Manipulating characteristic timescales and fiber morphology in simultaneous centrifugal spinning and photopolymerization

Rotary Jet Spinning (RJS): A Key Process to Produce Biopolymeric Wound Dressings

Wounds result from different causes (e.g., trauma, surgeries, and diabetic ulcers), requiring even extended periods of intensive care for healing, according to the patient's organism and treatment. Currently, wound dressings generated by polymeric fibers at micro and nanometric scales are promising for healing the injured area. They offer great surface area and porosity, mimicking the fibrous extracellular matrix structure, facilitating cell adhesion, migration, and proliferation, and accelerating the wound healing process. Such properties resulted in countless applications of these materials in biomedical and tissue engineering, also as drug delivery systems for bioactive molecules to help tissue regeneration. The techniques used to engineer these fibers include spinning methods (electro-, rotary jet-), airbrushing, and 3D printing. These techniques have important advantages, such as easy-handle procedure and process parameters variability (type of polymer), but encounter some scalability problems. RJS is described as a simple and low-cost technique resulting in high efficiency and yield for fiber production, also capable of bioactive agents' incorporation to improve the healing potential of RJS wound dressings. This review addresses the use of RJS to produce polymeric fibers, describing the concept, type of configuration, comparison to other spinning techniques, most commonly used polymers, and the relevant parameters that influence the manufacture of the fibers, for the ultimate use in the development of wound dressings.

Macromolecular relaxation, strain, and extensibility determine elastocapillary thinning and extensional viscosity of polymer solutions

Delayed capillary break-up of viscoelastic filaments presents scientific and technical challenges relevant for drop formation, dispensing, and adhesion in industrial and biological applications. The flow kinematics are primarily dictated by the viscoelastic stresses contributed by the polymers that are stretched and oriented in a strong extensional flow field resulting from the streamwise gradients created by the capillarity-driven squeeze flow. After an initial inertiocapillary (IC) or viscocapillary (VC) regime, where elastic effects seem to play no role, the interplay of capillarity and viscoelasticity can lead to an elastocapillary (EC) response characterized by exponentially-slow thinning of neck radius (extensional relaxation time is determined from the delay constant). Less frequently, a terminal visco-elastocapillary (TVEC) response with linear decay in radius can be observed and used for measuring terminal, steady extensional viscosity. However, both IC/VC-EC and EC-TVEC transitions are inaccessible in devices that create stretched necks by applying a step strain to a liquid bridge (e.g., capillary breakup extensional rheometer). In this study, we use dripping-onto-substrate rheometry to obtain radius evolution data for unentangled polymer solutions. We deduce that the plots of transient extensional viscosity vs. Hencky strain (scaled by the respective values at the EC-TVEC transition) emulate the functional form of the birefringence-macromolecular strain relationship based on Peterlin's theory. We quantify the duration and strain between the IC/VC-EC and the EC-TVEC transitions using measures we term elastocapillary span and elastocapillary strain increment and find both measures show values directly correlated with the corresponding variation in extensional relaxation time.

Mechanically Robust and Recyclable Cross-Linked Fibers from Melt Blown Anthracene-Functionalized Commodity Polymers

Melt blowing combines extrusion of a polymer melt through orifices and attenuation of the extrudate with hot high-velocity air jets to produce nonwoven fibers in a single step. Due to its simplicity and high-throughput nature, melt blowing produces more than 10% of global nonwovens (∼$50 billion market). Semicrystalline thermoplastic feedstock, such as poly(butylene terephthalate), polyethylene, and polypropylene, have dominated the melt blowing industry because of their facile melt processability and thermal/chemical resistance; other amorphous commodity thermoplastics (e.g., styrenics, (meth)acrylates, etc.) are generally not employed because they lack one or both characteristics. Cross-linking commodity polymers could enable them to serve more demanding applications, but cross-linking is not compatible with melt processing, and it must be implemented after fiber formation. Here, cross-linked fibers were fabricated by melt blowing linear anthracene-functionalized acrylic polymers into fibers, which were subsequently cross-linked via anthracene-dimerization triggered by either UV light or sunlight. The resulting fibers possessed nearly 100% gel content because of highly efficient anthracene photodimerization in the solid state. Compared to the linear precursors, the anthracene-dimer cross-linked acrylic fibers exhibited enhanced thermomechanical properties suggesting higher upper service temperatures (∼180 °C), showing promise for replacing traditional thermoplastic-based melt blown nonwovens in certain applications. Additionally, given the dynamic nature of the anthracene-dimer cross-links at elevated temperatures (> ∼180 °C), the resulting cross-linked fibers could be effectively recycled after use, providing new avenues toward sustainable nonwoven products.

Melt-Blown Cross-Linked Fibers from Thermally Reversible Diels-Alder Polymer Networks

Melt blowing is a process in which liquid polymer is extruded through orifices and then drawn by hot air jets to produce nonwoven fibers with average diameters typically greater than one micron. Melt-blown nonwoven fiber products constitute a significant fraction (i.e., more than 10%) of the $50 billion global nonwovens market. Thermoplastic feedstocks, such as polyethylene, polypropylene, poly(phenylene sulfide), and poly(butylene terephthalate), have dominated melt-blown nonwovens because of their combined cost, good chemical resistance, and high-temperature performance. Cross-linked nonwovens from other commodity polymers (e.g., (meth)acrylates, styrenics, silicones, etc.) could be attractive alternatives; however, no commercial cross-linked nonwovens currently exist. Here, cross-linked fibers were produced via one-step melt blowing of thermoreversible Diels-Alder polymer networks comprised of furan- and maleimide-functional methacrylate-based polymer backbones. These dynamic networks de-cross-link and flow like viscous liquids under melt-blowing conditions and then revert to a network via cooling-induced cross-linking during/after melt blowing. Finally, the resulting cross-linked fibers can be recycled after use because of their reversible dynamic nature, which may help address microfiber waste as a significant source of microplastic pollution.

Nanofibrous scaffolds for biomedical applications

Tissue engineering is an emergent and very interesting research field, providing potential solutions for a myriad of challenges in healthcare. Fibrous scaffolds specifically have shown promise as an effective tissue engineering method, as their high length-to-width ratio mimics that of extracellular matrix components, which in turn guides tissue formation, promotes cellular adhesion and improves mechanical properties. In this review paper, we discuss in detail both the importance of fibrous scaffolds for the promotion of tissue growth and the different methods to produce fibrous biomaterials to possess favorable and unique characteristics. Here, we focus on the pressing need to develop biomimetic structures that promote an ideal environment to encourage tissue formation. In addition, we discuss different biomedical applications in which fibrous scaffolds can be useful, identifying their importance, relevant aspects, and remaining significant challenges. In conclusion, we provide comments on the future direction of fibrous scaffolds and the best way to produce them, proposed in light of recent technological advances and the newest and most promising fabrication techniques.

Composite Fibers from Recycled Plastics Using Melt Centrifugal Spinning

New methods are being developed to enable the production of value-added materials from high-volume, low-cost feedstocks arising from domestic recycling streams. In this work, recycled bottle-grade polyethylene terephthalate, polystyrene, and polypropylene were spun into fibers from the melt using a centrifugal spinning technique. Mono-component fibers and 50/50 blends of each polymer and a 33/33/33 blend of all three polymers were evaluated. Fiber morphology, chemistry, thermal, and mechanical properties were probed. Fiber diameters ranged from ca. 1 to over 12 µm, with polypropylene fibers having the smallest fiber diameters. Mono-component fibers were generally defect-free, while composite fibers containing polypropylene were beady. Fibers made from polyethylene terephthalate had the highest tensile strength, and the addition of polyethylene terephthalate to the other polymers improved the mechanical properties of the blends. Nano- and micro-fibers from both pure and mixed waste streams are expected to have applications in myriad areas such as ultra/micro-filtration, composites, and insulation.

Pinch-off dynamics and dripping-onto-substrate (DoS) rheometry of complex fluids

Liquid transfer and drop formation/deposition processes involve complex free-surface flows including the formation of columnar necks that undergo spontaneous capillary-driven instability, thinning and pinch-off. For simple (Newtonian and inelastic) fluids, a complex interplay of capillary, inertial and viscous stresses determines the nonlinear dynamics underlying finite-time singularity as well as self-similar capillary thinning and pinch-off dynamics. In rheologically complex fluids, extra elastic stresses as well as non-Newtonian shear and extensional viscosities dramatically alter the nonlinear dynamics. Stream-wise velocity gradients that arise within the thinning columnar neck create an extensional flow field, and many complex fluids exhibit a much larger resistance to elongational flows than Newtonian fluids with similar shear viscosity. Characterization of pinch-off dynamics and the response to both shear and extensional flows that influence drop formation/deposition in microfluidic and printing applications requires bespoke instrumentation not available, or easily replicated, in most laboratories. Here we show that dripping-onto-substrate (DoS) rheometry protocols that involve visualization and analysis of capillary-driven thinning and pinch-off dynamics of a columnar neck formed between a nozzle and a sessile drop can be used for measuring shear viscosity, power law index, extensional viscosity, relaxation time and the most relevant processing timescale for printing. We showcase the versatility of DoS rheometry by characterizing and contrasting the pinch-off dynamics of a wide spectrum of simple and complex fluids: water, printing inks, semi-dilute polymer solutions, yield stress fluids, food materials and cosmetics. We show that DoS rheometry enables characterization of low viscosity printing inks and polymer solutions that are beyond the measurable range of commercially-available capillary break-up extensional rheometer (CaBER). We show that for high viscosity fluids, DoS rheometry can be implemented relatively inexpensively using an off-the-shelf digital camera, and for many complex fluids, similar power law scaling exponent describes both neck thinning dynamics and the shear thinning response.

Sulfur and Its Role In Modern Materials Science

Although well-known and studied for centuries, sulfur continues to be at the center of an extensive array of scientific research topics. As one of the most abundant elements in the Universe, a major by-product of oil refinery processes, and as a common reaction site within biological systems, research involving sulfur is both broad in scope and incredibly important to our daily lives. Indeed, there has been renewed interest in sulfur-based reactions in just the past ten years. Sulfur research spans the spectrum of topics within the physical sciences including research on improving energy efficiency, environmentally friendly uses for oil refinery waste products, development of polymers with unique optical and mechanical properties, and materials produced for biological applications. This Review focuses on some of the latest exciting ways in which sulfur and sulfur-based reactions are being utilized to produce materials for application in energy, environmental, and other practical areas.

Polyhedral Oligomeric Silsesquioxane-Containing Thiol-ene Fibers with Tunable Thermal and Mechanical Properties

Polyhedral oligomeric silsesquioxanes (POSS) are versatile inorganic-organic hybrid building blocks that have potential applications as reinforcement nanofillers, thermal stabilizers, and catalyst supports for metal nanoparticles. However, fabrication of fibrous materials with high POSS content has been a challenge because of the aggregation and solubility limits of POSS units. In this paper, we describe a robust and environmentally friendly fabrication approach of inorganic-organic hybrid POSS fibers by integrating UV initiated thiol-ene polymerization and centrifugal fiber spinning. The use of monomeric liquids in this approach not only reduces the consumption of heat energy and solvent, but it also promotes homogeneous mixing of organic and inorganic components that allows integration of large amount of POSS (up to 80 wt %) into the polymer network. The POSS containing thiol-ene fibers exhibited enhanced thermomechanical properties compared to purely organic analogs as revealed by substantial increases in residual weight and a factor of 4 increase in modulus after thermal treatment at 1000 °C. This simple fabrication approach combined with the tunability in fiber properties afforded by tailoring monomer composition make POSS containing thiol-ene fibers attractive candidates for catalyst supports and filtration media, particularly in high-temperature and harsh environments.

Passive trapping of rigid rods due to conformation-dependent electrophoretic mobility

We present computer simulations of a rigid rod in a combination of an extensional fluid flow and extensional electric field. The electrophoretic mobility of the rod is different parallel or perpendicular to the rod. The dependence of the mobility on the conformation (orientation) leads to a new phenomenon where the rods can be passively trapped in all directions at the stagnation point. This contrasts with the behavior in either fluid flow or electric field alone, in which an object can be pushed towards the stagnation point along some directions but is pushed away in others. We have determined the state space where trapping occurs and have developed a model that describes the strength of trapping when it does occur. This new phenomenon could be used in the future to separate objects based on a coupling between their mobility and ability to be oriented.