Unconfined fluid electrospun into high quality nanofibers from a plate edge

We demonstrate an easily-implemented, edge-plate geometry for electrospinning and produce high quality nanofibers from unconfined polymer fluids. We show that for electrospinning in general, the electric field gradient, not just the electric field amplitude, is a critical parameter for successful self-initiated jetting. Considering a single spinning site, the edge-plate configuration resulted in the same or a higher fabrication rate as traditional needle electrospinning, while producing nanofibers similar in quality (diameter, diameter distribution, and collected mat porosity): moreover, this novel configuration operates without the possibility of clogging and has high potential for scale-up. We analyze the fundamental physical processes which underlie edge-plate electrospinning, including electric field, working distance, and feed rate dependence and the resultant changes to the linear and whipping regions, and thus to the fiber diameter. We conclude that the edge-plate configuration functions in a remarkably similar manner to traditional needle electrospinning. (C) 2010 Elsevier Ltd. All rights reserved.