Lakshmi Natarajana,
Jackie Newa,
Aravind Dasari*a,
Suzhu Yub and
Munirah Abdul Mananb
aSchool of Materials Science and Engineering (Blk N4.1), Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798. E-mail: aravind@ntu.edu.sg; Fax: +65-67909081
bSingapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore 638075
First published on 10th September 2014
The article elucidates the mechanisms of formation of varying degrees of surface pores/pits on polylactic acid (PLA) fibers during electrospinning. The role of a combination of different parameters in governing pore formation was demonstrated. They include solvent vapor pressure (pv), solvent miscibility/interaction with water, solubility parameter, and relative humidity (RH) within the spinning unit. Our results indicated that traditional mechanisms like thermally induced phase separation (TIPS) and vapor induced phase separation (VIPS) were not responsible in the generation of surface porosity/pits. Instead, higher RH (water vapor, a non-solvent of the polymer), and its miscibility/interaction with solvent(s) were concluded to be relatively more important than the simple presence of a high pv solvent or a combination of high pv and low pv solvent system. Further, content of high pv solvent in solution determined the spherical or elliptical nature of pores/pits by affecting the level of saturation of nearby region of the interface between jet and air during the electrospinning process.
Recently, electrospinning technique, which enables production of fibers with high surface-to-volume ratios, has seen application in different fields where sorption is a critical parameter. Some of these fields include tissue engineering/drug delivery, sensors, oil adsorption, catalytic systems, and protective clothing. There are many excellent reviews on electrospinning discussing the underlying physics, interaction of surface tension of solvents and electrical forces, solution properties, etc.9–13 Readers are encouraged to refer to those publications for an insight into fundamentals of electrospinning. Another major advantage of electrospinning is the ability to induce porosity on the fibers in situ during spinning, which provide additional sites for adsorption. But there are many differences (and questions) on the proposed mechanisms of pore formation in the literature. Some of the commonly reported mechanisms are TIPS, VIPS, and evaporation induced phase separation (due to difference in vapor pressure of solvents).14–19
TIPS is based on the phenomenon that the solvent quality usually decreases when the temperature is decreased. Conventionally, after demixing is induced, solvent is removed by extraction, evaporation or freeze-drying.14 In electrospinning, fibers could be directly spun into a cryogenic liquid, and as a result of sudden drop in temperature, TIPS occurs between the solvent-rich and solvent-poor regions. Subsequently, after the solvent is evaporated in a controlled manner, pores form throughout the fiber (not just on the surface). However, this method generally yields bigger pores and thicker (broken) fibers due to immediate freezing, which affects fiber whipping and elongation.16 VIPS is based on precipitation by absorption/penetration of a non-solvent like water from the vapor phase into fiber jet.17 Bognitzki et al.20 even showed that porous fibers could be obtained by selective dissolution of polymer blends after electrospinning. They spun PLA/polyvinylpyrrolidone (PVP) with dichloromethane (DCM) as solvent. To obtain porosity, this was followed by either annealing the fibers to remove PLA or using water as a solvent to remove PVP.
Further, some have reported that porous fibers could be obtained during electrospinning by using a single (highly volatile) solvent through thermodynamically driven events.16,20 In here, it was believed that the solvent-rich regions were transformed into pores. Due to fast evaporation of the solvent, phase boundaries were crossed resulting in rapid phase separation and structure formation. However, it was noted that these phase morphologies exist only on the surface of fibers, which is debatable. In another investigation, the importance of solvent volatility in inducing pores on fibers rather than phase separation was emphasized.17 This was established by using high pv tetrahydrofuran, THF, low pv dimethylformamide, DMF and their combination (THF–DMF – 75/25% and 50/50%) as solvents for PS. With 100% THF, high density of pores was observed on PS fibers and they disappeared as the volatility of the mixed solvent system decreased (that is, with increase in DMF content).
Nonetheless, there are many questions on pore formation during electrospinning and it is not so direct to conclude based on only one particular factor like solvent volatility. In fact, in many studies, humidity (at which the fibers are spun) and solvent miscibility with (condensed) water are not considered (or mentioned). We believe that these in combination with vapor pressure of solvent and solubility parameter differences between solvent(s) and polymer might govern pore formation. This forms the fundamental basis of this study, that is, to elucidate the mechanisms of pore formation on fibers during electrospinning. For this purpose, PLA is chosen as the matrix and various solvents with different properties are chosen strategically (see Tables 1 and 2).
Solvent | Vapor pressure (kPa) | Dielectric constant | Hansen solubility parameter (MPa)1/2 | |||
---|---|---|---|---|---|---|
δd | δp | δh | δt | |||
Dichloromethane | 58.1 | 8.93 | 18 | 12.3 | 7.2 | 22.9 |
N,N-Dimethylformamide | 0.49 | 36.71 | 17.4 | 13.7 | 11.3 | 24.8 |
Methanol | 16.9 | 32.66 | 15.1 | 12.3 | 22.3 | 29.7 |
1,4-Dioxane | 4.95 | 2.21 | 19 | 1.8 | 7.4 | 20.5 |
1,2-Dichloroethane | 11.6 | 10.37 | 19 | 7.4 | 4.09 | 20.8 |
Electrospinning solution combinations | Designation | Porosity at ∼75% RH | |
---|---|---|---|
Single solvent system | PLA + DCM | A1 | Pores |
Binary and ternary solvent system | PLA + (70% DCM + 30% DMF) | A2 | No pores |
PLA + (40% DCM + 40% DCE + 20% DMF) | A3 | Pores | |
PLA + (90% DCM + 10% DMF) | A4 | Pores | |
PLA + (90% DCM + 10% methanol) | A5 | No pores | |
PLA + (70% DCM + 30% 1,4-dioxane) | A6 | Pores |
m = 0.206ρB[(100/%P) − 1] | (1) |
The fibrous sample mats were dried overnight in vacuum oven at 45 °C before analysis. Required amount of sample was placed in the cup of powder penetrometer (stem volume 0.412 ml) and tested first at low pressure (6.8927 × 102 to 6.8927 × 104 Pa) and then at high pressures (6.8927 × 102 to 6.8927 × 107 Pa) at a mercury filling pressure of 3.5824 × 103 Pa and equilibration time of 10 seconds. In this technique, mercury (non-wetting liquid) is forced into the spun fibers to assess pore volume. As the pressure is gradually increased, mercury is forced into the smaller pores. The pore radius and pressure are related by the Washburn equation (assuming that pores are cylindrical),
r = −2γcosθ/p | (2) |
An SEM micrograph of PLA fibers spun at a RH of ∼75% using a single solvent system (A1) is shown in Fig. 1a that reveals high density of pores. Although the temperature in the spinning unit is constant, high pv of DCM results in rapid solvent evaporation followed by evaporative cooling of the charged jet as it travels to the collector. This could result in TIPS. Obviously, evaporative cooling will be more effective on the surface of the fibers compared to the bulk and might as well explain the fact that these fibers only shows surface porosity and not throughout the cross-section (see Fig. 1b). Apart from condensation, moisture in the ambient could also act as a non-solvent by absorption and penetrating into polymer solution during electrospinning process, as explained earlier, and result in VIPS. For this mechanism, the difference in the pv of solvent (used in the electrospinning process) and non-solvent (from the ambient) is important as it determines which one will saturate the nearby region of the interface between jet and air. In the present case of DCM (pv ∼ 58.1 kPa) and water (pv ∼ 2.3 kPa), with reasonable confidence it is assumed that DCM will saturate the nearby region of the jet–air interface. This suggests that VIPS may not be the mechanism in this case. Another important parameter is the diffusion coefficient of the non-solvent in the selected polymer. This will govern the penetration efficiency and in turn determines whether pores are formed only on the surface or throughout the cross-section of the fiber.
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Fig. 1 SEM micrographs of PLA fibers spun at ∼75% RH with 100% by volume of DCM (a) top view; and (b) cross-section. |
Nonetheless, the spherical nature of the surface pores suggests that TIPS and VIPS are not the operating mechanisms (where elliptical or elongated pores along the fiber axis are more common). This means that the porosity is induced after fibers are deposited on the collector as a result of condensation of moisture in the air (as water is a non-solvent for PLA). Subsequently, these water droplets leave their imprint in the form of pores or pits on the surface of fibers (see Scheme 1). This is similar to the concept of ‘breath figures’, which was originally introduced by Aitken24 to explain the formation of water droplets on clean glass surfaces when exhaled breath condenses on those surfaces. Later, this was extended to describe condensation on different types of surfaces.25,26 Even analytical solutions describing the evolution in time were proposed.27 Breath figures were also used to characterize the degree of contamination on a (homogeneous) surface.28 If the surface is contaminated, condensation was expected to be strong, resulting in film formation.25 Needless to say that %RH plays a critical role in this process.
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Fig. 2 SEM micrographs of PLA fibers spun at ∼75% RH with different solvent combinations: (a) 70/30 DCM/DMF; (b) 40/40/20 DCM/DCE/DMF; and (c) 90/10 DCM/DMF. |
To explain this, it is important to understand other properties of these solvents like their miscibility and interactions with water. In A2, the solvent system was DCM/DMF in the ratio 70 to 30 by volume. Since the pv of DCM is very high compared to DMF, it is expected to evaporate relatively quickly during the electrospinning process leaving behind DMF. Therefore, at high RH levels, after the moisture in the air condenses onto the fiber surface, the H-bond interaction of DMF with water, C–H⋯O, plays an important role in hindering the deposition of condensate as separate droplets. Instead it is presumed that the condensate is coalesced and spread across the fiber surface. Subsequently, after the evaporation of water, a smooth surface morphology is generated without any pores or pits. This in fact is supported by the result that if the DMF content is reduced to 10% by volume, pit/pores were observed, however at a reduced density compared to A1 system (Fig. 2c).
To further elucidate on the effect of solvent miscibility/interaction with water, methanol and 1,4-dioxane are chosen in combination with DCM. Both methanol and dioxane are miscible with water but their hydrogen bonding component and pvs are different (Table 1). Although methanol's pv is much higher than that of DMF, methanol has H-bonding component twice as that of DMF, thus enabling even a lower amount of methanol to bond with moisture/droplets. This explains why there are no pores on the surface of fibers even with 90/10 DCM/methanol (Fig. 3a, A5); while 90/10 DCM/DMF showed reduced density of surface pits (Fig. 2c, A4) as explained before. Also, from the SEM micrograph of A5, it is evident that the fibers are flat and more like ribbons than tubular. This indicates the slower evaporation of solvent in combination with water, thus collapsing the fibers.29
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Fig. 3 SEM micrographs of PLA fibers spun at ∼75% RH with different solvent combinations: (a) 90/10 DCM/methanol; and (b) 70/30 DCM/dioxane. |
On the contrary, even with 30% dioxane (A6), the morphology is similar to 90/10 DCM/DMF with surface pores/pits. But 70/30 DCM/DMF didn't yield porous morphology, Fig. 2a. This is despite dioxane having a similar pv as DMF. This again reiterates the effect of solvent interaction with water.
From the above results, it is evident that at high RH levels, in the presence of low pv solvents, their interaction with water plays a dominant role in inducing surface pores/pits. This further explains why there are pores on the fibers of A3. The solvents in A3 have huge differences in pvs and their miscibility/interaction with water is different. DCM (pv ∼ 58.1 kPa) and DMF (∼0.49 kPa) were discussed earlier, whereas DCE with a pv of ∼11.6 kPa is immiscible with water. Also, the density of pores at these high RH conditions is determined by the magnitude of these interactions as well as the amount of low pv solvent. But interestingly, many of the pores are elongated along the fiber axis, giving an average aspect ratio of ∼2.3. As the amount of high pv DCM is only 40% by volume, expectedly, it cannot saturate the nearby region of the jet–air interface. This provides a chance for the water vapor in the ambient to be attracted to the positive charges distributed on the surface of fiber and condense as small droplets, thus undergoing stretching along with the fiber. This process is shown in Scheme 2.
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Fig. 4 SEM micrographs of A1 (a and b) and A2 (c and d) systems electrospun at different relative humidity levels ((a and c) – 35% and (b and d) – 45%). |
A2 and A3 systems were considered for porosity measurements because both these systems showed similar fiber diameters, 1.00 ± 0.20 μm and 1.08 ± 0.27 μm, respectively. By having this commonality and minimizing the differences in density of deposition, differences in inter-fiber porosity could be controlled. This enables an easy comparison of the effect of pores present on the surface. In A2 and A3, the area corresponding to inter-fiber porosity is 8.1 m2 g−1 and 8.2 m2 g−1, respectively (based on Fig. 5). This value is comparable to that of previous work by Yang et al.32 in which they reported the area of inter-fiber porosity to be ∼8 m2 g−1 for PLA fibers of similar size. By relating the average pore size as observed in SEM images with the porosimeter curve, it is clear that the peak in A3 (which is absent in A2) corresponds to the pores present on the surface. The calculated total pore area was ∼31.2 m2 g−1, corresponding to an average pore size of ∼63.0 nm. The total area (39.3 m2 g−1) is also comparable to that of 37.1 m2 g−1 for porous polyacrylonitrile fibers obtained by Nayani et al.33 However, in that study, the area corresponds to core–shell fibers having a hollow core and porous sheath. The porosity was obtained by non-solvent induced phase separation mechanism by directly spinning the fibers into a bath of non-solvent. In another recent study, Touny et al.34 synthesized porous PLA fibers using reactive electrospinning where water was liberated as a by-product during the formation of monetite (which was formed in situ by a reaction between calcium hydroxide and orthophosphoric acid). As a result of this water-induced pore formation mechanism, as expected, pores were elongated and present throughout the fiber. But even here, the surface area of porous fibers was found to be only 26.5 m2 g−1 at a monetite content of 28 wt%.
In summary, this study underlines the importance of understanding various intrinsic and extrinsic parameters on pore formation during electrospinning. The obtained pore size, shape and density are independent of the fiber diameter. This was also confirmed by changing the collector distance. However, further work is required to quantify the extent of (a) moisture condensation as a result of evaporative cooling when different solvents are used; and (b) hydrogen bonding and its relation to spreading of water droplets on the fiber surface.
As different applications require different levels of porosity, carefully choosing the solvent system and controlling the ambient conditions could help meet the requirements in a single step. This simplistic approach in enhancing the adsorption behavior will provide a comprehensive platform for a broad variety of applications including active food packaging, oil adsorption, moisture and odor management in fabrics, etc.
The presence of spherical pores on fibers suggested that pores were formed by condensation of moisture after fiber deposition (due to evaporative cooling of fiber surface) similar to the concept of breath figures. This suggested the importance of solvent vapor pressure, relative humidity and saturation of fiber jet–air interface by a high vapor pressure solvent in inducing (spherical) pores.
In the presence of low vapor pressure solvents and at high RH levels, solvent miscibility/interaction with water played a dominant role in inducing pores. This was demonstrated by considering binary and ternary solvent systems in which one of the solvents was miscible with water and had different hydrogen bonding parameter.
RH played a determining role in pore formation mechanisms. But at relatively low humidity levels of less than ∼30%, no pores were observed on the fibers in all systems.
The total pore area of fibers (A3) was ∼39.3 m2 g−1, as measured by mercury porosimeter.
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