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A Critique on Multi-Jet Electrospinning: State of the Art and Future Outlook Clothing and Fabrics Manufacture

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A Critique on Multi-Jet Electrospinning: State of the Art and Future Outlook Clothing and Fabrics Manufacture Nanotechnol Rev 2019; 8:236–245 Review Article Hosam El-Sayed*, Claudia Vineis, Alessio Varesano, Salwa Mowafi, Riccardo Andrea Carletto, Cinzia Tonetti, and Marwa Abou Taleb A critique on multi-jet electrospinning: State of the art and future outlook https://doi.org/10.1515/ntrev-2019-0022 clothing and fabrics manufacture. In 1738 Lewis Paul was Received Jan 29, 2019; accepted Jul 01, 2019 granted a patent for roller drafting spinning machinery [1]. Toward the end of the nineteenth century, the ring process Abstract: This review is devoted to discuss the unique char- was fairly well perfected, and its use was becoming stan- acteristics of multi-jet electrospinning technique, com- dard throughout the world. Ring spinning is about 250% pared to other spinning techniques, and its utilization in more productive than mule spinning and is simpler and spinning of natural as well as synthetic polymers. The less expensive to operate so; the mass production arose in advantages and inadequacies of the current commercial the 18th century with the beginnings of the industrial revo- chemical spinning methods; namely wet spinning, melt lution. spinning, dry spinning, and electrospinning are discussed. Yarns are usually spun from a various materials that The unconventional applications of electrospinning in tex- could be natural fibers viz., animal and plant fibers, or syn- tile and non-textile sectors are reported. Special empha- thetic ones. sis is devoted to the theory and technology of the multi- jet electrospinning as well as its applications. The current status of multi-jet electrospining and future prospects are outlined. Using multi-jet electrospinning technique, vari- 2 Types of spinning ous polymers have been electrospun into uniform blend nanofibrous mats with good dispersibility. In addition to Spinning process is classified according to the fiber types the principle of multi-jet electro electrospinning, the differ- which we want to process into: chemical spinning and me- ent devices used for this technique are also highlighted. chanical spinning. Keywords: Multi-jet electrospinning, biopolymers, nanofi- bres, nonwoven mats Mechanical spinning Mechanical spinning is a multistep process in which fibers 1 Introduction are spun into yarns physically. Viz., rotor, ring, friction, or self-twist spinning. Spinning is an art that has been utilized in formation of yarn by drawing out and twisting natural or synthetic fibers. Thousands of years ago, fibers were spun manu- Chemical spinning ally with simple tools as distaff and spindle. The spindle was the first tool used for spinning all the threads usedfor Making filament yarns from man-made fibers is feasible using chemical spinning operations. This is achieved by extruding the viscous polymer solution through a nozzle *Corresponding Author: Hosam El-Sayed: Industrial Textile Re- (spinneret). There are three main types of production pro- search Division, National Research Centre, El-Behouth St., Dokki, cesses to form synthetic fibers [2]. Giza, Egypt; Email: [email protected] The wet-spinning process: in which solidification of Claudia Vineis, Alessio Varesano, Riccardo Andrea Carletto, the soluble polymer occurs after a counter current diffu- Cinzia Tonetti: CNR-ISMAC, National Research Council of Italy- Institute for Macromolecular Studies, C. so G. Pella, 16-13900 Biella, sion between the spinning dope and the coagulation bath. Italy The dry-spinning process: where the evaporation of Salwa Mowafi, Marwa Abou Taleb: Industrial Textile Research the solvent contained in the spinning dope leads to solidi- Division, National Research Centre, El-Behouth St., Dokki, Giza, fication. Egypt Open Access. © 2019 H. El-Sayed et al., published by De Gruyter. This work is licensed under the Creative Commons Attribution 4.0 License A critique on multi-jet electrospinning: State of the art and future outlook Ë 237 Figure 1: Wet-spinning device [3] The melt-spinning process: where phase transforma- tion is due to the solidification from a molten mass. 3 Different techniques of chemical spinning 3.1 Wet spinning technique In this process a very viscous polymer solution is extruded through the small holes of a spinneret dipped in a liquid bath. Technological analysis of the wet spinning process is much more complicated than dry spinning where the spin- ning process is accompanied by chemical reaction. Solid- ification of the polymer occurs as a result of a diffusional exchange between the freshly prepared fluid filaments and this bath. During this process coagulation one or more of Figure 2: Melt-spinning process [8] the bath components diffuse into the filament, while the solvent diffuses out of it [3]. The polymer precipitates or 3.2 Melt spinning technique crystallizes as a consequence of this exchange, because it is rendered insoluble by chemical reaction of the polymer Melt spinning is the most appropriate and economic pro- or by an excessive buildup of non-solvent or by both [4] cess for polymer fiber manufacturing at industrial scales. (Figure 1). Spinning of polyester, or any other molten polymers like Wet spinning technique is found to have the advan- nylon and polypropylene, begins upon cooling the molten tage of producing reelable fiber that can be drawn and filament once it is withdrawn from the spinneret. Atthe tested for mechanical properties. Its main disadvantages same time, the filament is drawn towards the take-up sec- are (a) the slow rate of processing, as the produced fila- tion and the resulting tension offers a stretching in the ments need to be washed to remove impurities, and (b) molten filament itself [7]. low productivity. Polymers can be regenerated by wet spin- Because the apparent viscosity of the molten filament ning technique like, silk [5] and cellulose [6] by dissolu- increases as it cools, most of the stretching takes place tion in ionic liquids, followed by spinning in a coagulating in a region relatively close to the spinneret hole, whereas baths of methanol, acetonitrile, or water. Acrylic polymer most of the cooling takes place after leaving the hole as can be spun by wet spinning technique by dissolving the shown in Figure 2. The comparatively simple and easy pro- polymer in dimethyl formamide which can be coagulated cessing is the most important advantage of melt spinning. in water [4]. However, this technique has some drawbacks; Viz. possi- 238 Ë H. El-Sayed et al. ble fiber breakdown, heterogeneous thickness of the fila- fibril) or hollow shape (a tubule). The importance ofthis ment, and limit to the fineness of fiber and spinneret clog- method arises from the fabrication of nanometer tubules ging. and fibrils of various raw materials such as semiconduc- tors, metals, and electrically conducting polymers. Unlike drawing process, this method cannot make one-by-one 3.3 Dry spinning technique continuous nanofibers. The phase separation process con- sists of several steps; namely dissolution, gelation, extrac- In the process of dry spinning, the fiber structure is formed tion with various solvent, freeze-drying which leads to for- by forcing the polymer solution out through fine nozzle mation of porous nano-foam. The phase separation pro- and then evaporating the solvent. Technological analysis cess is found to take a relatively long time to convert the of the dry spinning process is much more difficult than polymer into the nano-porous foam. In self-assembly pro- of melt spinning which is treated as a problem of struc- cess, the pre-existing components are self-organized to the tural formation in a one-component system. Unlike melt required forms and functions. Like the phase separation spinning, in both dry and wet spinning, the polymer dis- process, the self-assembly is a time-consuming process solves in different solvents and the resulting solution or in spinning continuous polymer nanofibers. Electrospin- suspension is viscous spin dope [9]. This process mainly in- ning is a type of dry spinning technique where the solvent troduces another species, which is consequently removed, is evaporated under high voltage. Thus, the electrospin- and therefore it is more expensive than conventional melt ning process turns out to be the most developing process spinning processes. It is used in cases where the poly- for mass production of one-by-one continuous nanofibers mer may decompose thermally when melted or in cases from different polymers. where specific surface properties of the filaments are de- sired where melt spinning produces smooth surface fila- ment and dry spinning produces rough surface filament. 5 Electrospinning and its The rough surfaces may be necessary for better dyeing steps or for special yarn features (Figure 3). applications The process of polymer fiber formation within an electric field has been known since the 1930s. This technique was named electrostatic spinning or electro-spinning in the 1990s. Electro-spinning is the proper method to produce nanofibers [19]. Since 1980s and especially in recent years, the electrospinning process especially similar to that de- scribed by Baumgarten [20], has acquired more attention probably due to the excessive interest in nanotechnology, where ultrafine fibers for various polymers with submi- Figure 3: Dry-spinning process [10] crons or nanometer scale can be easily fabricated with this technique. A variety of polymers can be spun each from a specific solution and collected in the form of nonwo- ven mats. In addition, the ability to produce highly porous 4 Innovative processes for fiber nano-fibrous membranes with structural integrity is also an attractive feature of electrospinning [21]. When the di- manufacture ameters of spun fibers are decreased from micro-scale (e.g. 10–100 µm) to submicro-scale or nano-scale (e.g. 10–100 A number of processing techniques such as drawing [11], × 10−3 µm), then the fibers exhibit new technically fasci- template synthesis [12, 13], phase separation [14], self- nating features; Viz. up to 100% increase in the surface assembly [15, 16], electrospinning [17, 18] etc., have been area to volume ratio, enhanced superficial functions, im- used to prepare nanofibers in recent years.
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