Electrospinning of UHMWPE Nanofibers: Challenges and Solution Strategies
Keywords:
UHMWPE nanofibers, Electrospinning, Green solvent systems, Thermo-reversible gelation, TBAB additive, TerpeneAbstract
This study investigates the feasibility of fabricating nanofibers from ultra-high molecular weight polyethylene (UHMWPE) using electrospinning, a technique traditionally limited by UHMWPE's high melt viscosity, poor solubility, and low electrical conductivity. A series of experimental trials were conducted using different polymer grades, solvent systems, conductivity-enhancing additives, and thermal control strategies. Initial trials using decalin revealed homogeneous dissolution at elevated temperatures (~130 °C) but were limited by rapid thermo-reversible gelation and high viscosity, which inhibited continuous fiber formation. Thermal stabilization using silicone pad heaters and oil baths extended spinnability, yet precise temperature control remained a challenge. To improve electro-spinnability, additives such as tetra-n-butylammonium bromide (TBAB) and cyclohexanone were introduced, resulting in improved conductivity and Taylor cone formation. A novel approach utilizing terpene—a biocompatible and non-carcinogenic solvent—demonstrated promising results in dissolving UHMWPE while reducing toxicological concerns. However, successful and continuous nanofiber production remained constrained by the narrow thermal processing window between the needle tip and collector. The findings highlight the critical interplay between solvent selection, rheology, conductivity, and thermal environment in the electrospinning of UHMWPE.
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