U.S. patent application number 14/826131 was filed with the patent office on 2016-02-18 for system and method for automating production of electrospun textile products.
The applicant listed for this patent is Electroloom, Inc.. Invention is credited to Marcus Foley, Aaron Rowley, Joseph White.
Application Number | 20160047075 14/826131 |
Document ID | / |
Family ID | 55301736 |
Filed Date | 2016-02-18 |
United States Patent
Application |
20160047075 |
Kind Code |
A1 |
Foley; Marcus ; et
al. |
February 18, 2016 |
SYSTEM AND METHOD FOR AUTOMATING PRODUCTION OF ELECTROSPUN TEXTILE
PRODUCTS
Abstract
A system and method for producing a textile product which
includes an insulated enclosure; an electrospinning dispensing
system positioned along at least one face of the insulated
enclosure; a solution supply system with a solution transport
connection to the electrospinning dispensing system; a mold
structure; a cyclical mold actuator mechanically coupled to the
mold structure; and a charge unit electrically connected to the
electrospinning dispensing system and the mold structure.
Inventors: |
Foley; Marcus; (San Jose,
CA) ; Rowley; Aaron; (San Francisco, CA) ;
White; Joseph; (San Francisco, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Electroloom, Inc. |
San Mateo |
CA |
US |
|
|
Family ID: |
55301736 |
Appl. No.: |
14/826131 |
Filed: |
August 13, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62037238 |
Aug 14, 2014 |
|
|
|
62089447 |
Dec 9, 2014 |
|
|
|
62161404 |
May 14, 2015 |
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Current U.S.
Class: |
264/465 ;
425/174.8E |
Current CPC
Class: |
D04H 1/728 20130101;
D01D 5/0084 20130101; D04H 1/76 20130101 |
International
Class: |
D04H 3/005 20060101
D04H003/005 |
Claims
1. A system for producing a textile product comprising: an
insulated enclosure; an electrospinning dispensing system
positioned along at least one face of the insulated enclosure; a
solution supply system with a solution transport connection to the
electrospinning dispensing system; a mold structure; a cyclical
mold actuator mechanically coupled to the mold structure; and a
charge unit electrically connected to the electrospinning
dispensing system and the mold structure.
2. The system of claim 1, wherein the mold structure comprises a
mold fixture base that is interchangeably connectable to a mold
collector.
3. The system of claim 2, wherein the mold structure further
comprises a first mold collector that is a two-dimensional
projection mold and that is connectable to the mold fixture
base.
4. The system of claim 3, wherein the two-dimensional projection
mold comprises convex and concave edges.
5. The system of claim 3, wherein the two-dimensional projection
mold comprises at least one surface feature.
6. The method of claim 5, wherein the at least one surface feature
is a feature cutout.
7. The system of claim 5, wherein the at least one surface feature
is a textured pattern on the surface of the two-dimensional
projection mold.
8. The system of claim 2, wherein the mold structure comprises a
three-dimensional mold connectable to the mold fixture base.
9. The system of claim 1, wherein the mold fixture base is
interchangeably connectable to a two-dimensional projection mold;
and wherein the electrospinning dispensing system comprises a first
dispensing area directed at a first face of a connected
two-dimensional projection mold and a second dispensing area is
directed to a second face of the connected two-dimensional
projection mold.
10. The system of claim 9, wherein the cyclical mold actuator is a
linear actuator with an oscillating motion along a defined axis in
a plane defined by the first face.
11. The system of claim 1, wherein the electrospinning dispensing
system comprises an array of electrospinning dispensing nozzles
12. The system of claim 1, wherein the solution supply system
includes a solution cartridge system.
13. The system of claim 12, wherein the solution cartridge system
includes a solution cartridge with a first type of solution and a
second solution cartridge with a second type of solution, wherein
electrospun fiber produced from the first type of solution possess
different fiber properties from electrospun fiber produced from the
second type of solution.
14. The system of claim 1, wherein the solution supply system
includes a colorant system.
15. A method for producing a textile product comprising: fixing a
mold structure to a textile production system; actuating the mold
structure; and executing an electrospinning process across at least
one dispensing region onto the two-dimensional projection mold.
16. The method of claim 15, wherein the mold structure is a
two-dimensional projection mold.
17. The method of claim 16, wherein executing the electrospinning
process across at least one dispensing area comprises executing the
electrospinning from a first array of nozzles that is arranged
across a first dispensing region and from a second array of nozzles
that is arranged across a second dispensing region, wherein
electrospun fiber from the first array of nozzles is drawn towards
a first face of the two-dimensional projection mold, and wherein
electrospun fiber from the second array of nozzles is drawn towards
a second face of the two-dimensional projection mold; and wherein
at least one edge of the two-dimensional projection mold is a
transition edge.
18. The method of claim 15, wherein the mold structure is a
three-dimensional mold.
19. The method of claim 15, wherein executing an electrospinning
process comprises controlling the electrospinning process in a
fabric property transition mode, wherein the electrospinning
process in the fabric property transition mode is applied to a
defined region of the two dimensional projection mold.
20. The method of claim 19, wherein the fabric property transition
mode is configured for a transition of fabric type.
21. The method of claim 19, wherein the fabric property transition
mode is configured for a transition of fabric color.
22. The method of claim 19, wherein the fabric property transition
mode is a gradient transition mode.
23. The method of claim 19, wherein the fabric property transition
mode is a discrete transition mode.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims the benefit of U.S. Provisional
Application No. 62/037,238, filed on 14 Aug. 2014, U.S. Provisional
Application No. 62/089,447, filed on 9 Dec. 2014, and U.S.
Provisional Application No. 62/161,404, filed on 14 May 2015, which
are all incorporated in their entireties by this reference.
TECHNICAL FIELD
[0002] This invention relates generally to the field of textile
production, and more specifically to a new and useful system and
method for automating production of electrospun textile
products.
BACKGROUND
[0003] Electrospinning is the process of using electrical charges
to pull fibers out of a solution, typically consisting of a polymer
dissolved in a solvent, although the term can also be used to
describe alternative solutions, such as melting polymers and
pulling fibers from the resulting liquid. Electrospinning is
primarily used in biomedical research, and is limited to the
manufacturing of simple geometries such as sheets and tubes. This
process is typically achieved through the use of a fluid-dispensing
nozzle to which a strong electrical charge is applied. A collector
placed in front of the nozzle is then used to collect the fibers
and form the sheet or tube. Existing electrospinning processes fail
to produce complex geometries. Additionally, existing
electrospinning processes fail to provide for dynamic geometries.
Thus there is a need in the electrospinning field to create a new
and useful system and method for automating production of
electrospun textile products. This invention provides such a new
and useful system and method.
BRIEF DESCRIPTION OF THE FIGURES
[0004] FIG. 1 is a perspective view of a schematic representation
of a system of a preferred embodiment
[0005] FIG. 2 is an exploded schematic representation of portions
of the system during electrospinning onto 2D projection mold;
[0006] FIG. 3 is an exploded schematic representation of portions
of the system during electrospinning onto 3D mold;
[0007] FIG. 4 is an exploded schematic representation of portions
of the system during electrospinning onto a multi-faceted mold;
[0008] FIG. 5 is a schematic representation of insulating features
of an enclosure;
[0009] FIG. 6 is a cutaway view of an electrospinning dispensing
system directing fiber at the internal chamber of a mold
structure;
[0010] FIG. 7 is a detailed schematic of an electrospinning
dispensing system;
[0011] FIG. 8 is a detailed schematic of a representative
nozzle;
[0012] FIGS. 9A and 9B are schematic representations of exemplary
actuated electrospinning nozzles;
[0013] FIGS. 10A-10D are schematic representations of alternative
electrospinning dispensing techniques;
[0014] FIGS. 11A and 11B are schematic representations of a system
with electrospinning solution options;
[0015] FIGS. 12A and 12B are schematic representations of exemplary
cleaning systems;
[0016] FIG. 13 is a schematic representation of a solution supply
system;
[0017] FIG. 14 is a schematic representation of an exemplary
cartridge;
[0018] FIG. 15 is a schematic representation of an exemplary
pneumatic syringe cartridge;
[0019] FIG. 16 is a schematic representation of a syringe
cartridge;
[0020] FIG. 17 is a detailed schematic representation of a mold
structure;
[0021] FIGS. 18 and 19 are exemplary 2D projection molds with
surface features;
[0022] FIG. 20 is a schematic representation of a variation of the
system with an internal 3D printer;
[0023] FIGS. 21A and 21B are a schematic representations of 3D mold
variations;
[0024] FIG. 22 is a schematic representation of a mold structure
with a charged core;
[0025] FIG. 23 is a schematic representation of a method of a
preferred embodiment;
[0026] FIGS. 24 and 25 are flowchart representations of variations
of fabricating a mold structure;
[0027] FIG. 26 is a flowchart representation of an alternative
method of a preferred embodiment;
[0028] FIG. 27 is a schematic representation with a cross sectional
detail view illustrating an exemplary transitional edge;
[0029] FIGS. 28A and 28B are schematic representations of discrete
and gradient transitions along the fabric surface;
[0030] FIG. 29 is a schematic representation of a discrete
transition; and
[0031] FIG. 30 is a schematic representation of a gradient
transition.
DESCRIPTION OF THE EMBODIMENTS
[0032] The following description of the embodiments of the
invention is not intended to limit the invention to these
embodiments but rather to enable a person skilled in the art to
make and use this invention.
1. Introduction
[0033] The system and method for automating production of
electrospun textile products of preferred embodiments function to
produce complex three-dimensional shapes through the process of
electrospinning. Electrospinning uses strong electric fields to
pull fibers from liquids. The system and methods of the preferred
embodiments involve the design and use of a device employing
electrospinning to facilitate on-demand production of textile
products and fabrics in complex 3D shapes. The systems and methods
detailed herein include approaches for electrospinning for clothing
on demand, larger scale electrospinning chambers to contain large
textiles and articles of clothing, and controlled deposition of
fibers in and onto complex molds. The system and method preferably
involve the use of a standalone device wherein an electrospinning
dispensing system deposits fibers onto a mold structure. The mold
structure is changeable so as to enable customization of shape,
size, and features of an electrospun product.
[0034] The system and method enable the creation of electrospun
fabrics and textiles in 2-dimensional configurations as well as
complex, non-uniform 3-dimensional configurations. The process is
enabled by a variety of mechanisms that offer novel and highly
controlled approaches to fiber deposition. Using the process of
electrospinning to create articles of clothing and other textiles
on demand is itself a novel use for this technology. As opposed to
traditional textile manufacturing of 2D rolls of fabric that
require additional processing, the system and method can create
seamless 3D textile products in unique user-defined shapes. Another
unique element of the system and method described herein is
large-scale production capacity in three axes. Chambers large
enough to fit entire articles of clothing have not been utilized in
state-of-the-art electrospinning setups described in the
literature. Seamless one-piece textiles can be produced on complex
2D projection molds or 3D mold scaffolds of the necessary size.
Another aspect of the system and method is the controlled
deposition of fibers into complex shapes.
[0035] The system and method can also be used as a post-processing
technique for existing 3D structures and shapes. The system and
method can add layers of fibers to existing structures that would
otherwise be difficult to cover in a precise manner. The design and
approach of the system and method can be used to create patterns
and detail work in a controlled manner through management of the
electrospinning process and through mold design.
[0036] As one potential benefit, the system and method produce a
seamless textile product through a single manufacturing
process--textile production, patterning, and assembly can be
reduced to the electrospinning manufacturing process of a system of
a preferred embodiment. This can greatly simplify prototyping stage
of textile production as well as production.
[0037] The system and method can additionally function to provide a
substantially convenient approach to producing products in a
variety of forms through the use of dynamic mold systems. A user
can use 3D printing, laser cutting, and other suitable prototyping
techniques to easily create new molds that can be used to produce a
variety of clothing products.
[0038] The system and method function to address the unmet needs of
creating complex shapes through electrospinning. Traditional
electrospinning technology is limited to simple sheets and
cylinders. Such systems do not address complex geometry production,
adaptability of forms, or product scale that can result from
producing textile products. Collectors with complex shapes present
unique challenges for current electrospinning setups, resulting
from a number of factors, including non-uniform charge
distributions that prevent full deposition of fibers, and an
inability to produce patterned or textured fabrics. The use of
dynamic 3D geometries in electrospinning setups presents its own
unique set of challenges arising from a number of factors,
including regulating a gap distance between the structures and
dispensing array.
[0039] The system and method described herein is primarily
described as being applied to production of textile products such
as shirts, skirts, pants, hats, gloves, undergarments, or any
suitable textile product. However, the system and method may
alternatively be applied to the production of any suitable product
such as custom formed air filters, custom textile solutions,
on-demand textile solutions, or other suitable applications.
[0040] The systems and methods described herein include new
elements of electrospinning technologies including electrospinning
dispensing and collector design, and/or interaction of involved
subsystems.
[0041] As an exemplary list of features, the system and methods for
automating production of electrospun textile products may include
the following features and/or variations addressing the
electrospinning dispensing system: pneumatic syringes to provide
electrical insulation between the pump and dispensing array;
syringe cartridges for quick reloading of solutions; specific
tubing formulations and modifications that can promote consistent
pumping and charge distribution (including the minimization of
charge leakage/buildup); applications of near-field
electrospinning, which can be used to control the confinement of
the electrospun beam to produce highly controlled colors, patterns,
and details; combinations of electrospinning and melt spinning for
particular applications; methods to aid in fluid charge residence
and speed of fiber deposition; automated cleaning systems; using
reloadable cartridges; formation of fiber with multiple colors
(including different colors dispensed simultaneously through
various nozzles); formation of fibers of varying fiber types;
motion systems that control the gap distance (the distance between
the end of the nozzles and the surface of the structure) and
position of the dispensing system required to achieve uniform
coverage across sufficiently complex shapes; free-surface
electrospinning dispensing system, which may increase throughput
and reduce garment completion time; and/or other suitable
variations in the electrospinning delivery system and process.
[0042] As another exemplary list of features, the system and
methods for automating production of electrospun textile products
may include the following features and/or variations addressing the
electrospinning collector: use of "2D projection electrospinning"
to create seamless 3D shapes out of 2D projection plates while
avoiding many of the problems and challenges faced by
electrospinning to form complex 3D geometries; special coatings for
the 2D/3D scaffolding to ease in fabric confluence and removal;
charged or grounded cores to allow use of non-conductive scaffolds;
use of complex 3D structures as a fiber deposition target; mold
structures made from or coated in conductive paint/material; folded
mold structures to reduce system volume and promote textures;
patterns, and features in finished garments; and/or other suitable
variations in the electrospinning collector system and process.
2. System for Automating Production of Electrospsun Textile
Products
[0043] As shown in FIG. 1, a system for automating production of
electrospun textile products can include an insulated enclosure
110, an electrospinning dispensing system 120, a solution supply
system 130, a mold structure 140, a cyclical mold actuator 150, and
a charge unit 160.
[0044] In a preferred embodiment, the system is used in 2D
projection electrospinning, wherein the electrospun fibers are
deposited onto a flattened 2D projection mold as shown in FIG. 2.
The flattened 2D projection mold is preferably moved in a cyclical
pattern. Over time, the fibers coat the mold, and wrap around the
edges, creating a seamless object. The object, in this case a
garment, can then be removed from the mold and opened to fit over a
3D shape (e.g., a wearer's body). There are a number of advantages
to 2D projection electrospinning, including control of the
dispensing system, and possible elimination of the motion in
multiple dimensions. The machine depicted in FIG. 1 allows for
translation of the 2D projection mold along one defined axis.
Another potential benefit can include the reduction in the size and
footprint of the machine, which can enable the device to more
easily fit inside homes, closets, workshops, etc.
[0045] The preferred embodiment preferably includes a first and
second dispensing area that are directed in opposing directions so
as to dispense fiber on both sides of the 2D projection mold
simultaneously as shown in FIGS. 1 and 2. Alternative embodiments
could include a two-stage production process with a mold rotation.
The mold rotation can be manually performed or may be mechanically
automated.
[0046] In alternative embodiments, the system may alternatively be
applied to electrospinning onto 3D molds as shown in FIG. 3. The 3D
mold embodiment can include a mechanically actuated dispensing
system and/or or mold structure. In yet another embodiment, the
system can include a multi-faced (i.e., "faceted"), wherein at
least two electrospinning dispensing areas are aligned in
non-parallel orientations. The multi-faced embodiment can function
to apply the 2D projection electrospinning approach to 3D molds
with a limited set of substantially flat faces, wherein some of the
faces are aligned on intersecting planes as shown in FIG. 4. A
multi-faced approach may include variations of the 2D projection
electrospinning embodiment and/or 3D mold electrospinning
embodiment.
2.1 Insulated Enclosure
[0047] The insulated enclosure 110 of a preferred embodiment
functions to limit interference from the outside environment. The
insulated enclosure 110 is a structural chamber in which active
electrospinning occurs during the production process. The active
electrospinning area is the space between the charged parts of the
electrospinning dispensing system 120 and the mold structure
140.
[0048] Various components of the system use and control high
voltages of electricity that can be damaging to other components of
the system. The insulated enclosure along with other protective
elements isolates the source of electrical discharge in order to
prevent interference through (but not limited to) electrical
arcing. This can be done by way of a Faraday cage around sensitive
components and/or insulating the actuation seam to the area of
active electrospinning as shown in FIG. 5.
[0049] The insulated enclosure, in addition to providing electrical
insulation, can additionally function as a structural chassis on
which some or all of the components of the system may be directly
or indirectly coupled. The insulated enclosure 110 can include an
electrospinning sub-chamber and a controller sub-chamber. The
electrospinning sub-chamber can include insulating design elements
to shield electrical components in the control chamber from the
electromagnetic fields generated in the electrospinning
sub-chamber. The electrospinning sub-chamber of the insulated
enclosure can include framing supports and a set of walls. The
walls can be made from electrically insulating material such as
acrylic, glass, polycarbonate, or any suitable insulating material.
The insulated enclosure 110 can additionally include insulating
systems such as a Faraday cage. Additionally the walls can be used
as a mounting structure of the electrospinning dispensing system.
In one variation, a wall used to mount the electrospinning
dispensing system can include an array of possible nozzle mounting
elements. The nozzle mounting elements can be an array of
electrospinning nozzle holes. The number of electrospinning nozzle
holes can be greater than the number of supported electrospinning
nozzles which can function to give positioning options for the
electrospinning nozzles as shown in FIG. 1. A nozzle mounting
system can additionally include positioning options. In one
variation, a nozzle mounting element can enable a nozzle to be
repositioned along at least one axis and/or rotate about at least
one axis. In one variation, the nozzle mounting elements are static
positioning elements, but in an alternative variation, the
positioning of a nozzle mounting elements could be actuated and
controlled.
[0050] The controller sub-chamber is preferably a substantially
enclosed container, which can contain processors, solution supply
components of the solution supply system 130. The controller
sub-chamber can be a walled structure that acts as a base of the
system wherein the electrospinning sub-chamber sits above or on top
of the controller sub-chamber. Other arrangements or configurations
may alternatively be used. The controller sub-chamber can
additionally isolate components from the electrospun fiber.
[0051] The controller sub-chamber can include an access port
wherein the cyclical mold actuator 150 couples to the mold
structure 140. The cyclical mold actuator 150 is preferably
substantially contained within the controller sub-chamber to
isolate the motor and actuating components from the electromagnetic
fields of the electrospinning sub-chamber. The access port can be a
seam, gap, or defined hole. Insulating padding or other insulation
mechanisms can be used.
2.2 Electrospinning Dispensing System
[0052] The electrospinning dispensing system 120 of a preferred
embodiment functions to deliver, eject, or otherwise dispense
electrospun fiber onto the mold structure 140. The electrospinning
dispensing system employs the process of electrospinning but can
alternatively use alternative process variations such as melt
electrospinning, coaxial electrospinning, emulsion electrospinning,
and other suitable variations. The electrospinning dispensing
system 120 preferably delivers fiber to the outside of a mold
structure 140. However, alternatively or additionally, the
electrospinning dispensing system 120 can be centrally located with
a surrounding mold structure, and the electrospinning dispensing
system 120 can direct fiber application to the inside walls of a
mold structure as shown in FIG. 6.
[0053] The electrospinning dispensing system 120 preferably acts as
a source of fiber formed during extraction of the electrospinning
solution through an electrical charge. The electrospinning
dispensing system 120 preferably receives a supply of
electrospinning solution from the solution supply system 130. The
charge unit 160 can charge the electrospinning solution relative to
the mold structure to a charge point resulting in an eruption of
the electrospinning solution from a point on the electrospinning
dispensing system 120. During travel towards the mold structure,
the liquid transforms into a fiber. The fiber is preferably
substantially uniform and can have various properties depending on
the electrospinning solution and electrospinning process. As a
result of electrostatic repulsion, the fiber can experience a
whipping process wherein different parts of the fiber are pulled in
different directions towards the collector so as to contact the
collector over a collection zone.
[0054] The electrospinning dispensing system 120 preferably
includes an array of electrospinning dispensing nozzles 122 as
shown in FIG. 7. The array of electrospinning dispensing nozzles
122 includes a set of nozzles 124, alternatively referred to as
spinnerets. A nozzle 124 can be a hypodermic needle or any suitable
type of localized solution deliver mechanism. The nozzle 124 is
connected to the charge unit that delivers a high-voltage current
(preferably a direct current 5 to 50 kV) to the solution delivered
through the solution supply system 130.
[0055] In one variation, a longer nozzle can be used. An
alternative approach is to use a flange, wire, or other metallic
leads that extend from the body of the nozzle back into the tubing,
as shown in FIG. 8, thereby increasing charge residence time
without extending the length of the nozzle.
[0056] A nozzle is preferably mechanically coupled to a point on
the insulated enclosure 110, but may alternatively be structurally
supported by any suitable chassis. The nozzle 124 is preferably
fixtured so that a delivery port of the nozzle 124 is directed at
the mold structure 140. The nozzles can be repositionable through a
dynamic nozzle positioning system. In one variation, the nozzles
can be repositionable across a set of nozzle mounting elements
(i.e., a set of fixture points for a nozzle) in the insulated
enclosure 112. The repositionable property of the nozzles functions
to ensure the adaptability of an electrospinning setup with various
sized molds. The dynamic nozzle positioning system can be a grid of
nozzle support structures that allows nozzles to be placed in
custom arrangements depending on the requirements of the mold, and
adjusted throughout the electrospinning process, or through the use
of nozzles that can be slid along paths in the support structure. A
nozzle mounting element can be support structure such as a defined
cavity that presents a single positioning option (e.g., a nozzle
hole), a positioning axis (e.g., a defined groove in which a nozzle
may be fixed), or any suitable mechanism in which a nozzle can be
positioned.
[0057] The array of electrospinning nozzles 122 is preferably
positioned along one face of the insulated enclosure. The
dispensing area is preferably a surface of the insulated enclosure
110 and is preferably a flat, planar surface. The array of
electrospinning nozzles 122 are preferably mounted across a
two-dimensional area. The dispensing area can alternatively be
along a curved or non-uniform surface. The dispensing area surface
is preferably substantially parallel to a surface of the mold
structure to which the fiber will be deposited, which functions to
promote uniform gap distance between the nozzles and the collection
zone of a nozzle. There is preferably at least one subset of the
array of electrospinning nozzles 122 distributed on a first
surface. There can alternatively be multiple surfaces along which a
subset of the array of electrospinning nozzles 122 can be mounted.
The various subsets are preferably positioned around a
substantially centrally located mold structure 140. Preferably,
there is a first array of electrospinning nozzles 122 mounted along
a first surface and a second array of electrospinning nozzles 122
on a second surface as shown in FIGS. 1 and 2. The first array of
electrospinning nozzles is preferably mounted so as to direct
electrospinning in a direction opposing the direction of
electrospinning of the second array. The second array of
electrospinning nozzles are preferably positioned along a face such
that electrospinning on an opposing side of a mold structure.
[0058] As described below, the mold structure 140 is preferably
actuated relative to the electrospinning dispensing system 120, but
a subset or all of the nozzles in the array of electrospinning
nozzles 122 can be actuated as a group or individually as shown in
FIGS. 9A and 9B.
[0059] Alternative, electrospinning dispensing systems may
alternatively be used such as free surface or wire electrospinning.
To increase the rate of fiber deposition, and eliminate problems
caused by nozzle dispensing systems, a free surface electrospinning
setup can be used in conjunction with 2D projections or 3D molds.
Free surface electrospinning can be uniquely used in conjunction
with 2D projection molds, as movement of a free surface
electrospinning apparatus is prohibitively difficult due to its
size and complexity. A static, flat free surface electrospinning
setup may produce complex 3D garments from a 2D projection mold
without any motion of the dispensing system.
[0060] Free surface electrospinning uses a large surface area
electrode coated with conductive solution to produce a field of
fiber jets, as opposed to the one-jet-per-nozzle setup
traditionally used. In one variation, a free surface
electrospinning system includes a solution faucet that dispenses
the solution down a charged plate, and allow electrospinning to
take place from the surface of the plate as shown in FIG. 10A. This
could also be adapted to remove the plate, and allow charged fluid
to fall through the air while electrospinning before being
collected and recirculated. In another variation, a gravity-driven
system can use a solution reservoir positioned above a nozzle
array. Gravity drives the solution through nozzles composing a
nozzle array as shown in FIG. 10B. Another approach could use a
"bowl" system that dispenses electrospun fibers from the edge of
the bowl as shown in FIG. 10C. This could also make use of an
off-axis cleaning plate that spins and effectively cuts off polymer
build up from the edges of the plate. Lastly, a drum system could
allow for polymer to be electrospun from the edges of a rotating
drum, either through pump action or by the centrifugal force of the
fluid on the edge of the drum as shown in FIG. 10D.
[0061] In one variation, the electrospinning dispensing system 120
can be used to deliver varying colors, fiber types, and/or
fiber/textile qualities. The electrospinning dispensing system 120
can include individually configurable dispensing nozzles.
[0062] In a color control variation, at least a first and second
nozzle can be configured for a first and second fiber color. In one
implementation, fiber color configuration is controlled by
connection to different solution sources as shown in FIG. 11A. In
another implementation, an individual dispensing nozzle system can
include a colorant system that can dynamically color the solution
during delivery to the nozzle or during the electrospinning process
as shown in FIG. 11B. The colorant system may alternatively be any
suitable solution augmentation system that can act inline to one or
more nozzles. The first and second nozzles can be positioned in
substantially the same region (i.e., adjacent nozzle placement) so
as to have similar collection zones. The adjacent nozzles can be
individually controlled so as to control the mixing and/or layering
of fiber application during actuation of the mold structure 140.
Alternatively, the nozzles of different colors can be placed in
distinct regions in the array of electrospinning dispensing nozzles
122.
[0063] Similarly, at least a first and second nozzle can be
configured for different fiber types. For example, a first nozzle
can include a connection to a silk solution while a second nozzle
includes a connection to cotton solution.
[0064] In yet another alternative, the electrospinning process can
be altered through varying a property of the dispensing charge,
collector charge, nozzle properties, solution properties, nozzle
positioning (e.g., gap distance, angle, etc.), mold structure
actuation, or any suitable properties. These changes can be
substantially fixed changes or modulated over time.
[0065] In one variation, the electrospinning dispensing system 120
can include a multi-electrospinning process system, wherein there
are at least two different electrospinning processes used
simultaneously or in combination. In one implementation melt
spinning (which is a type of electrospinning that uses a heating
element to melt a polymer before fiber production through an
electric field) and electrospinning can be used simultaneously. A
melt electrospinning processes can be configured for a first
nozzle, and a second electrospinning process as described herein
can be used in a second nozzle, which can be used for a combination
of rapid fiber production and detail work.
[0066] The electrospinning dispensing system 120 can additionally
include a cleaning system, which functions to address the situation
of polymer buildup on the ends of the nozzles that may inhibit the
electrospinning process. In one variation, the cleaning system
includes a friction pad that is retractable over a nozzle as shown
in FIG. 12A. The friction pad can be a rubber diaphragm that a
nozzle is placed into and then retracted when polymer buildup
occurs. The contact with the friction pad is preferably sufficient
to remove polymer buildup. Other individual nozzle cleaning systems
may be used such as pressurized air systems, buildup-wiping arm, or
any suitable mechanism. Alternatively, the cleaning system may be a
nozzle array cleaning system wherein the cleaning mechanism type
cleans a collection of nozzles. In one variation a roller could be
used which extends a rubber surface or brushes over various nozzles
in succession as shown in FIG. 12B. Alternative cleaning approaches
also include the use of a moving plate that can remove built up
polymer from each nozzle/nozzle, and spinning brushes or arms that
can remove built up polymer from multiple nozzles on each pass.
2.3 Solution Supply System
[0067] The solution supply system 130 of a preferred embodiment
functions to deliver the electrospinning fluid to the
electrospinning dispensing system no.
[0068] The solution is preferably a solvent with melted or
dissolved solids, wherein a resulting fiber is formed from the
solution during the electrospinning process. The solution contains
various mixtures of fabric materials and solutions to dissolve and
carry them through the other components of the system. An
electrospinning solution can be used to form synthetic fiber,
cotton fiber, silk fibers, mixed fibers, and/or any suitable type
of fiber. One such solution consists of polyester and cellulose
(the main constituent found in cotton) dissolved in acetone.
Varying the ratio of polyester to cellulose changes the look and
feel of the resultant fibers. Another consists of silk that has
undergone a solubilization process and been dissolved in water. The
solution can also be comprised of non-fiber materials that add an
additional level of functionality to the fabric that is not present
in traditional textiles. For example, materials including (but not
limited to) medicinal chemicals or fire-retardants can be added to
the initial solution and carried with the resultant electrospun
fiber to be embedded in the resultant electrospun fabric. These
embedded materials can enable the use of the electrospun fabric in
medicinal or protective applications.
[0069] In a preferred embodiment, the solution supply system 130
includes a solution reservoir (e.g., a tank) 132, solution
transport 134 connected to the solution reservoir and the
electrospinning dispensing system 120, and a pump system 136 as
shown in FIG. 13. In the preferred dispensing system, the solution
transport 134 (e.g., tubing) runs between the solution reservoir
and/or a pump to at least one nozzle. The solution reservoir can be
a tank or any suitable container that stores the solution for
multiple nozzles. In another variation, there is a set of solution
reservoirs. The set of solution reservoirs can include different
solution types or the same solution type. Additionally, one of the
sets of solution reservoirs can be used by a single nozzle or a set
of nozzles. The solution transport 134 is preferably a set of
tubing connections. The solution transport 134 may alternatively be
any suitable piping system, channels, or other suitable system to
transport solution to the electrospinning dispensing system 120.
Herein, tubing will be used as the exemplary form of the solution
transport system.
[0070] To prevent charge flowing back down the tubing lines,
specific tubing formulations can be used. Less conductive plastic
tubing such as FEP lined Tygon can aid in preventing charge leakage
when compared to some varieties of soft rubber tubing.
Additionally, chokes or ferrite beads placed on or around the
tubing lines can be used to capture stray charge and prevent it
from flowing down the tubing lines.
[0071] The solution supply system can include a solution cartridge
system wherein the solution reservoir includes an attachable
reservoir. A solution cartridge can be swapped in and out so as to
enable easy and fast restocking of solution. Cartridges containing
the material solution can contain a quick releasing mechanism to
allow for easy insertion/removal in the device. Pods are also used
for cleaning the system with various solutions and/or air. Special
pods or subsections of existing pods are inserted for this purpose.
As shown in FIG. 14, one variation can include a pump system
actuator element such as a plunger or air connect; a bladder with a
cleaning liquid or air that can be pumped when the bladder is
punctured or otherwise engaged; a chamber of solution; and a
release valve. The release valve can be a quick release valve, a
puncturable seal, or any suitable type of valve.
[0072] A solution cartridge contains or can be filled with an
electrospinning solution as described above. A solution cartridge
can contain separation mechanisms within them to allow for
separating of chemical constituents. Different solution types can
be contained within one cartridge by leveraging specific gravities
to promote separation of the solution types as shown in FIG. 14.
Solution supplies of differing material may be mixed and blended to
allow for precise material makeup of an end fibrous garment.
Solution material control may be used to dynamically control color,
material properties (e.g., strength, fiber thickness, and the
like), fiber composition (e.g., breakdown of cotton, silk,
polyester, etc.), or other suitable properties. In one variation
solution mixing can be achieved through use of cartridges with
different solutions. In another variation, multiple solution supply
packages of differing solutions can be added to a cartridge. This
might manifest in precise control over how much of a material
constituent is present in the end product (e.g. 10% polyester).
Moreover, unique material makeups could be achieved with this
system when multiple solutions are available for selective supply
through the solution supply system 130. For instance, layers or
sections of a garment could be made of entirely different materials
(e.g. silk on the inside, nylon on the outside) without adding
seams, significant thickness, or other bonding steps or artifacts
to the end product.
[0073] As described above, a colorant system can be used to alter
the coloring of the solution. Dying the solution can be done to
allow for colored products. The dye may be applied before any other
processes, or dye can be placed within the nozzle, allowing for a
base solution to be combined before the fiber-pulling process. The
color-adding process can be remotely controlled; so various colors
can be added at various points of a single job or garment.
[0074] As an alternative to pumping the conductive solutions
through tubing to the dispensing nozzle, a pneumatic or hydraulic
powered syringe can be used directly as the dispensing system. In
this concept, a pneumatic or hydraulic line 1501 compresses a
special plunger 1502 in the syringe body, as shown in FIG. 15,
which dispenses the fluid at a controlled rate. This results in all
the electrically conductive material remaining in the syringe,
which is easier to control and mitigates charge
leakage/interference with other components of the machine.
[0075] A syringe pumping system can similarly use replaceable
cartridges. A syringe cartridge can include one or more loaded
syringes as shown in FIG. 16. Alternatively, the solution reservoir
of the cartridge can couple to form a syringe mechanism. A syringe
system can include the ability to maintain uniform pressure across
multiple lines of fluid simultaneously, and prevent clogging or
other dispensing abnormalities from impairing system function. The
replaceable cartridge system can use existing tubing, or contain
its own clean set of one-time-use tubing.
2.4 Mold Structure
[0076] The mold structure 140 of a preferred embodiment functions
to provide a collector element that acts as the mold for a
resulting textile product. The mold structure preferably includes a
mold collector 142 that can be mechanically coupled to the cyclical
mold actuator 150. The mold collector 142 functions as the core
element to which fiber is deposited during the electrospinning
process and, as such, includes a structural form that can define
the 3D properties of a resulting textile product. In one variation,
the mold collector 142 is a fixed element so as to produce
substantially similar textile products repeatedly. In another
variation, the mold collector 142 can be a transformable mold
collector wherein the shape, size, texture, conductive/collector
properties, and/or other properties can be manipulated so as to
alter the resulting 3D structural form of a resulting textile
product.
[0077] In a preferred embodiment, the core collector is replaceable
mold collector and couples to a mold fixture, which functions to
enable the mold collector to be exchanged so as to alter the
structural form of a resulting textile product through use of
different mold collector forms.
[0078] As shown in FIG. 17, the mold structure can include a mold
fixture base 144 that can be selectively and mechanically coupled
to a mold collector 142. The mold fixture base is preferably a
structural element that enables a mold structure to be slotted,
snapped, screwed, held, or otherwise held into a first position.
The mold fixture base 144 is preferably directly coupled to the
cyclical mold actuator 150 so as to transfer physical translation
of the mold actuator 150 to a fixture mold collector 142. The mold
fixture base 144 may be selectively coupled to the cyclical mold
actuator. In one variation, the mold structure 140 comprises of the
mold fixture base 144 without a mold collector 142--a user of the
system can supply a customized mold collector element during
use.
[0079] The mold collector 142, as described above, functions as
molded scaffolding to which fiber is deposited during use of the
system. Upon completion of a production process, a resulting
textile object can be released from the molded structure. In a
particular implementation, the resulting textile product can be a
substantially fully constructed textile product. Subtractive
manufacturing steps (e.g., cutting), textile treatment, and other
post-processing steps may be performed to finalize a constructed
product. However, the system can be used in the construction of a
base textile product as a fully realized 3D shape. For example, a
t-shirt, a skirt, pants, a hat, gloves, under garments, and other
textile products can be produced in a fully realized, 3D form
without requiring assembly of patterned fabric pieces.
[0080] The mold collector 142 can be a 2D projection mold. A 2D
projection mold is preferably a plate formed as a 2D projection
pattern. The fabric produced during the electrospinning process is
preferably applied to both sides (simultaneously or in different
stages), and the fabric on a front side and backside forms a
connected structure around the edges of the 2D projection pattern.
The 2D projection mold has some minimal thickness so as to provide
structural support.
[0081] 2D projection molds can include surface features. Surface
features can be holes, grooves, ridges, depressions, convex and/or
concave reliefs, bumps, surface curvature, texturing, or other
features. In one variation, a surface feature can be a feature
cutout. A feature cutout can be sized or formed so as to promote
fabric formation suspended across the cavity. A feature cutout can
result in different fabric thickness, transparency, texture, or
other fabric qualities depending on the formation of the pattern
feature cutout. As shown in FIG. 18, feature cutouts can be used to
cause a pattern to form along the bottom of a dress. Textured
surface features can also be used as shown in a shirt 2D projection
mold of FIG. 19, which will produce a corresponding texture on the
electrospun fibers covering them.
[0082] The 2D projection mold can optionally be formed with beveled
or curved edges, which may function to promote varying fabric
qualities on the transition from the front and back sides of the 2D
projection mold. Complex geometries are possible with 2D projection
molds, as depicted in FIG. 2, which shows a tank top complete with
straps, neck, and arm features. Complex geometries can include
non-linear edges as well as convex and/or concave edges.
[0083] A 2D projection mold will include an outer perimeter forming
the outside form. The 2D projection mold can additionally include
cutouts such as holes, slits, or other defined cavities within the
outer perimeter border. In some variations, a feature cutout or
other suitable surface features can be made so as to promote
transition between a front and backside. In another variation,
ridges, caverns, and other surface features can be placed along the
edges of the molds to prevent deposition of fibers and maintain
patency where desired (e.g. neck holes and arm holes). The molds
can also be coated with "mold release" agents such as PTFE and
silicon to assist with easy removal of electrospun material, and
prevent fibers from sticking to the mold causing layer
separation.
[0084] One potential benefit of the 2D projection mold is common
manufacturing tools exist to make it feasible for customized 2D
projection molds to be produced quickly and affordably. For
example, laser cutting, plotters, two-axis CNC machines, sheet
stamping, 3D printers, and other suitable manufacturing tools may
be used to create a 2D projection mold. As another variation, a 2D
projection mold template set can be used to construct different 2D
projection molds. Alternatively, the electrospinning system can be
augmented with a traditional FDM extruder head and gantry system to
print a mold inside of the chamber before coating it in electrospun
fabric.
[0085] The 2D projection mold can include varying levels of
complexity. The outer perimeter as well as internal cutouts can
include any suitable mixture of convex corners, concave corners, or
continuous contours. A convex corner is a substantially distinct
intersection of two edges that form a convex (i.e., greater than
180 degrees). A concave corner is a substantially distinct
intersection of two edges that forms a concave angle (i.e., less
than 180 degrees). Herein, the angle is measured from the outer
side of one edge to the outer side of a second edge. As shown in
FIG. 19, a t-shirt 2D projection mold will include convex corners
on the two bottom corners of the shirt as well as the sleeves, a
concave corner at each of armpit regions, and a curved contour
along the neck region.
[0086] At least one edge is preferably a transition edge. A
transition edge is where at least two faces of the mold are
connected during the electrospinning process. A transition edge can
be formed from some minimal thickness and edge spacing. The 2D
projection mold may include a set of non-transitional edges along
the perimeter where the back and front do not connect. A
non-transition edge can be formed from a 2D projection mold
extending beyond the electrospinning collection zone such that
fiber is not collected at a portion of an edge. Alternatively, the
charging or insulating properties of the 2D projection mold can be
configured so as to not receive substantial fiber collection. As
yet another variation, surface features can promote a
non-transition edge as shown in FIG. 27. As shown in FIG. 17, a 2D
projection mold with a trapezoidal 2D projection can be used to
create a skirt. The top and bottom openings of a skirt can be
formed through non-transition edges or through post-processing
(e.g., cutting).
[0087] A mold collector 142 may alternatively be a three
dimensional form. A system using a three dimensional mold collector
142 preferably includes actuation components either in the nozzles
or in the mold actuator 150 so as to regulate the gap distance
between the collector and the electrospinning dispensing system
(e.g., each of an array of nozzles). The gap distance is preferably
maintained within a determined window.
[0088] 3D mold collectors 142 can be static manufactured
structures. The whole 3D mold collector or a portion may be 3D
printed. The electrospinning setup itself could also be combined
with traditional 3D printing to create the unique 3D structures and
deposit fibers onto them all in one machine as shown in FIG. 20.
The design of certain 3D printed shapes themselves is also unique
to this system. The 3D printed shapes can include folds or
undulations to reduce their spatial volume while maximizing their
surface area as shown in FIG. 21A, thereby allowing a full sized
textile or article of clothing to be produced in a much more
compact volume. In conjunction with this (or independently) the
fibers can be deposited onto the inside of hollow structures as
opposed to the outside as shown in FIG. 6, to make fiber deposition
more contained and removal of the fibrous material easier. This
method would include elements related to contouring the fibers into
non-uniform areas of the hollow shape (for example, the sleeves on
a shirt) using a mechanical system or a combination of
electrical/magnetic controlled fiber deposition. To allow for
electrical conductivity, these structures can be printed/created
with electrically conductive material, or coated with electrically
conductive paint/coatings before acting as scaffolds for
electrospinning. A grounded rod, shaft, or other structure may also
be placed inside the 3D printed mold, thus generating the
appropriate electric field between the grounded object and the
dispensing system so that electrospun fibers are deposited on the
3D printed mold.
[0089] The structures can alternatively include dynamic form
features. A 3D mold collector can include adjustable mechanisms
that allow for custom sized garments or other textiles. The
adjustable mechanisms can include a manual belt/dial system, a
ratchet system, and a "puzzle" system as shown in FIG. 21B.
[0090] To allow for a much wider array of structure/scaffold
material options, the mold collector can include a grounded or
charged core as shown in FIG. 22. The core would be either charged
or grounded and would provide the electrical attraction force (also
known as a Coulombic attraction force). The mold collector 142
preferably provides the shaped form to which fiber is to
temporarily adhere during the electrospinning process. The cold is
preferably an internal component charged or grounded that attracts
the fibers towards it and onto the outside of the mold collector
142. Using this configuration, plastic or other non-conductive
materials can be electrospun to directly, which is not possible
using current electrospinning technology. Additionally, the core
can be shaped with non-uniform shape so as to alter the attractive
forces. When using conductive structures, the charged core can
allow for an easy connection to the structure (via a wired
connection or by using a conductive platform).
2.5 Mold Actuator
[0091] The cyclical mold actuator 150 of a preferred embodiment
functions to move the mold structure 140 so as to achieve desired
fiber coverage. The cyclical mold actuator promotes relative motion
of the mold structure to the fiber deposition nozzles/system. A
flexible seam will be used to seal off the electronic/mechanical
connections and maintain an electrically insulated chamber ideal
for electrospinning.
[0092] In a preferred implementation, the cyclical mold actuator
can be a linear actuator that moves a mold structure 140 back and
forth along an axis. An axis of motion is preferably aligned in a
plane that is perpendicular to the main direction of
electrospinning of the electrospinning dispensing system, which
functions to move the mold collector such that the gap distance is
maintained between the mold collector and the nozzles. The
actuation is preferably horizontal but may alternatively be
vertical, or along any suitable axis. In alternative variations,
the cyclical mold actuator can move in a circular pattern. In yet
other variations, the cyclical mold actuator 150 can rotate and/or
translate the mold structure 140 in any suitable manner.
[0093] In one mode, the cyclical mold actuator 150 can actuate so
to achieve substantially uniform fiber coverage on the mold
collector 142. A production process instance may desire non-uniform
fiber coverage, and the cyclical mold actuator 150 may be used to
achieve the non-uniform properties. The cyclical mold actuator 150
may be controlled in combination with the electrospinning
dispensing system 120, the solution supply system 130 and the
charge unit 150. Different fabric effects may be achieved by
altering the electrospinning process in synchronization with the
position of the mold collector manipulated by the cyclical mold
actuator 150.
[0094] The charge unit 160 of a preferred embodiment functions to
charge the solution so as to promote the electrospinning process.
The charge unit 160 can be any suitable voltage source. The charge
unit 160 can be electrically connected to an electrical applicator
in the electrospinning system 120. The electrical applicator in one
variation is a conductive nozzle acting as an emitter of the
solution/fiber. Alternatively, a conductive lead could be situated
so as to apply a charge to the solution. The charge unit 160 may
additionally or alternatively be applied to the mold structure. In
a preferred variation, the mold structure is grounded. In another
variation, the mold structure can be charged with preferably an
opposite polarity. In yet another variation, the electrospinning
dispensing system can be grounded while the mold structure can be
charged so as to attract the solution. The charge unit 160 can be a
regulated constant charge. The charge unit 160 may alternatively
include a dynamically controlled charge output. The voltage output
may be altered during the electrospinning process, which may
function to alter the electrospinning process.
[0095] The system preferably includes a control unit, which
functions to manage the operation of the system. The controller can
be an internal processing system, but may alternatively be an
external application operative on an outside computing device
(e.g., desktop computer). The controller is preferably
communicatively connected to each of the active components such
that solution delivery, electrospinning process (e.g., charge
and/or nozzle control), and/or actuation can be controlled. The
system may additionally include any suitable commonly found device
components such as a user interface elements; a data link; safety
mechanisms; power supply, and/or any suitable components.
3. Method for Automating Production of Electrospun Textile
Products
[0096] As shown in FIG. 23, a method for automating production of
electrospun textile products of a preferred embodiment can include
fixing a mold structure to a textile production system S110,
actuating the mold structure S120, and executing an electrospinning
process across a dispensing area S130. As with the system above,
the method functions to produce three dimensional textile forms
during a self-contained manufacturing process. The method
preferably employs the fiber production process of electrospinning
across a two dimensional area to form at least one circumferential
covering of electrospun fabric on a mold structure. The mold
structure through its 2D projection form and/or 3D form promotes a
resulting shape of a three dimensional textile product.
Accordingly, one potential benefit is the customization and control
of a resulting three-dimensional form through use of a replaceable
mold structure.
[0097] The method is preferably implemented through a textile
production system such as the system described above. The textile
production system is preferably a self-contained electrospinning
setup within which the mold structure can be fixture and where the
electrospinning process can be managed and controlled. The method
may alternatively be implemented through any suitable system or
combination of system setups.
[0098] Block S110, which includes fixing a mold structure to the
textile production system, functions to accept a replaceable mold
structure. Fixing a mold structure preferably enables a mold
structure to be configured specifically for a production run. A
mold structure can be used repeatedly to produce multiple textile
products. A first mold structure may additionally be exchanged for
a second mold structure. The mold structure preferably defines the
resulting 3D form of the textile product. The mold structure can
additionally alter the fabric texture or properties.
[0099] In a preferred variation, the mold structure is a 2D
projection mold. A 2D projection is preferably a substantially
planar structure with a front and back face cut out with a 2D
projection that maps to a 3D form. The 2D projection mold is
preferably substantially similar a 2D projection mold as described
above. The method can additionally include translating a 3D form
into a 2D projection mold. For example, a designer may use a 3D
design program to create a 3D model of a desired form. Translating
the three dimensional form into a 2D projection mold produces a 2D
projection mold shape that can be used in achieving at least an
approximation of 3D form. Translating to a 2D projection mold may
include modification of a source 3D model to enable use of a 2D
projection mold, which functions to adapt a 3D model when
particular details are not readily feasible through a 2D projection
mold. Alternatively, the mold structure can be a 3D mold.
Application of the method for 3D molds can include actuating the
gap distance of an electrospinning dispensing system and the 3D
mold. Such actuation can be performed on the 3D mold, the
dispensing system (e.g., the nozzle), or a combination. The method
can additionally be applied to multi-faced molds in a similar
manner as described in the system above.
[0100] The method can additionally include fabricating the mold
structure S100. Fabricating the mold structure S100 can include
fabricating the mold structure through an internal fabrication
process of the textile production system S102 as shown in FIG. 24.
An internal fabrication process can include a 3D printing process,
computer controlled plotting process, or laser cutting process.
[0101] Fabricating the mold structure can additionally or
alternatively include producing surface features on the mold
structure S104 as shown in FIG. 25. The surface features can
produce various textile artifacts on produced textile products.
Surface features can include texturing, producing three-dimensional
reliefs, defined cavities, and/or other types of reliefs on the
mold structure. In one variation, a surface features can include
applying conductive and non-conductive regions onto the mold
structure which functions to augment the attraction of electrospun
fibers to a specific region of the mold structure. A mold structure
can additionally include release coatings to aid in the removal of
a manufactured textile product.
[0102] Block S120, which includes actuating the mold structure,
functions to move the mold structure to promote desired fiber
coverage on the mold structure. A mold structure is preferably
actuated during the electrospinning process. In one variation, the
actuation is controlled. Actuation of the mold structure is
preferably a cyclical actuation pattern. More specifically, the
cyclical actuation pattern is a repeated path in a plane
substantially perpendicular to the direction in which fiber is
dispensed during electrospinning. In the case of a 2D projection
mold, perpendicular can be defined as an angular alignment such
that actuation of the 2D projection mold within the plan does not
result in a change in the general gap distance between the 2D
projection mold and a nozzle. Particular gap distances may change
during the course of actuation such as when the edge of a 2D
projection mold is actuated back and forth in front of a nozzle.
The actuation is preferably a linear cyclical motion back-and-forth
along an axis (e.g., horizontal, vertical, etc.). The actuation may
alternatively be along two axes, one or more rotational axis, or in
any suitable dimension. The actuation speed can be constant, follow
an acceleration pattern, and/or dynamically change according to the
mold. While the actuation is preferably a repeated cyclical
pattern, the motion can alternatively be a singular complex path,
dynamically determined, even random, or any suitable motion
pattern. In the case of a 3D mold, multi-axis actuation (three or
more) may be used to regulate gap distance within a gap distance
window. In an alternative implementation, actuation of an
electrospinning nozzle can be used to regulate gap distance.
[0103] Block S130, which includes executing electrospinning process
across a dispensing area, functions to dispense fiber from an
electrospinning dispensing system. In one variation the dispensing
area is defined by an array of dispensing nozzles. In alternative
variations, the dispensing area may be defined by a set of
electrospinning wires, a pool of solution, or a free-surface
electrospinning system.
[0104] The fiber size and morphology, and therefore the resulting
"feel" and mechanical properties can be partially controlled in a
number of ways when executing the electrospinning process,
including alternating the gap distance using custom sized
wiring/gaps on the structure, and/or changing the mechanical
characteristics of the charge and spin. The fabric solution can
also contain additives such as dyes and colorants that will remain
on the electrospun fiber after it has been pulled from solution.
This system can also create patterns of color and texture on
complex or flat shapes. The method can achieve such results through
the use of varying control processes including charge modification,
electrical and magnetic field manipulation, and mechanical motion.
By changing the electrical and magnetic fields that guide the
fibers to the collector (electrostatic forces), the fibers can be
directed to particular, discrete parts of the structure. This, in
collaboration with dynamically manipulating the potential
difference between the dispenser and collector, can create complex
user-defined patterns of fibers.
[0105] Controlling the confinement of the electrospun fibers can
promote obtaining precise fiber deposition and complex patterns.
Through independent control of the voltages supplied to both the
nozzles as well as the structure and motion systems that allow for
single or multi axis movement of the nozzles and/or the structure,
the confinement of the electrospun beam can be precisely
controlled.
[0106] Executing the electrospinning process preferably includes
executing the electrospinning process across a first dispensing
area in a first surface and a second dispensing area in a second
surface. This is of particular utility when actuating a 2D
projection mold--a front face and back face of the 2D projection
mold can receive fiber application simultaneously with two active
dispensing areas.
[0107] Executing the electrospinning process preferably includes
charging the solution supplied to the dispensing area and grounding
a collector of the mold structure. The collector of the mold
structure is charged to create a charge differential between the
dispensing area and the mold structure. Alternatively, both the
dispensing area and collector are charged to two different charges.
In another variation, the dispensing area may be grounded while the
collector is charged.
[0108] Additionally, the method can include managing delivery of
electrospinning solution to the dispensing area. As one variation,
managing can include accepting a solution cartridge, which
functions to allow replaceable and/or refillable cartridges to be
added or removed to the textile production system.
[0109] The method can additionally include controlling
electrospinning process for a fabric property transition S140,
which functions to augment or configure the electrospinning process
to change fiber and/or fabric properties in a defined region of the
mold structure. Fabric properties can include fabric type or
composition, fabric formation (e.g. "weave" pattern), fabric color,
and/or any suitable property. Controlling the electrospinning
process for a fabric property transition S140 preferably includes
controlling the electrospinning process over a defined region
according to a discrete transition mode or a gradient transition
mode.
[0110] Controlling electrospinning in a discrete transition mode
promotes the creation of a discrete transition between fabric
sections collected on the mold structure, wherein there is a
substantially defined edge between the two fabric types. Herein, a
defined edge can be where the fabric quality changes in less than
one centimeter and preferably in under 0.25 centimeters. In one
variation, the discrete transition is across the surface of the
fabric as shown in FIG. 28B. For example, the sleeves of a t-shirt
may be made of one fabric while the body is made of a second fabric
with the transition happening at the beginning of the arm portion.
In a second variation, the discrete transition can be in the layers
of the fabric as shown in FIG. 29. A bottom layer may be a first
fabric while a top layer can be of a second fabric. A discrete
transition can be achieved through executing electrospinning
process in a first mode and changing to executing electrospinning
process in a second mode. In the case of the discrete layer
transition, a first layer of fabric can be electrospun onto the
mold structure and then, once the first layer is complete, a second
layer of fabric can be electrospun onto the mold structure.
[0111] Controlling electrospinning in a gradient transition mode
promotes the creation of a gradient transition, which is
characterized as a gradual transition of fabric collected on the
mold structure. A gradient transition can be achieved through
executing electrospinning process in a first mode and progressively
changing to executing electrospinning process towards a second
mode. Gradient transitions can be across a fabric surface as shown
in FIG. 28B or a fabric layer as shown in FIG. 30.
[0112] In the case of gradient surface transitions, the method can
include augmenting the electrospinning process according to the
actuation of the mold structure and control of a dispenser in the
electrospinning process. The controlled dispenser is preferably at
least one nozzle in the array of nozzles. Control of
electrospinning from the at least one nozzle can be augmented by
altering the charge applied to the solution electrospun from the
nozzle; by altering the charge of the collector or mold structure,
by altering the solution entering the nozzle, by actuating the
nozzle (e.g., to modify the gap distance or direction solution
erupts from the nozzle), and/or any suitable change. The changes
are preferably gradual with multiple stages progressing towards a
final mode. As in a gradient, there may be multiple transitional
modes that act as guides in the transition. For example, a gradient
transition from red fiber to green fiber may also have intermediary
fiber qualities of blue and yellow.
[0113] The electrospinning process for a nozzle can be changed over
time according to the position of the mold structure during
actuation of the mold structure. For example, when the mold
structure is in a first position, the electrospinning process for a
first nozzle is in a first mode, and, when the mold structure is in
a second position, the electrospinning process for the first nozzle
is in a second mode. Such electrospinning process control can be
applied across an array of nozzle such that the combined
electrospun fabric creates a desired effect on the formed fabric.
The nozzles in an array of nozzles can be in any suitable mode at
different times.
[0114] In one variation, the method can include monitoring fiber
coverage and augmenting the actuation and/or electrospinning
process. Monitoring can include inspecting the mold structure with
an imaging tool during the electrospinning process and
characterizing fabric state in a region of the mold structure. The
imaging tool can be a camera operating in the visual frequency
range but may alternatively be an IR camera or any suitable type of
imaging tool. Fabric state can include amount of coverage, depth of
coverage, or any suitable type of characterization. In another
variation, monitoring may be accomplished through alternative
sensing approaches. For example, different regions of the mold
structure can detect the state of adhered fiber to produce a fabric
state characterization. Augmenting the actuation can be used to
concentrate fiber application in particular regions. The
electrospinning process can similarly be altered to change the
fiber application for particular regions. For example, a nozzle
substantially responsible for a particular region may be turned up
or down (i.e., electrospun fiber production increased or decreased)
according to the fiber covering for the particular region.
Monitoring and resulting augmentation can happen in substantially
real-time. Monitoring and augmentation may alternatively happen
periodically.
[0115] The method may additionally include applying a
post-processing step, which can function to strengthen the fabric,
add texture, or augment the formed fabric. In one variation, prior
to removing electrospun fabric from the mold structure, light based
or chemical based curing processes can take place inside the
chamber. To cure, color, or texture only specific regions of the
coated mold, projectors or lasers can be used to selectively expose
areas of the electrospun fabric to light.
[0116] As one exemplary usage scenario, the method can include
receiving design direction through a remote ordering system
software that allows an individual to create unique clothing and
fabric designs as 3D models, akin to CAD software for traditional
3D printing systems. This software would allow the full design and
customization of apparel and fabric items, which includes the
design elements (including but not limited to: colors, prints,
patterns, and feel) as well as fit (including but not limited to:
size of the overall item and subcomponents of a fabric item (e.g. a
sleeve, a collar)).
[0117] Online software would enable orders for these designs to be
submitted to a website, which could then produce and fulfill these
orders as a service. Individuals would visit the website and select
from items that are available and place orders for those items.
Individuals would also have the ability to upload their own custom
design and request fulfillment of the item to be sent to them.
Users of the website would also have the option to purchase and/or
download designs created by others for use a fabric printer that
they own. This acquired design could then be created with their own
machine, provided the materials were available.
[0118] As described above, one potential benefit of the method is
the customization and control of a resulting three dimensional
textile form through use of a replaceable mold structure. A user of
the manufacturing process can alter, update, and/or define a
completely different three-dimensional form through changing of a
mold structure. The manufacturing process is preferably performed
repeatedly in the same setup with differing mold structures. During
an exemplary usage scenario, a method of a preferred embodiment can
include producing a first textile product defined by a first mold
structure and producing a second textile product defined by a
second mold structure. As shown in FIG. 26, the method more
specifically includes fixing a first mold structure to a textile
production system S210, actuating the first mold structure S220
while executing a first electrospinning process across a dispensing
area S230, removing the first mold structure, fixing a second mold
structure to the textile production system S210', actuating the
second mold structure S220' while executing a second
electrospinning process across a dispensing area S230'. A first
electrospun textile product can be removed from the first mold
structure upon completion. Similarly, a second electrospun textile
product can be removed from the second mold structure. The first
and second mold structures can be substantially unique as will be
the resulting three-dimensional forms of their respective textile
products. Such a usage method can demonstrate the three dimensional
form capabilities of the process as well as the control and
adaptability over the resulting three dimensional textile
product.
[0119] The systems and methods of the embodiments can be embodied
and/or implemented at least in part as a machine configured to
receive a computer-readable medium storing computer-readable
instructions. The instructions can be executed by
computer-executable components integrated with the application,
applet, host, server, network, website, communication service,
communication interface, hardware/firmware/software elements of a
user computer or mobile device, wristband, smartphone, or any
suitable combination thereof. Other systems and methods of the
embodiment can be embodied and/or implemented at least in part as a
machine configured to receive a computer-readable medium storing
computer-readable instructions. The instructions can be executed by
computer-executable components integrated by computer-executable
components integrated with apparatuses and networks of the type
described above. The computer-readable medium can be stored on any
suitable computer readable media such as RAMs, ROMs, flash memory,
EEPROMs, optical devices (CD or DVD), hard drives, floppy drives,
or any suitable device. The computer-executable component can be a
processor but any suitable dedicated hardware device can
(alternatively or additionally) execute the instructions.
[0120] As a person skilled in the art will recognize from the
previous detailed description and from the figures and claims,
modifications and changes can be made to the embodiments of the
invention without departing from the scope of this invention as
defined in the following claims.
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