Edge electrospinning for high throughput production of quality nanofibers

A novel, simple geometry for high throughput electrospinning from a bowl edge is presented that utilizes a vessel filled with a polymer solution and a concentric cylindrical collector. Successful fiber formation is presented for two different polymer systems with differing solution viscosity and solvent volatility. The process of jet initiation, resultant fiber morphology and fiber production rate are discussed for this unconfined feed approach. Under high voltage initiation, the jets spontaneously form directly on the fluid surface and rearrange along the circumference of the bowl to provide approximately equal spacing between spinning sites. Nanofibers currently produced from bowl electrospinning are identical in quality to those fabricated by traditional needle electrospinning (TNE) with a demonstrated ~ 40 times increase in the production rate for a single batch of solution due primarily to the presence of many simultaneous jets. In the bowl electrospinning geometry, the electric field pattern and subsequent effective feed rate are very similar to those parameters found under optimized TNE experiments. Consequently, the electrospinning process per jet is directly analogous to that in TNE and thereby results in the same quality of nanofibers.