Electrospinning has enabled creation of excellent materials for a great number of applications. Previously, it was based on less productive capillary spinners. The present study is based on recent efforts to elevate electrospinning technology to an industrial level by simultaneously provoking innumerable polymeric jets from a sufficiently large liquid surface to increase productivity. Particularly, it deals with electrospinning from free surface of conductive liquids and validates a formulated hypothesis that explains self-organization of jets on one-dimensional free liquid surfaces in terms of electrohydrodynamic instability of surface waves. Here, it is shown how the hypothesis, based on a profound analysis of a dispersion law, explains that above a certain critical value of applied electric field intensity∕field strength the system starts to be self-organized in mesocopic scale due to the mechanism of the “fastest forming instability.” The mechanism plays a key role in selecting a particular wave with a characteristic wavelength whose amplitude boundlessly grows faster than the others. The fastest growing stationary wave, according to the hypothesis, marks the onset of electrospinning from a free liquid surface with its jets originating from the wave crests. Singularity of this approach lies in predicting critical values of the phenomenon, viz., critical field strength and corresponding critical interjet distance. The critical field strength, will, thereafter, be used in defining a unique dimensionless electrospinning number. It will, subsequently, be shown how the critical interjet distance, i.e., the maximal distance between the neighboring jets, simply depends on the capillary length. The capillary length represents a latent characteristic spatial scale of the system. The theory also predicts interjet distance for field strengths above the critical value. The said prediction is universally applicable for all conductive liquids if it is expressed in terms of the dimensionless parameters of the interjet distance and the electrospinning number. The theory also predicts relaxation time, necessary for spontaneous jetting after a high voltage is applied. The theoretical considerations are eventually compared to that of Zeleny’s, obtained for capillary electrospinner to demonstrate universality of the approach. Eventually, jetting from free liquid surface on specially designed linear cleft electrospinner are observed, analyzed, and compared to the theoretical predictions obtaining satisfactory results.

Nanofibrous materials are essential components for a wide range of applications, particularly in the fields of medicine and material engineering. These include protective materials, sensors, cosmetics, hygiene, filtration and energy storage. The most widely used and researched technology in these fields is electrospinning. This method for producing fibers yields highly promising results thanks to its versatility and simplicity. Electrospinning is employed in multiple forms, among which needle and needleless direct current (DC) variants are the most distinctive. The former is based on the generation of just one single jet from a nozzle; hence this fabrication process is not very productive. The latter uses the destabilization of free liquid surfaces by means of an electric field, which enhances the throughput since it produces numerous jets, emitted from the surfaces of rollers, spheres, strings and spirals. However, although some progress in total producibility has been achieved, the efficiency of the DC method still remains relatively low. A further drawback of DC electrospinning is that both variants need a collector, which makes it difficult to combine DC electrospinning easily with other technologies due to the presence of the high field strength within the entire spinning zone. This paper describes our experiments with AC electrospinning. We show that alternating current (AC) electrospinning based on a needleless spinning-electrode provides a highly productive smoke-like aerogel composed of nanofibers. This aerogel rises rapidly from the electrode like a thin plume of smoke, without any need for a collector. Our work shows that AC needleless electrospinning gains its efficiency and collector-less feature thanks to the creation of a perpetually charge-changing virtual counter-electrode composed of the nanofibers emitted. High-speed camera recordings demonstrate the formation mechanism of the nanofibrous plume, which is wafted by an electric wind. This wind's velocity field is experimentally investigated. One potential use of AC needleless electrospinning is demonstrated here by spinning it into a yarn.

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Nanotechnologies allow the production of yarns containing nanofibres for use in composites, membranes and biomedical materials. Composite yarns with a conventional thread core for mechanical strength and a nanofibrous envelope for functionality, e.g. biological, catalytic, have many advantages. Until now, the production of such yarns has been technologically difficult. Here, we show an approach to composite yarn production whereby a plume of nanofibers generated by high throughput AC needleless and collectorless electrospinning is wound around a classic thread. In the resulting yarn, nanofibres can form up to 80% of its weight. Our yarn production speed was 10 m/min; testing showed this can be increased to 60 m/min. After the yarn was embedded into knitwear, scanning electron microscope images revealed an intact nanofibrous envelope of the composite yarn. Our results indicate that this production method could lead to the widespread production and use of composite nanofibrous yarns on an industrial scale.

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Abstract. Wet electrospinning is a useful method for 3-dimensional structure control of nanofibrous materials. This innovative technology uses a liquid collector instead of the metal one commonly used for standard electrospinning. The article compares the internal structural features of polycaprolactone (PCL) nanofibrous materials prepared by both technologies. We analyze the influence of different water/ethanol compositions used as a liquid collector on the morphology of the resultant polycaprolactone nanofibrous materials. Scanning electron micro-photographs have revealed a bimodal structure in the wet electrospun materials composed of micro and nanofibers uniformly distributed across the sample bulk. We have shown that the full-faced, twofold fiber distribution is due to the solvent composition and is induced and enhanced by increasing the ethanol weight ratio. Moreover, the comparison of fibrous layers morphology obtained by wet and dry spinning have revealed that beads that frequently appeared in dry spun materials are created by Plateau-Rayleigh instability of the fraction of thicker fibers. Theoretical conditions for spontaneous and complete immersion of cylindrical fibers into a liquid collector are also derived here.

Poly(ε‐caprolactone) (PCL) biopolymer nanofibers and micro‐fibers have been fabricated for the first time at the rates up to 14.0 g per hour using a needleless and collectorless alternating current electrospinning technique. By combining the ac‐voltage, “green” low toxicity glacial acetic acid (AA) as the solvent and sodium acetate (NaAc) as an additive, beadless PCL fibers with diameters tunable from 150 nm to 2000 nm, varying surface morphology and degree of self‐bundling are obtained. In this new approach, the addition of NaAc plays a crucial role in improving the spinnability of PCL solution and fiber morphology. NaAc reveals the concentration‐dependent effect on charge transfer and rheological properties of the PCL/AA precursor, which results in broader ranges of spinnable PCL concentrations and ac‐voltages suitable for rapid manufacturing of PCL‐based fibers. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016, 133, 43232.

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