate containing Staphylococcus aureus after overnight growth at 37° C., Dii. shows control streak plate from Di after being treated with a polymer-only electrospun mesh, and finally, Diii. shows a large bacterial death zone where antibiotic-containing electrospun fibers were deposited and dissolved to kill bacteria.

[0029] FIG. 5 Depiction of using the portable ES device to produced polymer fiber mats doped with commercial pH sensing compounds. In literature, it has been shown that pH change can indicate impending bacterial infection. The portable ES device allows direct deposition of pH sensing materials onto open wound sites. After deposition, color change could indicate an impending infection and deployment of preventative measures or early treatment could be employed to reduce severe side effects.

[0030] FIG. 6 A. Photo of electrospun mat produced by the portable ES device. The polymer used contained conductive dopants. B. Scanning electron micrograph showing the fiber morphology of the electrospun mat from A. C. Using a four-point probe, current was sourced through the conductive fiber mat and potential difference was measured. The resulting current-voltage (I-V) curves show that current indeed traveled through the fiber mat. Lack of electrical signals across the fiber mat would indicate non-conductivity. I-V characteristics are governed by Ohm's Law.

[0031] FIG. 7 Solid Works model of the portable ES device. During ES, pre-dissolved or melted solid polymer are delivered to the spinneret by mechanical force. Due to the charge or grounded state of the spinneret and conductive ring, an electrostatic force pulls polymer from spinneret tip towards the conductive ring. Airflow delivered to the system forces polymer materials through the ring center and away from the ring, onto a charged or non-charged substrate beyond the device.

[0032] FIG. 8 Plan view of the portable ES device. During ES, pre-dissolved or melted solid polymer are delivered to the spinneret by mechanical force. Due to the charge or grounded state of the spinneret and conductive ring, an electrostatic force pulls polymer from spinneret tip towards the conductive ring. Airflow delivered to the system guides polymer materials away from the ring and through the ring center, onto a charged or non-charged substrate beyond the device.

[0033] FIG. 9 Depiction of the crossflow embodiment of the portable ES device. In the crossflow system, electrostatic force directs polymer materials toward an electrode before being re-directed by a perpendicular airflow stream onto a charged or non-charged substrate located perpendicular to the spinneret and electrostatic field and outside of the barrel of the device.

[0034] FIG. 10 Plan view showing the crossflow embodiment of the portable ES device. In the crossflow system, electrostatic force directs polymer materials toward an electrode before being re-directed by a perpendicular airflow stream onto a charged or non-charged substrate located perpendicular to the spinneret and electrostatic field and outside of the barrel of the device.

DETAILED DESCRIPTION OF THE INVENTION

[0035] Portable ES devices in the prior art, which utilized a system where a ground or high-voltage substrate or a ground or high-voltage surface behind a non-charged substrate is required are depicted in FIG.1. FIG. 1A shows a Portable ES set up 100 that includes a non-charged substrate 101 that must be delivered a high voltage signal 102 to pull polymer from a grounded 103 spinneret tip 104 to the substrate 101. FIG. 1B shows a portable ES set up 105 that includes a non-charged substrate 101 that must be grounded 103 to pull polymer from high voltage 102 charged spinneret tip 104 to substrate 101. FIG. 1C depicts a Portable ES set up 106 that includes a non-charged substrate 101 that must be placed in the electrostatic field 107 between the grounded 103 spinneret 104 and a surface 108 that is supplied with high voltage 102. FIG. 1D depicts a Portable ES set up 109 that includes a non-charged substrate 101 that must be placed in the electrostatic field 107 between the high voltage charged 102 spinneret 104 and a surface 108 that is grounded 103.

[0036] The invention described herein is a portable ES device that allows deposition directly onto surfaces that may or may not carry charge. FIG. 2, FIG. 7-10. The portable ES device 200 described herein allows direct deposition onto charged or non-charged surfaces or substrates 201 that exist outside the electric field 202 created by the device 200. While the electrostatic force encased within the portable ES device provides the force necessary to create polymer fibers or droplets from liquified polymer, it does not require the deposition surface or substrate 201 to be charged or grounded, nor does it require a charged or grounded surface 108 be placed behind the desired deposition surface or substrate 201. Using airflow means 203, the described portable ES device 200 forces polymer materials outside of the device and onto charged or non-charged surfaces or substrates 201.

[0037] As depicted in FIGS. 2, 7 and 8, electrostatic force pulls polymer from the spinneret 204 toward a ring electrode 205, at which point, airflow 203 comprised of airflow means 210 connected to a first end 211 of the barrel 212 of the device overcomes the electrostatic force and directs polymer through the center of the ring electrode 205 and onto a deposition surface or substrate 201 beyond the second end 213 of the portable ES device barrel 212, regardless of the charge of the deposition surface or substrate 201. This system does not require the substrate 201 be exposed to the electric field 202, thereby allowing for direct deposition onto living things without presenting a shock hazard. Furthermore, the deposition surface or substrate is not required to be grounded. In one embodiment of the portable ES device 200, shown in FIG. 2A, a grounded 206 spinneret 204 and high voltage 208 conductive ring electrode 205 are used to deposit onto a non-conductive substrate 201. FIG. 2B depicts another embodiment of the portable ES device 200, wherein a spinneret 204 connected to high voltage 208 and a grounded 206 ring electrode 205 are used to deposit onto a non-conductive substrate 201.

[0038] The portable ES device described herein is comprised of the following components:

[0039] (1) Battery powered or plugged in airflow means 210 for control over fiber placement onto a charged or non-charged surface 201 outside of the device barrel 212.

[0040] (2) Airflow connect system 214 that centers the spinneret 204 in the airflow stream and connects airflow means 210 to the rest of the system.

[0041] (3) Device barrel 212, which encapsulates the spinneret 204, which is either connected to high voltage 208 or is grounded 206.

[0042] (4) A conductive, enclosed spinneret 204 that is connected to high voltage 208 or ground 206 and is the port of entry for polymer into the system.

[0043] (5) Polymer is delivered into the spinneret 204 by way of a mechanically-powered means 220. Said mechanically-powered means 220 are preferably comprised of a pump system. Said mechanically-powered means can be further comprised of a syringe.

[0044] (6) A conductive electrode, preferably comprised of a ring electrode 205, which is placed near the second end 213 of the device barrel 212 and can be positioned within, on the edge of, or outside of the device barrel 212. Positioning said conductive electrode on the outside of said barrel 212 has the added advantage of completely isolating said conductive electrode from the electrospun material being deposited.

[0045] (7) A thermal system 250 comprising a controller and heating means to allow the option of using solid instead of solvent-dissolved polymer in the system. The thermal system 250 melts solid polymers real-time as they enter the spinneret 204 and move through the barrel 212 of the portable ES system 200. (8) A power supply means used to supply the system with high voltage 208. Said power supply means can comprise an EMCO CB 101 device that converts low DC voltage to high DC, a 12 V battery, and a 5V signal controller to vary potential output.

[0046] (9) The portable ES device 200 further comprises quick-connect components that can be assembled and disassembled easily and rapidly for device maintenance and preparation.

[0047] (10) The ES device 200 can be further comprised of an optional crossflow embodiment 230 depicted in FIGS. 9 and 10, where the crossflow system comprises an electrostatic field 202 directing polymer materials toward a conductive electrode 231 before being re-directed by a perpendicular airflow stream 232 onto a non-charged or grounded substrate 201 located perpendicular to the spinneret 204. Said conductive electrode 231 can be located within the device barrel 212 or on the outside of said device barrel, which has the added advantage of completely isolating said conductive electrode from the electrospun material to be deposited. Said conductive electrode 231 can be further comprised of a ring electrode 205. In this embodiment, the system is further comprised of a first perpendicular opening 240 of said device barrel 212, where said airflow means 210 is connected to direct said perpendicular airflow stream 232 through the device barrel 212 perpendicular to said electrostatic field 202. Said airflow stream 232 then exits the device barrel 212 through a second perpendicular opening 241 of said device barrel 212. Said second perpendicular opening can be selectively fitted with a perpendicular barrel 242, through which electrospun fibers are deposited onto said surface or substrate 201. Said perpendicular barrel 242 can be shaped and sized in any manner to accommodate different application sizes, thicknesses, etc. This embodiment further reduces potential electrostatic field exposure of the surface or substrate receiving the deposition. Furthermore, this embodiment reduces electrode fouling and the necessity to clean electrodes during use.

[0048] The portable ES device 200 described herein has dramatically reduced size as compared to a typical tabletop electrospinner. This allows the portable ES device to be easily handled by hand and allows the user to manually coat surfaces evenly. In a traditional ES unit, a complex structure such as a ball would be coated unevenly. However, the handheld, portable ES device 200 described herein can be maneuvered to evenly coat non-charged or charged surfaces 201 such as complex implants or wound beds.

[0049] The ES device described herein does not require a charged or grounded surface behind the desired deposition surface or substrate 201. Using the portable ES device described herein, the substrate to be deposited onto is not placed within the electrostatic field during ES, nor is required to be supplied with a voltage or grounded in order for polymer to be deposited onto the surface. Examples of non-charged, non-grounded substrates used to demonstrate deposition with the portable ES device are pictured in FIG. 3. FIG. 3A is a photo of electrospun fibers deposited by the portable ES device onto fetal porcine skin. FIG. 3B is a photo of electrospun fibers deposited by the portable ES device onto an apple. FIG. 3C is a photo of electrospun fibers deposited by the portable ES device onto fabric. FIG. 3D is a photo of electrospun fibers deposited by the portable ES device onto dampened rawhide held at physiological temperature.

[0050] In the literature, there are many examples where traditional, tabletop ES fabrication was used to make biomedical materials. The portable ES device claimed here allows these materials to be deposited directly into wound sites, onto implants, and onto tissues or organs. Such uses of the device prevent contamination by handling and decrease time to treatment. By using antibiotic doped polymers the portable ES device can deposit onto non-conductive surfaces and dissolve to release antibiotics to prevent bacterial growth as shown in FIG. 4. FIG. 4A is a photo of portable ES device depositing antibiotic-containing polymer fibers directly onto a non-conductive agar plate. FIG. 5B is a photo of antibiotic-containing polymer fiber mesh deposited onto a non-conductive substrate and peeled up before being placed in petri dish. FIG. 4C is a photo of antibiotic-containing fiber mesh from B after being dropped onto a bacterial plate and allowed to dissolve, thereby releasing the antibiotics. FIG. Di is a photo of a streak plate containing Staphylococcus aureus after overnight growth at 37° C. FIG. Dii shows control streak plate from Di after being treated with a polymer-only electrospun mesh, and finally, FIG. Diii shows a large bacterial death zone where antibiotic-containing electrospun fibers were deposited and dissolved to kill bacteria.

[0051] The portable ES device can also be used to deposit pH sensing materials for early detection of impending infection, which is depicted in FIG. 5. In literature, it has been shown that pH change can indicate impending bacterial infection. The portable ES device allows direct deposition of pH sensing materials onto open wound sites. After deposition, color change could indicate an impending infection and deployment of preventative measures or early treatment could be employed to reduce severe side effects.

[0052] The portable ES device can also be used to produce electrospun mats with conductive dopants. FIG. 6A is a photo of an electrospun mat produced by the portable ES device. The polymer used contained conductive dopants. FIG. 6B is a scanning electron micrograph showing the fiber morphology of the electrospun mat from FIG. 6A. FIG. 6C shows using a four-point probe, current was sourced through the conductive fiber mat and potential difference was measured. The resulting current-voltage (I-V) curves show that current indeed traveled through the fiber mat. Lack of electrical signals across the fiber mat would indicate non-conductivity. I-V characteristics are governed by Ohm's Law.

[0053] Those skilled in the art will recognize many other applications of the portable ES device, where direct deposition of fibers onto charged or non-charged surfaces would be useful and such uses are contemplated within this disclosure.

[0054] Distinguishing capabilities of the portable ES device subject of this patent described herein include, but are not limited to the ability to deposit onto any conductive or non-conductive substrate, the ability to be moved by hand to coat complex surfaces evenly, and the ability electrospin conductive materials reliably. In a traditional ES unit, ES conductive polymers results in an electric circuit that connects the conductive spinneret, through the conductive polymer being electrospun, to the conductive deposition substrate. This connected electric circuit results in arcing and unpredictable material deposition. In the portable ES device claimed here, the electric field is completely encased in the device barrel and is not exposed to environmental factors. In addition, because conductive polymer fibers do not make contact with the ring electrode and are instead forced through the ring center by air and/or are isolated from the electrospun material by the device barrel, artifacts from a connected electrical circuit are prevented. Furthermore, the cross-flow embodiment reduces potential electrostatic field exposure of the surface or substrate receiving the deposition.

[0055] It is understood that the foregoing examples are merely illustrative of the present invention. Certain modifications of the articles and/or methods may be made and still achieve the objectives of the invention. Such modifications are contemplated as within the scope of the claimed invention.