Differential-Integral method in polymer processing: Taking melt electrospinning technique for example

Abstract

A concept of Differential-Integral (DI) method applied in polymer processing and molding was proposed, which included melt DI injection molding, DI nano-composites extrusion molding and melt differential electrospinning principle and equipment. Taking the melt differential electrospinning for example to introduce the innovation research progress, two methods preparing polymer ultrafine fiber have been developed: solution electro-spinning and melt electro-spinning, between which solution electro-spinning is much simpler to realize in lab. More than 100 institutions have endeavored to conduct research on it and more than 30 thousand papers have been published. However, its industrialization was restricted to some extend because of the existence of toxic solvent during spinning process and poor mechanical strength of resultant fibers caused by small pores on fiber surface. Solvent-free melt electrospinning is environmentally friendly and highly productive. However, problems such as the high melt viscosity, thick fiber diameter and complex equipment makes it relatively under researched compared with solution electrospinning. With the purpose of solving the shortage of traditional electro-spinning equipment with needles or capillaries, a melt differential electro-spinning method without needles or capillaries was firstly proposed. Nearly 50 related patents have been applied since 2005, and systematic method innovations and experimental studies have also been conducted. The prepared fiber by this method had exhibited small diameter and smooth surface. The average fiber diameter can reach 200-800 nm, and the single nozzle can yield two orders of magnitude more than the capillaries. Based on the above principle, complete commercial techniques and equipment have been developed to produce ultra-fine non-woven fabrics for the applications in air filtration, oil spill recovery and water treatment, etc.