SYSTEMS AND METHODS FOR TOP DOWN AND BOTTOM UP ELECTROSPINNING

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/686,471 , filed Aug. 23, 2024, and entitled, “Systems and Methods for Top Down and Bottom Up Electrospinning”, the entire disclosure of which is hereby incorporated by reference herein.

TECHNICAL FIELD

Embodiments described herein relate generally to electrospinning systems and methods that allow switching between top-down and bottom-up electrospinning, and/or enable the simultaneous use of top-down and bottom-up electrospinning processes.

BACKGROUND

Electrospinning, also known as electrostatic fiber spinning, is a technique used to create fibers with nano- or micrometer dimensions by stretching a viscoelastic melt or solution under the influence of an externally applied electrostatic field. The process involves a setup where a reservoir or source containing a polymer solution or melt is positioned at a certain distance from a grounded collector, with the solution or melt being extruded through a nozzle (e.g., a syringe tip). When a high voltage is applied, charged ions accumulate around the polymer droplet. As the voltage increases, Coulombic repulsion between the ions overcomes surface tension, deforming the droplet into a “Taylor cone.” At a critical voltage, a fine fiber jet is extruded from the Taylor cone towards the grounded collector, and any solvent present evaporates during this transit, resulting in a dry, dense fibrous mesh.

There are two predominant methods for mass production of nanofibers: the top-down method and the bottom-up method. In the top-down method, fiber formation occurs in the direction of gravity, which generally yields high production rates but can encounter issues with gel drops that affect fiber quality. Conversely, the bottom-up method involves fiber formation against the direction of gravity, which avoids the gel drop issue but tends to have lower yields.

The choice between these methods typically depends on the type of polymer being used and specific quality control requirements. This has traditionally required the installation of separate machines for each method, leading to significant investment costs and additional installation space resulting in a larger footprint.

SUMMARY

Embodiments described herein relate generally to electrospinning systems and methods that enable the use of both top-down and bottom-up electrospinning techniques for the production of porous materials that include a plurality of nanofibers adhered to one another to achieve a predetermined thickness. Specifically, these embodiments facilitate the transition between top-down and bottom-up electrospinning techniques and/or enable the simultaneous execution of both processes.

In some embodiments, described herein is a system including a first collector plate, a second collector plate offset from the first collector plate, and a deposition assembly disposed between the first collector plate and the second collector plate. The deposition assembly includes a support element extending between the first and second collector plates, and a set of orifices disposed on a side of the support element. The side of the support element faces one of the first collector plate or the second collector plate, and the set of orifices is configured to allow corresponding streams of a polymer solution to be communicated with at least one of the first or the second collector plate. The deposition assembly further includes an actuator operably coupled to the support element. The actuator is configured to move the support element between a first orientation in which the set of orifices face the first collector plate, and a second orientation in which the set of orifices face the second collector plate. In some embodiments, the support element extends parallel to the first and second collector plates.

In some embodiments, the side is a first side, and the set of orifices is a first set of orifices, and the deposition assembly further includes a second set of orifices disposed on a second side of the support element opposite the first side. In some embodiments, a method includes: disposing a first carrier member on a first collector plate; disposing a second carrier member on a second collector plate, the second collector plate offset from the first collector plate; positioning a support element between the first and second collector plates, the support element comprising a first set of orifices disposed on a first side of the support element, the first side facing the first collector plate; ejecting a first polymer solution from the first set of orifices onto the first carrier member; and collecting nanofibers formed from the first polymer solution on the first carrier member.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings. Optional items in all figures shown in dashed lines.

FIG. 1 is a block diagram of an electrospinning system, according to an embodiment.

FIG. 2 is an illustration of an electrospinning system, according to an embodiment.

FIG. 3 is an illustration of an electrospinning system, according to an embodiment.

FIGS. 4A-4C are perspective views of a support element, according to an embodiment.

FIG. 5 is a block diagram of a method 10 for producing porous materials, according to an embodiment.

Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

DETAILED DESCRIPTION

In some embodiments, systems and methods described herein can integrate both top-down and bottom-up electrospinning processes within a single unit, thereby eliminating the need for separate equipment for each process. In some embodiments, systems and methods described herein allow concurrent use of the top-down and bottom-up processes within a single unit.

Nanofibers are used in a wide range of applications due to their unique properties such as, for example, high surface area to weight ratio, low density, high pore volume, small pore size, superior stiffness, and higher tensile strength as compared to conventional fibers. Electrospinning is a versatile and scalable fabrication technique that can be used to produce nanoscale fibers with diameters ranging from a few nanometers up to micrometers. In a typical electrospinning process, a high voltage is applied to a polymer solution or melt loaded in a syringe. When the electrical forces overcome the surface tension of the liquid or melt, a charged jet or stream is ejected from the tip of the syringe, orifice, or nozzle. As the jet travels in the air, one of two things generally occur: for techniques using a polymer solution, solvent(s) included in the polymer solution evaporate as the jet travels, leaving behind thin solid fibers; for melt electrospinning or other solvent-free techniques, the polymer stream or jet undergoes solidification as it travels, without any solvent evaporation involved. In both cases, the solidified nanofibers can be collected on a carrier (e.g., a carrier layer, or spool). The nanofibers can be stacked on the carrier to form a porous nanofiber web, for example, a porous nanofiber thin layer.

In prevalent mass-production methods, two primary techniques are employed: the top-down method and the bottom-up method. Both methods have unique advantages and face distinct challenges. The top-down method involves fiber formation in the direction of gravity. This technique is known for its high production rates, making it suitable for large-scale manufacturing. However, one significant issue with the top-down method is the occurrence of gel drops. These gel drops form when the polymer solution does not completely transition into fibers, leading to inconsistencies and defects that affect the quality of the final product. This issue necessitates stringent quality control measures to ensure the reliability of the nanofibers produced. Conversely, the bottom-up method forms fibers against the direction of gravity. This technique effectively avoids the problem of gel drops, resulting in more consistent fiber quality. However, the bottom-up method tends to have lower yields compared to the top-down method, which can be a significant drawback when high production volumes are required. The lower yield is often due to the increased difficulty in maintaining a stable fiber formation process against the force of gravity.

The choice between these methods typically depends on the specific type of polymer being used and the quality control requirements of the production process. This has traditionally required the installation of separate machines for each method, leading to significant investment costs and additional installation space. Furthermore, quality control issues persist, with top-down machines facing difficulties in solving gel drop problems, while bottom-up machines struggle with achieving high yields.

To address these challenges, various innovations and enhancements have been proposed in the literature. For instance, researchers have explored the use of coaxial electrospinning, which can help mitigate some of the issues associated with both top-down and bottom-up methods by stabilizing the jet formation and reducing the occurrence of gel drops. Additionally, advancements in the design of spinnerets and the application of auxiliary electric fields have shown promise in improving yield and fiber quality for both methods. However, these solutions often require further modifications to existing equipment or additional components, which can still entail considerable costs and space requirements.

In contrast, embodiments described herein address the challenges in nanofiber production by integrating both the top-down and bottom-up methods within a single unit (e.g., in a single assembly). This approach reduces the need for separate equipment for each method, thus reducing investment costs and saving installation space. By utilizing the combined strengths of both methods, the integrated system provides flexibility in production, allowing manufacturers to switch between methods as required to optimize for different polymers and quality control criteria. Consequently, the production of high-quality nanofibers becomes more efficient and versatile, enhancing overall manufacturing processes. In addition, the embodiments described herein can facilitate simultaneous use of both top-down and bottom-up methods, allowing production of two different nanofibers concurrently.

The system described herein offers multiple benefits, such as significantly reducing manufacturing time by combining processes and eliminating the need for multiple machines. By integrating both methods, the system enhances product quality, as it can adapt to the specific requirements of various polymers and mitigate issues like gel drops and low yields. The versatility of switching between top-down and bottom-up methods within a single unit also leads to cost savings by reducing waste and minimizing the need for extensive quality control measures. Additionally, this integrated approach simplifies the production line, making it more efficient and easier to manage, ultimately leading to higher throughput and better scalability for mass production of nanofibers.

Systems and methods described herein can be used for manufacturing of porous materials including a plurality of nanofibers adhered together to achieve a predetermined thickness. In some embodiments, the porous materials are per-and polyfluoroalkyl substances (PFAS) free. In some embodiments, the multi-layered porous materials can be configured or formulated to be vapor permeable and/or waterproof, which makes the multi-layered porous materials described herein beneficial for the textile industry.

In some embodiments, the polymer solution used in the electrospinning process is free of per- and polyfluoroalkyl substances (PFAS). PFAS-free formulations may include biodegradable or environmentally friendly polymers such as polymers including, but not limited to, polylactic acid (PLA), polycaprolactone (PCL), or cellulose derivatives. These materials may offer reduced environmental impact and can be suitable for applications in medical textiles, filtration, and consumer goods.

As used in this specification, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, the term “a member” is intended to mean a single member or a combination of members, “a material” is intended to mean one or more materials, or a combination thereof.

The term “substantially” when used in connection with “cylindrical,” “linear,” and/or other geometric relationships is intended to convey that the structure so defined is nominally cylindrical, linear or the like. As one example, a portion of a support member that is described as being “substantially linear” is intended to convey that, although linearity of the portion is desirable, some non-linearity can occur in a “substantially linear” portion. Such non-linearity can result from manufacturing tolerances, or other practical considerations (such as, for example, the pressure or force applied to the support member). Thus, a geometric construction modified by the term “substantially” includes such geometric properties within a tolerance of plus or minus 5% of the stated geometric construction. For example, a “substantially linear” portion is a portion that defines an axis or center line that is within plus or minus 5% of being linear.

As used herein, the term “set” and “plurality” can refer to multiple features or a singular feature with multiple parts. For example, when referring to a set of fibers, the set of fibers can be considered as one electrode with multiple portions, or the set of electrodes can be considered as multiple, distinct fibers. Thus, a set of portions or a plurality of portions may include multiple portions that are either continuous or discontinuous from each other. A plurality of particles or a plurality of materials can also be fabricated from multiple items that are produced separately and are later joined together (e.g., via mixing, an adhesive, or any suitable method).

As used herein, the term “porous” refers to a material which has voids throughout the internal structure which form an interconnected or closed air path from one surface to the other.

As described herein, the term “nanofiber” refers to a fiber having a cross-sectional width, for example, diameter in a range of about 1 nm to about 1,000 nm, inclusive.

FIG. 1 is a block diagram of an electrospinning system 100, according to an embodiment. The system 100 includes a deposition assembly 110, a first collector plate 120a, and a second collector plate 120b offset from the first collector plate 120a. The deposition assembly 110 is disposed between the first collector plate 120a, and the second collector plate 120b. The electrospinning system 100 can be used for manufacturing a porous material including a plurality of nanofibers, that may be adhered together to form a nanofiber layer having a predetermined thickness.

The role of the deposition assembly 110 is to deposit a plurality of fibers onto either the first collector plate 120a, the second collector plate 120b, or both. The deposition assembly 110 includes a support element 130, a set of orifices 140 disposed on a side of the support element 130, and a reorientation mechanism 150 (e.g., an actuator) operably coupled to the support element 130. The deposition assembly 110 can optionally include a conduit 160 that is in fluid communication with the set of orifices 140. The set of orifices 140 are configured to allow corresponding streams of a polymer solution or a polymer melt to be communicated with at least one of the first or the second collector plate. The reorientation mechanism 150 is configured to move the support element 130 between a first orientation in which the set of orifices face the first collector plate 120a, and a second orientation in which the set of orifices face the second collector plate 120b.

In some embodiments, in the first configuration of the system 100, the first collector plate 120a is configured to receive a first polymer solution or melt from the set of orifices 140 disposed on a side of the support element 130. In some embodiments, in the second configuration of the system 100, the second collector plate 120b is configured to receive a second polymer solution or melt from the set of orifices 140 disposed on a side of the support element 130. In some embodiments, the first and the second polymer solutions or melts can include the same material. In some embodiments, the first and the second polymer solutions or melts can be different in terms of composition and/or physicochemical properties (e.g., molecular weight, chain length, degree of polymerization, melting point, glass transition temperature, density, tensile strength, elongation, chemical resistance etc.). In some embodiments, at least one of the first polymer or the second polymer is PFAS-free. In some embodiments, the first and the second polymer solutions can independently include one or more type of polymers. Adapting the system configuration based on the polymer type enables the selection of either a top-down or bottom-up approach tailored to the polymer's properties, thereby optimizing production efficiency and enhancing product quality. In some embodiments, the first and the second polymer solutions can independently include thermoplastic and/or thermosetting polymers capable of being electrospun. In some embodiments, the first and the second polymer solutions can independently include a hydrophilic polymer or a hydrophobic polymer. In some embodiments, the first and the second polymer solutions can independently include polyurethane and/or its copolymers such as polyetherurethane, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, or any other suitable polymer, or any suitable combination thereof.

In some embodiments, the first collector plate 120a can be positioned parallel to and at a first pre-determined distance from the support element 130. In some embodiments, the second collector plate 120b can be positioned parallel to and at a second pre-determined distance from the support element 130 opposite the first collector plate 120a. In some embodiments, the first and the second pre-determined distance can be same. In embodiments, the first and the second pre-determined distance can be different. In other words, the support element 130 can be disposed in between the first collector plate 120a and the second collector plate 120b, and located equidistant from each of the first and second collector plates 120a and 120b, or closer to one of the first or second collector plates 120a or 120b, relative to the other of the first or second collector plates 120a or 120b. In some embodiments, the first and the second pre-determined distance can be adjusted depending on the type of a polymer that is ejected from the set of the orifices and operational parameters (e.g., voltage applied to the orifices 140).

In some embodiments, at least one of the first collector plate 120a or the second collector plate 120b can have a patterned surface. In some embodiments, the patterned surface may include nano or micro patterns disposed or defined on the collector plates 120a, 120b. In some embodiments, the nano and/or micro patterns can include grooves, ridges, pillars, or lattice structures formed via lithography, embossing, laser etching, and/or the like. These surface features may serve to guide fiber orientation, enhance adhesion, or create spatially defined zones of porosity. In some embodiments, the patterned collector surface may be tailored to specific application requirements, such as directional strength, filtration efficiency, or aesthetic texture in textile products.

In some embodiments, the first collector plate 120a and the second collector plate 120b can independently be formed of at least one of stainless steel, paper, non-woven fabric, or plastic substrate. In some embodiments, at least one of the first collector plate 120a and the second collector plate 120b can be electrically grounded. In some embodiments, at least one of the first collector plate 120a and the second collector plate 120b can be polarized at a predetermined electrostatic potential. That is, in some embodiments, at least one of the first collector plate 120a and the second collector plate 120b can be connected to a voltage supply so as to apply a positive or negative potential thereto.

In some embodiments, a carrier can be disposed onto at least one of the first collector plate 120a or the second collector plate 120b. In some embodiments, the carrier disposed on the first collector plate 120a and the second collector plate 120b can be same. In some embodiments, the carrier disposed on the first collector plate 120a and the second collector plate 120b can be compositionally or physically (e.g., having different thickness) different. In some embodiments, the carrier can act as a stabilizing and/or protective layer for the nanofibers formed onto the collector plates 120a, 120b. In some embodiments, the carrier can be a textile, a woven such as a monofilament or knitted fabric, or nonwovens. The carrier can have various properties such as being hydrophobic, oleophobic, repellent against sweat, blood, allergens, pathogens, flame retardant, and/or anti-static. In some embodiments, the carrier may include a polymer, a plastic, cellulose, or a composite material. In some embodiments, the carrier can be a conventional support used for collecting and/or supporting electrospun nanofibers, for example, serve a as a substrate for electrospun nanofibers. In some embodiments, the carrier may include a cellulosic material, for example, paper or cardboard, which can serve as a stable and porous surface conducive to fiber deposition. In some embodiments, the carrier may include textiles, that may be woven and/or non-woven, which may provide versatility in surface texture and mechanical properties, and may be used to form attire. In some embodiments, the carrier may include solid surfaces like glass slides or silicon wafers, which may offer precise control over fiber alignment and distribution, for example, for applications requiring defined patterning or surface modification. Additionally, the carrier can take the form of a mesh or screen, enhancing structural support and airflow. In some embodiments, the carrier is physically coupled to a carrier roll. Once the fibers are deposited on the carrier, the carrier can then be rolled onto a nanofiber roll. In some embodiments, the nanofiber roll is physically coupled to the carrier roll. That is, in some embodiments, once the fibers are deposited, the carrier may be wound onto a nanofiber roll, which may be mechanically coupled to the carrier roll for continuous operation.

The support element 130 extends between the first collector plate 120a and the second collector plate 120b, aligning with or supporting the orientation of these plates. The support element 130 can extend between the first collector plate 120a and the second collector plate 120b in various configurations, as long as the set of orifices 140 is positioned to allow the corresponding streams of polymer solution to be communicated with at least one of the first or second collector plates. In some embodiments, the support element 130 extends parallel to at least one of the collector plates 120a or 120b. The support element 130 can be formed into any suitable shape that maintains the alignment (e.g., parallel alignment) of the set of orifices 140 with the first and second collector plates.

In some embodiments, the support element can be in a form of a bar or a rod extending in a longitudinal direction and positioned between, and optionally parallel to the first collector plate 120a and the second collector plate 120b. In some embodiments, the support element 130 may include a hollow bar defining a channel therethrough through which the polymer solution or melt may be communicated from one to the other longitudinal length thereof. In such embodiments, a plurality of orifices 140 (e.g., apertures or through holes) may be defined along a length of the support element at fixed or variable distances from each other. The plurality of orifices 140 may serve as nozzles through which the polymer solution or melt communicated through the channel of the support element 130 may be selectively ejected towards the first collector plate 120a or the second collector plate 120b. For example, the plurality of orifices 140 may be defined on one side of the support element 130. The reorientation mechanism 150 may be configured to selectively orient the side of the support element 130 towards the first or second collector plate 120a, 120b such that polymer solution or melt is ejected from the plurality of orifices 140 towards the corresponding first or second collector plate 120a or 120b. In some embodiments, the plurality of orifices 140 may be defined on each of a first side of the support element 130 that faces the first collector plate 120a, and a second side of the support element 130 opposite the first side, which faces the second collector plate 120b. Such implementations may enable simultaneous ejection of the polymer solution or melt towards each of the first and second collector plates 120a, 120b thus enabling simultaneous top-down and bottom-up electrospinning.

In some embodiments, the support element 130 may include a plurality of elongated members, such as bars or rods, disposed parallel to each other and extending longitudinally between the first and second collector plates 120a, 120b. Each of the plurality of elongated members may be equipped with its own set of orifices configured to dispense polymer solution during electrospinning. To facilitate independent operation, each elongated member (e.g., a bar) may be mechanically coupled to a dedicated actuation mechanism, such as an individual motor or pulley system, enabling selective rotation or reorientation of each bar. This modular configuration can allow for localized control over fiber deposition, thereby supporting the simultaneous formation of different fiber types and/or compositions on different regions of the collector plates 120a, 120b. In some embodiments in which the support element 130 defines a channel therethrough, a cross-sectional width (e.g., diameter) of the support element 130 can vary along its length. For example, a cross-sectional width of the channel may decrease from an inlet of the channel towards an opposite end of the channel, which may be closed. This can increase a velocity of the polymer solution or melt traveling through the channel to account for pressure drops due to polymer solution or melt being ejected from the nozzles disposed proximate to the inlet, and thus enable the polymer solution or melt to be ejected from each of the plurality of orifices at substantially the pressure (e.g., within a ±10% pressure range).

In some embodiments, the support element 130 is configured to transition from a first configuration where the first collector plate 120a faces the set of orifices 140 to a second configuration where the second collector plate faces the set of orifices 140 in response to an activation of the reorientation mechanism 150. In some embodiments, the support element is configured to rotate by 180 degrees around its longitudinal axis.

In some embodiments, the support element 130 can be made of any suitable material that allows performing its function. For example, in some embodiments, the support element 130 can be made of at least one of a metal, a plastic, or a composite material. In some embodiments, the support element 130 can be made of stainless steel. In some embodiments, the support element 130 can be mounted on a mount operably coupled to the reorientation mechanism 150. In some embodiments, the support element 130 can be mounted on a pivot mount on at least one axial end thereof.

In some embodiments, the plurality of orifices 140 may include nozzles disposed on one or more surfaces of the support element 130. Each of the plurality of nozzles may be configured to independently receive the polymer solution or melt. In some embodiments, the deposition assembly includes the conduit 160 that is in fluid communication with each orifice of the plurality of orifices 140. In such embodiments, the conduit 160 can be configured to receive a stream of a polymer solution or a polymer melt from a reservoir. That is, in some embodiments, the conduit 160 is configured to communicate the polymer solution/melt to the each of the orifices 140. In some embodiments, the conduit 160 is coupled to each orifice from the plurality of orifices 140 through any suitable connections such as tubing. In some embodiments, the plurality of orifices 140 can be defined along a surface of the conduit 160. In some embodiments, the conduit 160 is disposed on the support element 130. In some embodiments, the conduit 160 is disposed within the support element 130, utilizing an internal space within its body.

The conduit 160 can be made of any suitable material that is compatible with the operational parameters (e.g., solvent used in a polymer solution, pressure applied when a stream of a polymer solution is received, etc.). In some embodiments, the conduit 160 includes a channel for delivery of a polymer solution/melt from a reservoir to the plurality of orifices 140. In some embodiments, the conduit 160 can be made of at least one of a synthetic resin, a thermoplastic material, a thermosetting material, a metal, a metal alloy, a polymer, or a composite material.

The plurality of orifices 140 is configured to receive a stream of a polymer solution or melt from a reservoir such that the polymer solution or melt is ejected from each orifice 140 of the plurality of orifices 140 onto to the corresponding first or second collector plate 120a or 120b. The plurality of orifices 140 can include more than two orifices 140, and the number of orifices 140 can be adjusted depending on the length of the support element 130 and the collector plates 120a, 120b, as well as operational parameters. In some embodiments, the plurality of orifices 140 can be disposed on the side of the support element 130 as a row with a pre-determined space between each orifice. In some embodiments, the plurality of orifices 140 may include multiple set of orifices, each set of orifices being disposed parallel to each other. In some embodiments, each orifice 140 from the plurality of orifices 140 can have the same diameter. In some embodiments, each orifice of the plurality of orifices 140 can have different diameter. The diameter of the orifices 14—can be adjusted based on desired properties of a fiber (e.g., nanofiber) to be obtained via the system 100 (e.g., fiber diameter, distribution of fibers on the collector plate etc.).

In some embodiments, each of the plurality of orifices 140 can include a nozzle disposed on the side of the support element 130. In some embodiments, the nozzle can be coupled to each orifice from the plurality of orifices 140. The nozzle can be any means used to control or shape the flow of a polymer solution/melt. In some embodiments, the nozzle can be convergent (i.e., narrowing down from a wide diameter to a smaller diameter in the direction of the flow). In some embodiments, the nozzle can be divergent (i.e., expanding from a smaller diameter to a larger one). In some embodiments, the nozzle can be a single orifice nozzle, a coaxial nozzle, a triaxial nozzle, a side-by-side orifice nozzle, and a multi-core nozzle. In some embodiments, the nozzle can include a needle. In some embodiments, the nozzle can be a single needle nozzle. The dimensions of the nozzle (e.g., length, diameters at axial ends etc.) can be varied depending on the operational conditions and desired fiber properties. In some embodiments, the nozzle can be formed from at least one of a metal or an alloy.

The reorientation mechanism 150 allows the support element 130 to reorient (e.g., rotate or pivot) such that at least a portion of the plurality of orifices 140 defined in or disposed on the support element 130 selectively face the first collector plate 120a or the second collector plate 120b. In the first orientation, the plurality of orifices 140 in the support element 130 align with the first collector plate 120a, creating a first flow path for ejected polymer melt or solution towards the first collector plate 120a. When the reorientation mechanism 150 moves the support element 130 to the second orientation, the plurality of orifices 140 now face the second collector plate 120b, creating a second flow path for ejected polymer melt or solution towards the second collector plate 120b. This mechanism provides flexibility in controlling the direction of flow based on the orientation of the support element 130. In some embodiments, the reorientation mechanism 150 can be actuated via at least one of a mechanical, a hydraulic, an electromagnetic or an electrical actuation mechanism. In some embodiments, the reorientation mechanism 150 can include a pivot shaft. In some embodiments, the reorientation mechanism 150 can be activated manually. In some embodiments, the reorientation mechanism 150 can include at least one of rotating shafts, motors (e.g., stepper motors, servo motors), actuators, cam mechanisms, gear mechanisms, or pulleys.

In some embodiments, the plurality of orifices 140 include a first set of orifices and a second set of orifices. In such embodiments, first set of orifices are defined in or disposed on a first side of the support element 130 facing, and the second set of orifices is disposed on a second side of the support element 130 opposite the first side. This allows for the concurrent formation of fibers on both the first collector plate 120a and the second collector plate 120b, thereby decreasing manufacturing time. Additionally, this configuration may enable the use of different polymers, allowing different types of fibers to be formed simultaneously on the first collector plate 120a and the second collector plate 120b. In some embodiments, the first set of orifices are configured to receive a first polymer solution, and the second set of orifices are configured to receive a second polymer solution. In some embodiments, the first polymer solution can be different from the second polymer solution in terms of composition and/or physicochemical properties. In some embodiments, the first polymer solution and the second polymer solution can be the same. In embodiments where a first polymer solution and a second polymer solution are used concurrently, the system 100 may include separate fluidic channels, conduits, and/or reservoirs for each polymer solution to prevent cross-contamination. In such embodiments, the flow rate and/or applied voltage for each polymer solution may be independently controlled to tailor the resulting fiber morphology and deposition characteristics on the respective collector plates 120a, 120b.

FIG. 2 shows an illustration of an electrospinning system 200, according to an embodiment. The system 200 can be used for manufacturing a porous material including a plurality of nanofibers. As shown, the system 200 includes a first collector plate 220a, a second collector plate 220b offset from the first collector plate 220a, and a support element 240 disposed between the first collector plate 220a, and the second collector plate 220b. The system 200 further includes a conduit 260a disposed on a first side the support element 240, and a first plurality of nozzles 240a disposed on the conduit 260a. The system 200 further includes an actuator 250 operably coupled to the support element 130 and configured to move the support element 230 between a first orientation in which the first plurality of nozzles 240a face the first collector plate 220a, and a second orientation in which the first plurality of nozzles 240a face the second collector plate 220b. The system 200 further includes an electrical energy source 270 operably coupled to at least one of the conduit 260a, or the first plurality of nozzles 240a. The system 200 can further include a reservoir 290a configured to house a first polymer solution (or a melt), and operably coupled to the conduit 260a. The system 200 can optionally include a conduit 260b disposed on a second side of the support element 240, and a second plurality of nozzles 240b disposed on the conduit 260b. As illustrated, the second side of the support element 240 is opposite to the first side. The system 200 can optionally include a reservoir 290b configured to house a second polymer solution (or a melt), and operably coupled to the conduit 260b. In some embodiments, the system 200 may include a distribution header 295a configured to receive a first polymer solution from the reservoir 290a to deliver a stream of the first polymer solution to the conduit 260a. In some embodiments, the system 200 may include a distribution header 295b configured to receive a second polymer solution from the reservoir 290b to deliver a stream of the first polymer solution to the conduit 260b. The system 200 can further include an air flow control system 280 to regulate humidity within the system 200.

In some embodiments, the first collector plate 220a, the second collector plate 220b, the support element 240, the actuator 250, the conduit 260a, 260b, the nozzle 240a, 240b, the first polymer solution, and the second polymer solution are similar or substantially the same as the first collector plate 120a, the second collector plate 120b, the support element 140, the reorientations mechanism 150, the conduit 160, the plurality of orifices 140, the first polymer solution, and the second polymer solution of the system 100 as described above with respect to FIG. 1, and therefore, not described in further detail herein.

In some embodiments, the electrical energy source 270 is a high voltage power supply (e.g., between 5-50 kV, depending on the viscosity and dielectric constant of the polymer solution) to overcome the surface tension of the polymer solution in each nozzle from the plurality of nozzles 240a, 240b (hereinafter collectively referred to as nozzles 240). In some embodiments, each nozzle from the plurality of nozzles 240 is in electrical communication with the electrical energy source 270. In some embodiments, the nozzles 240 may be formed from a metal such as stainless steel such that an electrical communication can be facilitated between the nozzles 240 and the electrical energy source 270. In some embodiments, the electrical energy source 270 is configured to charge the nozzles 240 positively or negatively (depending on the desired fiber properties) to create an electric field that draws the polymer solution or melt out of the nozzles 240. In some embodiments, the electrical energy source 270 is configured to charge the polymer solution within the nozzles 240 to overcome the surface tension of the polymer solution in the nozzle 240 (e.g., forming a Taylor cone), resulting in the polymer solution exiting the nozzle 240. In some embodiments, the collector plates 220a, 220b (hereinafter collectively referred to as “collector plates 220”) are grounded.

In some embodiments, the electrical energy source 270 can include a first electrical energy source and a second electrical energy source. In some embodiments, the first electrical energy source is electrically coupled to the nozzles 240, and the second electrical energy source is electrically coupled to at least one of the first collector plate 220a or the second collector plate 220b. In some embodiments, the second electrical energy source is configured to selectively communicate electrical energy to the first collector plate 220a in the first orientation and the second collector plate 220b in the second orientation. In some embodiments, the voltage provided by first electrical energy source to the nozzles 240 is higher than the voltage provided by the second electrical energy source to the corresponding collector plates 220.

Voltage selection is crucial in forming a stable Taylor cone. By applying a high voltage potential difference to a charged polymer solution, the electrostatic forces can overcome the surface tension of the solution, leading to the formation of a charged polymer jet. The diameters of electrospun fibers can vary based on process parameters such as the solution's viscosity and conductivity, as well as the voltage required to form a charged jet. In some embodiments, the electrical energy source 270 is configured to supply voltage to the nozzles 240 to produce a Taylor cone in the polymer solution.

In some embodiments, the electrical energy source 270 is configured to provide at least about 1 kV, at least about 5 kV, at least about 10 kV, at least about 15 kV, at least about 20 kV, at least about 25 kV, or at least about 30 kV to the nozzles 240. In some embodiments, the electrical energy source 270 is configured to provide no more than about 50 kV, no more than about 45 kV, no more than about 40 kV, no more than about 35 kV, no more than about 30 kV, no more than about 25 kV, no more than about 20 kV, or no more than about 15 kV to the nozzles 240.

The reservoirs 290a, 290b (hereinafter collectively referred to as reservoirs 290) are configured to hold a polymer solution or a polymer melt. The reservoir 290 can be a storage tank. The reservoir can be formed of any suitable metal, polymer, or a composite material that is compatible with the polymer solution and the operational parameter (such as internal pressure etc.). In some embodiments, the polymer solution within the reservoirs 290 may be continuously or periodically stirred during the use of system 200. The reservoirs 290 can include a heater, a coolant, or any suitable device to control and adjust the temperature of the polymer solution within the reservoir 290. This ensures the polymer solution remains at the desired temperature for optimal processing.

In some embodiments, the system 100 may include a temperature control unit operably coupled to the reservoir or the conduit. The temperature control unit can be configured to maintain the polymer solution within a desired temperature range. In some embodiments, the desired temperature range can include a temperature range of about 20° C. to about 35° C., inclusive of all ranges and values therebetween. By maintaining the temperature of the polymer solution within the desired temperature range, the system 100 can provide consistent polymer viscosity, flow characteristics, and/or the like, which may be desirable for stable jet formation and/or uniform fiber morphology. Such temperature control may be particularly beneficial when processing thermally sensitive polymers or blends.

In some embodiments, the polymer solution within the reservoir 290 has a temperature of at least about 18° C., at least about 19° C., at least about 20° C., at least about 21° C., at least about 22° C., at least about 23° C., at least about 24° C., at least about 25° C., at least about 26° C., at least about 27° C., at least about 28° C., at least about 29° C., at least about 30° C., at least about 31° C., at least about 32° C., at least about 33° C., at least about 34° C., or at least about 35° C. In some embodiments, the polymer solution within the reservoir 290 has a temperature of no more than about 44° C., no more than about 43° C., no more than about 42° C., no more than about 41° C., no more than about 40° C., no more than about 39° C., no more than about 38° C., no more than about 37° C., no more than about 36° C., no more than about 35° C., no more than about 34° C., no more than about 33° C., no more than about 32° C., no more than about 31° C., no more than about 30° C., no more than about 29° C., no more than about 28° C., no more than about 27° C., no more than about 26° C., no more than about 25° C., no more than about 24° C., no more than about 23° C., no more than about 22° C., no more than about 21° C., or no more than about 20° C. Combinations of the above-referenced temperatures are also possible (e.g., at least about 18° C. and no more than about 44° C. or at least about 20° C. and no more than about 28° C.), inclusive of all values and ranges therebetween. In some embodiments, the polymer solution within the reservoir 290 has a temperature of about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., about 30° C., about 31° C., about 32° C., about 33° C., about 34° C., about 35° C., about 36° C., about 37° C., about 38° C., about 39° C., about 40° C., about 41° C., about 42° C., about 43° C., or about 44° C., inclusive.

In some embodiments, the reservoir 290 may be operably coupled to a pressurizer to quantitatively fed into the plurality of nozzles 240 and/or into the conduits 260a, 260b (hereinafter collectively referred to as “conduits 260”). The pressurizer may be disposed within the reservoir 290 or outside the reservoir 290. In some embodiments, the pressurizer is configured to provide a stream of polymer solution to the conduits 260 with a pre-determined flow rate and with a pre-determined pressure. In some embodiments, the pressurizer is configured to control the uniform flow of air pressure within the reservoir 290. This can prevent surging issues caused by traditional pumps. In some embodiments, the pressurizer include a pump.

In some embodiments, the system 200 may include the distribution headers 295a, 295b (hereinafter collectively referred to as “distribution headers 295”) to ease transportation of polymer solution from the reservoirs 290. In some embodiments, the distribution headers 295 are configured to ensure a homogenous flow of the polymer solution to the conduits 260 and the nozzles 240. In some embodiments, pressure control units and/or temperature control units can be operably coupled to the distribution headers 295.

In some embodiments, the system 200 is implemented in a controlled environment, for example, a temperature and/or humidity controlled environment, with specific temperature and humidity conditions maintained within a facility, such as a temperature and/or humidity controlled room, chamber, or compartment. That is, in some embodiments, at least one of a temperature or a relative humidity of a closed environment where the system 200 is implemented can be maintained at a constant level during the use of system 200.

In some embodiments, the system 200 may include the air flow control unit 280. The air flow control unit 280 is configured to maintain relative humidity of at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, or at least about 55%, within the system 200. In some embodiments, the air flow control unit 280 is configured to maintain relative humidity of no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, or no more than about 35%, within the system 200. Combinations of the above-referenced relative humidity values are also possible (e.g., at least about 30% and no more than about 60% or at least about 40% and no more than about 55%), inclusive of all values and ranges therebetween. In some embodiments, the air flow control unit 280 is configured to maintain relative humidity of about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60%, within the system 200. As used herein, the term “relative humidity” refers to the ratio of the partial pressure of water vapor in the gas phase to the saturated vapor pressure of water at the temperature of the processing atmosphere.

In some embodiments, the system 200 may be housed within a controlled environment (e.g., an electrospinning chamber) in which the relative humidity is actively monitored and adjusted. The air flow control unit 280 may include desiccant-based dehumidifiers, humidifiers, and sensors to actively monitor and regulate the relative humidity within the electrospinning chamber. In some embodiments, maintaining humidity within a desired humidity range can be critical for consistent fiber morphology and/or solvent evaporation rates. In some embodiments, the air flow control unit may operate in closed-loop feedback with humidity sensors to dynamically adjust airflow and moisture content, thereby optimizing electrospinning conditions for different polymer systems.

FIG. 3 shows an illustration of an electrospinning system 300, according to an embodiment. The system 300 can be used for manufacturing a porous material including a plurality of nanofibers. As shown, the system 300 includes a first collector plate 320a, and a second collector plate 320b offset from the first collector plate 320a. The system 300 further includes a first support element 340a and a second support element 340b disposed between the first collector plate 220a, and the second collector plate 220b. The system 300 includes a first set of nozzles 340a disposed on a side of the first support element 340a, the side of the first support element 340a facing the first collector plate 310a. The system 300 includes a second set of nozzles 340b disposed on a side of the second support element 340b, the side of the second support element 340b facing the second collector plate 310b.

As shown, the system 300 further includes a first carrier 316a disposed onto the first collector plate 310a, and a second carrier 316b disposed on the second collector plate 310b. In some embodiments, the first carrier 316a is disposed between a first carrier roll 312a and a first nanofiber roll 314a. In some embodiments, the second carrier 316b is disposed between a second carrier roll 312b and a first nanofiber roll 314b. The first and the second nanofiber rolls 314a, 314b (hereinafter collectively referred to as “nanofiber rolls 314”) are configured to pull the first and the second carriers 316a, and 316b (hereinafter collectively referred to as “carriers 316”) from the first and second carrier rolls 312a, 312b (hereinafter collectively referred to as “carrier rolls 312”) and wind the carriers 316 along with the nanofibers formed via electrospinning disposed thereon, around the nanofiber rolls 314. In some embodiments, both the carrier rolls 312 and the nanofiber rolls 314 can be mechanically coupled to a motor. This connection can be facilitated through a shaft or a similar mechanical component. The motor provides the necessary rotational force, driving both the carrier rolls 312 and the nanofiber rolls 314.

In some embodiments, the first collector plate 320a, the second collector plate 320b, the first and second support elements 340a and 340b, the nozzles 240a, 240b, the carrier, the first polymer solution, and the second polymer solution are similar or substantially the same as the first collector plate 120a, the second collector plate 120b, the support element 140, the nozzle, the carrier, the first polymer solution, and the second polymer solution of the system 100 as described above with respect to FIG. 1.

The system 300 allows increasing the manufacturing rate by facilitating concurrent implementations of both top-down and bottom-up electrospinning techniques. In addition, the system allows simultaneously obtaining fibers having different compositional and/or physical properties. In some embodiments, the nozzles 340a are configured to receive a first polymer solution from a first reservoir, and the nozzles 340b are configured to receive a second polymer solution from a second reservoir. In such embodiments, the first polymer solution can be ejected from the nozzles 340a onto the first collector plate 310a and the second polymer solution can be ejected from the nozzles 340b onto the second collector plate 310b. In some embodiments, the first and the second polymer solutions are the same. In some embodiments, the first and the second polymer solutions are different from each other in terms of at least one of composition, or a physicochemical property.

In some embodiments, the first carrier 316a and the second carrier 316b can have differing material compositions. In some embodiments, the first carrier 316a and the second carrier 316b can have similar or substantially same material compositions.

In some embodiments, the first nanofiber roll 314a can include a first porous material disposed on the first carrier 316a, for example, include first nanofibers electrospun on the first carrier 316a, as described herein. That is, in some embodiments, the first carrier 316a can be coupled to the first porous material. In some embodiments, the second nanofiber roll 314b can include a second porous material disposed on the second carrier 316b, for example, include second nanofibers electrospun on the second carrier 316b, as described herein. That is, in some embodiments, the second carrier 316b can be coupled to the second porous material. In some embodiments, the first porous material and the second porous material can have differing material compositions. In some embodiments, the first porous material and the second porous material can have differing textures. In some embodiments, the first porous material and the second porous material can have similar or substantially same material compositions. In some embodiments, the carriers 316 can be bonded to the first and the second porous materials by methods well known in the art, including but not limited to reactive hot-melt bonding, laser bonding, ultrasonic welding, lamination, thermal calendering, gluing, or a combination thereof. For example, the hotmelt-bonding can be carried out with an adhesive (e.g., an epoxy, acrylate and/or polyurethane adhesives).

In some embodiments, the first and the second porous material are in a form of a nanofiber web. As used herein, the term “nanofiber web”, refers to a film formed from a plurality of nanofibers (e.g., electrospun fibers) that are stacked on top of each other. The nanofiber web can be formed by electrospinning a polymer solution or a polymer melt on a carrier member. In some embodiments, the nanofiber web can be formed with a defined porosity, i.e., at least with a defined pore size and/or pore distribution. In some embodiments, at least one of the first and the second porous material is free of per-and polyfluoroalkyl substances (PFAS).

FIG. 4A shows a perspective view of a support element 440 with a reorientation mechanism 450 coupled thereto, according to an embodiment. In some embodiments, the support element 440 can include multiple bars, rods or spindles (411a to 411d). The support element 440 is configured to rotate between the first side and the second side. While shown as including four bars 411a-411d, in some embodiments, the support element 440 can include any number of bars (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or even more).

The reorientation mechanism 450 includes a first pulley 452 coupled to a belt 454. Second pulleys 462a are coupled to a first axial end of each of the bars 441a of the support element 440 and offset from the first pulley 452. The length of the belt 454 is also disposed around a portion of each of the second pulleys 462a such that the belt 454 is operably coupled to the first pulley 452 and the second pulleys 462a. The belt 454 may be configured to be disposed taut around the first pulley 452 and the second pulleys 462a such that rotation of the first pulley 452 causes the belt 454 to displace, which in turn causes the second pulleys 462a to rotate, thus reorienting the corresponding bars 441a-441d. In this manner, each bar (411a to 411d) of the support element 440 is configured to be rotated by the displacement of the belt 454. In some embodiments, the actuation mechanism 450 also includes a lever 456 coupled to the first pulley 452. as shown in FIG. 4A, which may be configured for manual, mechanized, and/or automated operation. For example, a user can engage the lever 456 to rotate the first pulley 452 and thereby, the support element 440 between the first and second orientations. In some embodiments, a motor can additionally, or alternatively be coupled to the first pulley 452 to automate the reorientation.

FIG. 4B provides a closer view of a second axial end of the support element 440 opposite the first axial end on. A casing 458 configured to house support pulleys 462b of the support element 440 so as to mechanically support and reinforce the support element 440 at the second axial end, as well as allow reorientation thereof. The distance “D” between each bar can be adjusted depending on the system parameters and/or requirements (e.g., width of carrier, width of collector plate, nozzle parameters etc.). In some embodiments, the casing 442 may include a belt. In some embodiments, the support pulleys 462b may include bearings. FIG. 4C is a closer perspective view similar to FIG. 4A.

FIG. 5 is a block diagram of a method 10 for producing porous materials, according to an embodiment. In some embodiments, the method 10 can be performed by implementing the systems 100, 200, and 300 described with respect to FIGS. 1-3. The method 10 can allow concurrent or sequential use of bottom-up and top-down electrospinning, thereby increasing the efficiency of production. The method 10 includes disposing a first carrier member on a first collector plate and a second carrier member on a second collector plate, at step 11. The second collector plate is offset from the first collector plate. The method 10 further includes disposing a first set of orifices on a first side of a support element, at step 12. The first side of the support element faces the first collector plate. The method 10 can optionally include disposing a second set of orifices on a second side of the support element, at step 13, the second side being opposite to the first side. The method 10 further includes ejecting a first polymer solution from the set of orifices to the first carrier member, at step 14. The method 10 optionally include ejecting a second polymer solution from the set of orifices onto the second carrier member, at step 15. Step 15 can be implemented when step 14 is partially completed or fully completed prior to step 15. Once the first polymer solution is ejected onto the first carrier member, the method 10 then can include moving the support element (e.g., rotating the support element by 180 degrees), at step 16, such that the first set of orifices switch from facing the first collector plate to facing the second collector plate. Once the first set of orifices face the second collector plate, the method 10 can include ejecting a second polymer solution from the set of orifices onto the second carrier member, at step 17.

In some embodiments, the first collector plate, the second collector plate, the support element, the orifices, the carrier members, the first polymer solution, and the second polymer solution are similar or substantially the same as the first collector plate 120a, the second collector plate 120b, the support element 140, the nozzle, the carrier members, the first polymer solution, and the second polymer solution of the system 100 as described above with respect to FIG. 1.

At step 11, at least one of the first carrier member or the second carrier member may be coupled to a pulley such that at least one of the first carrier member or the second carrier member is movable with respect to the corresponding collector plate. At step 12, a first set of orifices is disposed on a first side of the support element such that the first set of orifices is configured to communicate corresponding streams of a first polymer solution towards the first collector plate. In some embodiments, the first set of orifices may be defined along a surface of the support element. In some embodiments, the first set of orifices may be disposed on a surface of a conduit that is disposed on the first side of the support element. Optionally, at step 13, a second set of orifices can be placed on the opposite side of the support element, allowing for the simultaneous ejection of the first polymer onto the first carrier member and the second polymer solution onto the second carrier member. At step 14, a first polymer solution can be ejected from the first set of orifices onto the first carrier member to form a first porous material. In some embodiments, the step 14 includes receiving a first polymer solution from a reservoir into the first set of orifices, and electrically connecting the first set of orifices to an electrical energy source. In some embodiments, when step 13 is partially or fully performed, the method can include step 15 to concurrently form a second porous material with the first porous material. In some embodiments, the method 10 can include moving the support element, at step 16, in response to an activation of the actuation mechanism such that the first set of orifices transition from a first configuration where the first collector plate faces the first set of orifices to a second configuration where the second collector plate faces the first set of orifices. At step 17, a second polymer solution can be ejected from the second set of orifices onto the second carrier member to form a second porous material. In some embodiments, the step 17 includes receiving a second polymer solution from a reservoir into the first set of orifices, and electrically connecting the second set of orifices to an electrical energy source.

In some embodiments, the first porous material and/or the second porous material can include a plurality of nanofibers. In some embodiments, the nanofibers have a thickness of at least about 100 nm, at least about 150 nm, at least about 200 nm, at least about 250 nm, at least about 300 nm, at least about 350 nm, at least about 400 nm, at least about 450 nm, at least about 500 nm, at least about 550 nm, at least about 600 nm, at least about 650 nm, at least about 700 nm, at least about 750 nm, at least about 800 nm, at least about 850 nm, at least about 900 nm, or at least about 950 nm. In some embodiments, the nanofibers have a thickness of no more than about 1 μm, no more than about 950 nm, no more than about 900 nm, no more than about 850 nm, no more than about 800 nm, no more than about 750 nm, no more than about 700 nm, no more than about 650 nm, no more than about 600 nm, no more than about 550 nm, no more than about 500 nm, no more than about 450 nm, no more than about 400 nm, no more than about 350 nm, no more than about 300 nm, no more than about 250 nm, no more than about 200 nm, or no more than about 150 nm. Combinations of the above-referenced thicknesses are also possible (e.g., at least about 100 nm and no more than about 1 μm or at least about 100 nm and no more than about 700 nm), inclusive of all values and ranges therebetween.

As used herein, the term “fiber thickness” refers to the average fiber thickness (e.g., diameter) of the plurality of nanofibers included in a nanofiber web.

In some embodiments, the first porous and/or the second porous material can have an average pore size of at least about 100 nm, at least about 150 nm, at least about 200 nm, at least about 250 nm, at least about 300 nm, at least about 350 nm, at least about 400 nm, at least about 450 nm. In some embodiments, the first porous and/or the second porous material can have an average pore size of no more than about 500 nm, no more than about 450 nm, no more than about 400 nm, no more than about 350 nm, no more than about 300 nm, no more than about 250 nm, no more than about 200 nm, or no more than about 150 nm. Combinations of the above-referenced pore sizes are also possible (e.g., at least about 100 nm and no more than about 500 nm or at least about 200 nm and no more than about 400 nm), inclusive of all values and ranges therebetween.

Various concepts may be embodied as one or more methods, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. Put differently, it is to be understood that such features may not necessarily be limited to a particular order of execution, but rather, any number of threads, processes, services, servers, and/or the like that may execute serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, and/or the like in a manner consistent with the disclosure. As such, some of these features may be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovations, and inapplicable to others.

In addition, the disclosure may include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file additional applications, continuations, continuations-in-part, divisionals, and/or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments. Depending on the particular desires and/or characteristics of an individual and/or enterprise user, database configuration and/or relational model, data type, data transmission and/or network framework, syntax structure, and/or the like, various embodiments of the technology disclosed herein may be implemented in a manner that enables a great deal of flexibility and customization as described herein.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

As used herein, in particular embodiments, the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

The phrase “and/or,” as used herein in the specification and in the embodiments, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the embodiments, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the embodiments, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the embodiments, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

In the embodiments, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure. Where methods and steps described above indicate certain events occurring in a certain order, those of ordinary skill in the art having the benefit of this disclosure would recognize that the ordering of certain steps may be modified and such modification are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. The embodiments have been particularly shown and described, but it will be understood that various changes in form and details may be made.