Apparatuses and methods for the production of microfibers and nanofibers

Abstract

Described herein are apparatuses and methods of creating fibers, such as microfibers and nanofibers. The methods discussed herein employ centrifugal forces to transform material into fibers. Apparatuses that may be used to create fibers are also described.

1 . A device for use in a microfiber and/or nanofiber producing system, the device comprising:
 a body comprising a body cavity and a coupling member, wherein the body cavity is configured to receive material to be produced into a fiber, wherein the body is couplable to a driver through the coupling member; and   at least two blades extending from the body, wherein each of the blades comprises a blade cavity coupled to the body cavity, wherein material to be produced into a fiber passes from the body cavity to the blade cavity during use, and wherein one or more openings are formed at or proximate to an end of each blade extending through a side wall of the blade;   wherein, during use, rotation of the body causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers.   
     
     
         2 . The device of  claim 1 , wherein the device comprises:
 a first member comprising: a first member central portion; at least two arms extending from the first member central portion; a first member coupling surface formed along an edge of the first member central portion and the arms extending from the first member central portion; and one or more grooves formed in the first member coupling surface, proximate to an end of the arms,   a second member comprising: a second member central portion; at least two arms extending from a second member central portion; a second member coupling surface formed along an edge of the second member central portion and the arms extending from the second member central portion; and one or more grooves formed in the first member coupling surface, proximate to an end of the arms, wherein the fiber producing device is couplable to a driver through the coupling member;   wherein the first member coupling surface is coupled to the second member coupling surface to form the fiber producing device, and wherein the first member central portion and the second member central portion combine to form the body, and wherein at least two of the first member arms couple to at least two of the second member arms to form the at least two blades extending from the body;   wherein the one or more grooves of the first member arms are substantially aligned with the one or more grooves of the corresponding second member arms to form one or more openings extending through side walls of the formed blades.   
     
     
         3 . The device of  claim 1 , wherein the device comprises:
 a first member comprising: a first member central portion; at least two arms extending from the first member central portion; a first member coupling surface formed along an edge of the first member central portion and the arms extending from the first member central portion; and one or more openings extending through a sidewall of each of the arms of the first member, proximate to an end of the arms,   a second member comprising: a second member central portion; at least two arms extending from a second member central portion; a second member coupling surface formed along an edge of the second member central portion and the arms extending from the second member central portion; the coupling member coupled to the second member central portion; wherein the fiber producing device is couplable to a driver through the coupling member;   wherein the first member coupling surface is coupled to the second member coupling surface to form the fiber producing device, and wherein the first member central portion and the second member central portion combine to form the body, and wherein at least two of the first member arms couple to at least two of the second member arms to form the at least two blades extending from the body.   
     
     
         4 . The device of  claim 1 , wherein the device comprises:
 a first member comprising: a first member central portion; at least two arms extending from the first member central portion; a first member coupling surface formed along an edge of the first member central portion and the arms extending from the first member central portion; and one or more openings extending through a sidewall of each of the first member arms, proximate to an end of the arms,   a second member comprising: a second member central portion; at least two arms extending from a second member central portion; a second member coupling surface formed along an edge of the second member central portion and the arms extending from the second member central portion; and one or more openings extending through a sidewall of each of the second member arms, proximate to an end of the arms;   wherein the first member coupling surface is coupled to the second member coupling surface to form the fiber producing device, and wherein the first member central portion and the second member central portion combine to form the body, and wherein at least two of the first member arms couple to at least two of the second member arms to form the at least two blades extending from the body.   
     
     
         5 . The device of  claim 1 , wherein the device has two blades extending from opposing sides of the body. 
     
     
         6 . The device of  claim 1 , wherein the blades are set at a pitch of between about 5° to about 30° with respect to a longitudinal plane running perpendicular to the body. 
     
     
         7 . The device of  claim 1 , wherein the blades have an aerodynamic profile. 
     
     
         8 . A microfiber and/or nanofiber producing system comprising:
 a fiber producing device comprising:
 a body comprising a body cavity and a coupling member, wherein the body cavity is configured to receive material to be produced into a fiber, wherein the body is couplable to a driver through the coupling member; and 
 at least two blades extending from the body, wherein each of the blades comprises a blade cavity coupled to the body cavity, wherein material to be produced into a fiber passes from the body cavity to the blade cavity during use, and wherein one or more openings are formed at or proximate to an end of each blade extending through a side wall of the blade; 
 wherein, during use, rotation of the body causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers; 
   a driver capable of rotating the fiber producing device, wherein the body of the fiber producing device is couplable to the driver through the coupling member; and   wherein, during use, rotation of the body causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers.   
     
     
         9 . The system of  claim 8 , wherein the device comprises:
 a first member comprising: a first member central portion; at least two arms extending from the first member central portion; a first member coupling surface formed along an edge of the first member central portion and the arms extending from the first member central portion; and one or more grooves formed in the first member coupling surface, proximate to an end of the arms,   a second member comprising: a second member central portion; at least two arms extending from a second member central portion; a second member coupling surface formed along an edge of the second member central portion and the arms extending from the second member central portion; and one or more grooves formed in the first member coupling surface, proximate to an end of the arms, wherein the fiber producing device is couplable to a driver through the coupling member;   wherein the first member coupling surface is coupled to the second member coupling surface to form the fiber producing device, and wherein the first member central portion and the second member central portion combine to form the body, and wherein at least two of the first member arms couple to at least two of the second member arms to form the at least two blades extending from the body;   wherein the one or more grooves of the first member arms are substantially aligned with the one or more grooves of the corresponding second member arms to form one or more openings extending through side walls of the formed blades.   
     
     
         10 . The system of  claim 8 , wherein the device comprises:
 a first member comprising: a first member central portion; at least two arms extending from the first member central portion; a first member coupling surface formed along an edge of the first member central portion and the arms extending from the first member central portion; and one or more openings extending through a sidewall of each of the arms of the first member, proximate to an end of the arms,   a second member comprising: a second member central portion; at least two arms extending from a second member central portion; a second member coupling surface formed along an edge of the second member central portion and the arms extending from the second member central portion; the coupling member coupled to the second member central portion; wherein the fiber producing device is couplable to a driver through the coupling member;   wherein the first member coupling surface is coupled to the second member coupling surface to form the fiber producing device, and wherein the first member central portion and the second member central portion combine to form the body, and wherein at least two of the first member arms couple to at least two of the second member arms to form the at least two blades extending from the body.   
     
     
         11 . The system of  claim 8 , wherein the device comprises:
 a first member comprising: a first member central portion; at least two arms extending from the first member central portion; a first member coupling surface formed along an edge of the first member central portion and the arms extending from the first member central portion; and one or more openings extending through a sidewall of each of the first member arms, proximate to an end of the arms,   a second member comprising: a second member central portion; at least two arms extending from a second member central portion; a second member coupling surface formed along an edge of the second member central portion and the arms extending from the second member central portion; and one or more openings extending through a sidewall of each of the second member arms, proximate to an end of the arms;   wherein the first member coupling surface is coupled to the second member coupling surface to form the fiber producing device, and wherein the first member central portion and the second member central portion combine to form the body, and wherein at least two of the first member arms couple to at least two of the second member arms to form the at least two blades extending from the body.   
     
     
         12 . The system of  claim 8 , wherein the device has two blades extending from opposing sides of the body. 
     
     
         13 . The system of  claim 8 , wherein the blades are set at a pitch of between about 5° to about 30° with respect to a longitudinal plane running perpendicular to the body. 
     
     
         14 . The system of  claim 8 , wherein the blades have an aerodynamic profile. 
     
     
         15 . The system of  claim 8 , further comprising a heating device thermally coupled to the fiber producing device. 
     
     
         16 . The system of  claim 8 , wherein the fiber producing device is enclosed in a chamber, and wherein the environment inside the chamber is controllable. 
     
     
         17 . The system of  claim 8 , wherein the driver is capable of rotating the fiber producing device at speeds of greater than about 1000 rpm. 
     
     
         18 . The system of  claim 8 , further comprising a collection system surrounding at least a portion of the fiber producing device, wherein fibers produced during use are at least partially collected on the collection system. 
     
     
         19 . A method of producing microfibers and/or nanofibers, comprising:
 placing material in a fiber producing device, the fiber producing device comprising:
 a body comprising a body cavity and a coupling member, wherein the body cavity is configured to receive material to be produced into a fiber, wherein the body is couplable to a driver through the coupling member; and 
 at least two blades extending from the body, wherein each of the blades comprises a blade cavity coupled to the body cavity, wherein material to be produced into a fiber passes from the body cavity to the blade cavity during use, and wherein one or more openings are formed at or proximate to an end of each blade extending through a side wall of the blade; 
 wherein, during use, rotation of the body causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers; 
   rotating the fiber producing device at a speed of at least about 1000 rpm, wherein rotation of the fiber producing device causes material in the body to be ejected through one or more openings to produce microfibers and/or nanofibers; and   collecting at least a portion of the produced microfibers and/or nanofibers.   
     
     
         20 - 40 . (canceled)