Review of Droplet Printing Technologies for Flexible Electronic Devices: Materials, Control, and Applications.

Flexible devices have extensive applications in areas including wearable sensors, healthcare, smart packaging, energy, automotive and aerospace sectors, and other related fields. Droplet printing technology can be utilized to print flexible electronic components with micro/nanostructures on various scales, exhibiting good compatibility and wide material applicability for device production. This paper provides a comprehensive review of the current research status of droplet printing technologies and their applications across various domains, aiming to offer a valuable reference for researchers in related areas.

Identification and dynamic monitoring of electrospinning jet assisted by coaxial laser.

The accurate and rapid detection and recognition of jet features are key to dynamic monitoring and online control of the electrospinning process. In this study, a real-time recognition system based on OpenCV was introduced into a coaxial laser-assisted electrospinning system to solve the difficulties of accurate jet recognition and to promote an image processing algorithm response. The jet images with laser assistance were more clearly visible than those without laser assistance, and a significant contrast in grayscale levels existed in the jet image to help distinguish jet features. Subsequently, separate algorithms were designed for the jet visible length calculation, and the recognized visible length of the jet and algorithm running speed were compared. The average visible length of the jet with laser assistance was 11.49 mm, which increased by 1.59 mm compared to that without laser assistance. In addition, the running time of the algorithm with laser assistance was 24.89 ms, reduced by 14.84 ms compared to that without laser assistance, indicating the effectiveness of laser assistance to promote the accuracy and running speed of the jet image recognition process. Additionally, real-time detection of the jet angles was achieved to identify instances of excessive deflection during the electrospinning process. Overall, this study has significant potential to promote the dynamic monitoring of an electrospinning jet.

Ethyl cellulose/gelatin/ß-cyclodextrin/curcumin nanofibrous membrane with antibacterial and formaldehyde adsorbable capabilities for lightweight and high-performance air filtration.

Functionalization of bio-based nanofibers is the development tendency of high-performance air filter. However, the conventional structural optimization strategy based on high solution conductivity greatly hinders the development of fully bio-based air filter, and not conducive to sustainable development. This work fabricated fully bio-based nanofibrous membrane with formaldehyde-adsorbable and antibacterial capabilities by electrospinning low-conductivity solution for high-performance air filtration and applied to lightweight mask. The "water-like" ethyl cellulose (EC) was selected as the base polymer to "nourish" functional materials of gelatin (GE), ß-cyclodextrin (ßCD), and curcumin (Cur), thus forming a solution system with high binding energy differences and electrospinning into ultrafine bimodal nanofibers. The filtration efficiency for 0.3 µm NaCl particles, pressure drop, and quality factor were 99.25 %, 53 Pa, and 0.092 Pa-1, respectively; the bacteriostatic rates against Escherichia coli and Staphylococcus aureus were 99.9 % and 99.4 %, respectively; the formaldehyde adsorption capacity was 442 µg/g. This is the first report on antibacterial and formaldehyde-adsorbable high-performance air filter entirely made from bio-based materials. This simple strategy will greatly broaden the selection of materials for preparing high-performance multifunctional air filter, and promote the development of bio-based air filter.

Coaxial Electrospun Tai Chi-Inspired Lithium-Ion Battery Separator with High Performance and Fireproofing Capacity.

Organic flame-retardant-loaded battery separator offers a new opportunity for battery safety. However, its poor thermal stability still poses serious safety issues. Inspired by Tai Chi, an "internal-cultivating and external-practicing" core-shell nanofibrous membrane was prepared by coaxial electrospinning, wherein the shell layer was a mixture of polyvinylidene fluoride, silicon dioxide (SiO2), and graphene oxide (GO) and the core layer contained triphenyl phosphate (TPP). SiO2 and GO enhanced the thermal stability and electrochemical performance. The encapsulated TPP prevented heat transfer and the degradation of electrochemical performance caused by its direct dissolution. This separator exhibited outstanding thermal stability and flame retardancy: it did not burn and remained relatively intact (91.2%) in an open flame for 15 s. The battery assembled with a composite separator showed excellent performance: the initial capacity reached 164 mA h/g and maintained 95% after 100 charge-discharge cycles. This novel strategy endows high-performance lithium batteries with relatively higher safety.

Fast on-off controlling of electrohydrodynamic printing based on AC oscillation induced voltage.

Stability control of electrohydrodynamic (EHD) printing technology is urgent needed for efficient fabrication of flexible electronics. In this study, a new fast on-off controlling technology for micro droplets of EHD is proposed by applying an AC induced voltage. The suspending droplet interface is broken through quickly, and the impulse current can be significantly reduced from 527.2 to 50.14 nA, which greatly reduces its negative impact on jet stability. What's more, time interval of jet generation can be shortened by a factor of three, while not only significantly improving the uniformity of the droplets, but effectively reducing the droplet size from 195 to 104 µm. Moreover, the controllable and mass formation of micro droplets are realized, but also the structure of each droplet is able to be controlled independently, which promoted the development of EHD printing technology in more fields.

State Recognition of Multi-Nozzle Electrospinning Based on Image Processing.

The online monitoring of a multi-jet electrospinning process is critical to the achievement of stable mass electrospinning for industrial applications. In this study, the construction of an ejection state recognition system of a multi-jet electrospinning process based on image processing is reported. The ejection behaviors regarding multi-nozzle electrospinning were recorded by CMOS industrial cameras in real time. The characteristic information regarding the multi-jet cone tip was obtained by processing the images regarding Roberts operator edge detection, Hough transform line detection, and mask histogram analysis. The jet anomalies of the hanging droplets in the nozzle outlet area could be obtained and identified by the vision. The identification accuracy towards the target hanging droplets was more than 85%. This work reports the intelligent control of large-scale multi-nozzle electrospinning equipment.

Numerical Simulation of Motion and Distribution Characteristics for Electrospray Droplets.

Electrospray is a typical technology to prepare large amounts of droplets at micro/nano scale. Establishing the relationship between the processing parameters and the motion and distribution characteristics for electrospray droplets is an effective approach to guide the uniform deposition of the electrospray membrane. In this paper, a dynamic model of electrospray droplets based on the fully resolved direct numerical simulation (FR-DNS) method was constructed, and the spatial motion behaviors of charged droplets were simulated. The coupling effect of electric field force, the charge repulsive force, and the gravity on the motion and distribution of electrospray droplets was studied, and the relationship between processing parameters including the applied voltage and distance from the nozzle to the collecting plate and the spatial distribution of charged droplets was clarified in a direct way. The simulation model provided a good approach for the quantitative description of the motion and distribution behaviors for electrospray droplets, which would help to guide the control of the electrospray jet ejection process.

High-performance multifunctional electrospun fibrous air filter for personal protection: A review.

With the increasingly serious air pollution and the rampant coronavirus disease 2019 (COVID-19), preparing high-performance air filter to achieve the effective personal protection has become a research hotspot. Electrospun nanofibrous membrane has become the first choice of air filter because of its small diameter, high specific surface area and porosity. However, improving the filtration performance of the filter only cannot meet the personal needs: it should be given more functions based on high filtration performance to maximize the personal benefits, called, multifunctional, which can also be easily realized by electrospinning technology, and has attracted much attention. In this review, the filtration mechanism of high-performance electrospun air filter is innovatively summarized from the perspective of membrane. On this basis, the specific preparation process, advantages and disadvantages are analyzed in detail. Furthermore, other functions required for achieving maximum personal protection benefits are introduced specifically, and the existing high-performance electrospun air filter with multiple functions are summarized. Finally, the challenges, limitations, and development trends of manufacturing high-performance air filter with multiple functions for personal protection are presented.

One-Step Preparation of PVDF/GO Electrospun Nanofibrous Membrane for High-Efficient Adsorption of Cr(VI).

Mass loading of functional particles on the surface of nanofibers is the key to efficient heavy metal treatment. However, it is still difficult to prepare nanofibers with a large number of functional particle loads on the surface simply and efficiently, which hinders the further improvement of performance and increases the cost. Here, a new one-step strategy was developed to maximize the adhesion of graphene oxide (GO) particle to the surface of polyvinylidene fluoride (PVDF) nanofibers, which was combined with coaxial surface modification technology and blended electrospinning. The oxygen content on the as-prepared fiber surface increased from 0.44% to 9.32%, showing the maximized GO load. The increased adsorption sites and improved hydrophilicity greatly promoted the adsorption effect of Cr(VI). The adsorption capacity for Cr(VI) was 271 mg/g, and 99% removal rate could be achieved within 2 h for 20 mL Cr(VI) (100 mg/L), which was highly efficient. After five adsorption-desorption tests, the adsorption removal efficiency of the Cr(VI) maintained more than 80%, exhibiting excellent recycling performance. This simple method achieved maximum loading of functional particles on the fiber surface, realizing the efficient adsorption of heavy metal ions, which may promote the development of heavy-metal-polluted water treatment.

Multistage-Split Ultrafine Fluffy Nanofibrous Membrane for High-Efficiency Antibacterial Air Filtration.

Antibacterial air filtration membranes are essential for personal protection during the pandemic of coronavirus disease 2019 (COVID-19). However, high-efficiency filtration with low pressure drop and effective antibiosis is difficult to achieve. To solve this problem, an innovative electrospinning system with low binding energy and high conductivity was built to enhance the jet splitting, and a fluffy nanofibrous membrane containing numerous ultrafine nanofibers and large quantities of antibacterial agents was achieved, which was fabricated by electrospinning polyamide 6 (PA6), poly(vinyl pyrrolidone) (PVP), chitosan (CS), and curcumin (Cur). The filtration efficiency for 0.3 µm NaCl particles was 99.83%, the pressure drop was 54 Pa, and the quality factor (QF) was up to 0.118 Pa-1. CS and Cur synergistically enhanced the antibacterial performance; the bacteriostatic rates against Escherichia coli and Staphylococcus aureus were 99.5 and 98.9%, respectively. This work will largely promote the application of natural antibacterial agents in the development of high-efficiency, low-resistance air filters for personal protection by manufacturing ultrafine nanofibers with enhanced antibiosis.

Directional Water Transport Janus Composite Nanofiber Membranes for Comfortable Bioprotection.

The Janus membrane has a huge prospect for personal comfortable protection. However, there still is a huge imbalance between the comfort and protection of the existing Janus membrane. There is an urgent need to further improve the comprehensive performance of the protective membrane to realize both protection and comfort. Herein, we report the Janus membrane with directional water transport capacity and dust rejection performance by compounding the polyvinyl chloride hydrophobic nanofiber membrane and polyamide-6 blended polyvinyl pyrrolidone hydrophilic nanofiber membrane. This Janus composite nanofiber membrane exhibited an excellent dust rejection efficiency of 99.99%, air permeability of 42.15 mm/s, which was 76 times that of the commercial waterproof and breathable PTFE membrane, water vapor transmission rate of 4.89 kg/(m2 × 24 h), and accumulative one-way transport capacity of 888.7%. In addition, the breakthrough pressure of the Janus membrane in the reverse direction (i.e., hydrophilic layer to hydrophobic layer) was four times that in the positive direction (i.e., hydrophobic layer to hydrophilic layer), suggesting it to be a potential substrate for comfortable bioprotection with a comprehensive protection capability.

Directional Transportation in a Self-Pumping Dressing Based on a Melt Electrospinning Hydrophobic Mesh.

Self-pumping wound dressings with directional water transport ability have been widely studied for their function of directional extraction of excessive biofluid from wounds while keeping the wound in a moderately humid environment to realize rapid wound healing. However, the existing solutions have not paid close attention to the fabrication of a nonirritating hydrophobic layer facing the wounds, which may cause irritation to wounds and thereby further worsen inflammation. Herein, a flexible and elastic thermoplastic polyurethane (TPU) hydrophobic microfiber mesh (TPU-HMM) produced by melt electrospinning (MES) is reported. The TPU-HMM was compounded to a hydrophilic nanofiber membrane, which was fabricated by blending with polyamide 6 and poly(ethylene glycol) (PA6-PEG) to form a composite self-pumping dressing, for which the breakthrough pressure in a reverse direction was 12.8 times than that in a positive direction and the forward water transmission rate was increased by 700%. It shows good directional water transport ability and is expected to absorb excessive biofluid of the wounds. This solvent-free and easy-process TPU-HMM provides a new strategy for the development of functional self-pumping textiles, and the solvent-free fabrication method for fibers, which eliminates the potential toxicity brought by solvent residues, offers more possibilities for its applications in biomedicine.

Self-Supporting Three-Dimensional Electrospun Nanofibrous Membrane for Highly Efficient Air Filtration.

High-performance air filtration was the key to health protection from biological and ultrafine dust pollution. A self-supporting, three-dimensional (3D) nanofibrous membrane with curled pattern was electrospun for the filtration, of which the micro-fluffy structure displayed high-filtration efficiency and low-pressure drop. The flow field in the 3D filtration membrane was simulated to optimize the process parameters to increase the filtration performance. The qualification factor increased from 0.0274 Pa-1 to 0.0309 Pa-1 by 12.77% after the optimization of the electrospinning parameters. The best filtration efficiency and pressure drop were 93.6% and 89.0 Pa, separately. This work provides a new strategy to fabricate 3D structures through the construction of fiber morphology and promotes further improvement of air filtration performance of fibrous filters.

Three-dimensional composite electrospun nanofibrous membrane by multi-jet electrospinning with sheath gas for high-efficiency antibiosis air filtration.

Three-dimensional (3D) composite polyvinylidene fluoride (PVDF)/polyacrylonitrile (PAN) electrospun nanofibrous membranes combining both thick and thin nanofibers have been fabricated by the method of multi-jet electrospinning with sheath gas to realize high-efficiency air filtration under a low pressure drop. The thin PAN nanofibers form a dense membrane, with a strong capturing ability on the ultra-fine particles, while the thick PVDF nanofibers play a 3D supporting effect on the thin PAN nanofibers. In this case, the combination results in a fluffy membrane with higher porosity, which could achieve the airflow passing through the membrane without the air pressure drop. The effects of the composite manner of thick nanofibers and thin nanofibers are investigated, in order to optimize the air filtration performance of the 3D composite nanofibrous membrane. As a result, the maximum quality factor for air filtration could reach up to 0.398 Pa-1. The particle-fiber interaction model was used to simulate the air filtration process as well, and the simulation results were fairly consistent with the experimental results, providing a guidance method for the optimization of composite nanofibrous membrane for high-efficiency air filtration. More interestingly, a cationic poly[2-(N,N-dimethyl amino) ethyl methacrylate] (PDMAEMA) was added in the PVDF solution to obtain a composite air filtration membrane with excellent antibiosis performance, which achieved the highest inhibition rate of approximately 90%. In short, this work provides an effective way to promote antibiosis air filtration performance by using an electrospun nanofibrous membrane, and might also effectively accelerate the biological protection application of current air filtration membranes.

Self-Powered Electrospun Composite Nanofiber Membrane for Highly Efficient Air Filtration.

Highly efficient air filtration with low pressure drop is the key to air purification. In this work, a self-powered electrospun nanofiber membrane with an electrostatic adsorption effect was prepared to improve the filtration efficiency of micro/nano particles. The composite membrane was comprised of polyvinyl chloride (PVC) nanofibers and polyamide-6 (PA6) nanofibers. The triboelectric effect between the two adjacent nanofiber membranes generated electrostatic charges under the action of air vibration, by which the electrostatic adsorption with the same pressure drop was enhanced. The electrostatic voltage on the self-powered nanofiber membrane was 257.1 mV when the flow velocity was 0.1 m/s. For sodium chloride (NaCl) aerosol particles with a diameter of 0.3 µm, the removal efficiency of the self-powered composite nanofiber membrane was 98.75% and the pressure drop was 67.5 Pa, which showed a higher quality factor than the membrane without electrostatic charges. This work provides an effective way to improve the filtration performance of air filter membranes.

Jet Mode Recognition of Electrohydrodynamic Direct-Writing Based on Micro/Nano Current.

The online recognition of jet mode is important for the accurate control and further application of electrohydrodynamic direct-writing (EDW) technology. An EDW system with a current detection module is built for jet mode recognition. The current of the EDW jet is measured to recognize the jet mode when printing patterned structures. Then, a data processing program with a digital Kaiser low-pass filter is developed in MATLAB, via which the noise of the current signal is reduced. The features of EDW current, including the current fluctuation and the peak current intervals, are studied to recognize different jet modes. The current characteristics of three jet modes are investigated: droplet ejection mode, Taylor cone ejection mode, and retractive ejection mode. The Taylor cone ejection mode has the smallest coefficient of variation of peak current. This work provides a good way of designing the optimized control algorithm and of realizing the closed-loop control system, which contributes to enhancing the jet stability and accelerating the application of EDW technology.

Arced Multi-Nozzle Electrospinning Spinneret for High-Throughput Production of Nanofibers.

The stable and continuous ejection of multiple jets with high densities is the key to the application of electrospinning technology. An arced multi-nozzle spinneret was designed to increase the production efficiency of electrospinning. The distribution of the electrical field was simulated to optimize the nozzles' distribution of the spinneret. When the nozzles were arranged in an arc array, a relatively uniform electrical field could be obtained, which was beneficial for the weakening of electrical interference among the nozzles. Under the optimized electrical field, multiple jets from each nozzle could be ejected in a stable and continuous way. With the increase of the applied voltage, the electrical stretching force became larger, and there were fewer bonding structures. The average diameter of the electrospun nanofibers decreased with the increase of the applied voltage. When the distance between the inner nozzle and the collector increased, the charged jets suffered a larger stretching effect, resulting in the decrease of the average diameter of the electrospun nanofibers. The electrospinning current increased with the applied voltage and decreased with the distance between the inner nozzle and the collector, which is an important aspect for the monitoring of electrospinning jets. This work provides an effective way to promote the production efficiency of electrospun nanofibrous membranes.

Measurement and Time Response of Electrohydrodynamic Direct-Writing Current.

The micro/nano current is an important characteristic to reflect the electrohydrodynamic direct-writing (EDW) process. In this paper, a direct-written current measurement system with a high signal to noise ratio was proposed to monitor the charged jets, providing the data basis for the promotion of stability and precision of the EDW jet. The electrical characteristics of the printing process were studied, the electrohydrodynamic direct-written current was associated with the stability of charged jet and the accuracy of direct-written patterns. There was an impulse current when the front end of the jet reached the collector and then a stable jet could be gained. With the increase of applied voltage, the severe fluctuation of measured current increased, the charged jet became more unstable and the accuracy of direct-written parallel lines was lower. The effects of processing parameters on direct-written current were also investigated. The average direct-written current at the stable stage increased as the applied voltage and polymer concentration increased, and it decreased as the distance from the nozzle to the collector increased. This research will promote the development and applications of EDW technology in the fields of micro/nano manufacturing.

Continuous Near-Field Electrospraying Using a Glass Capillary Nozzle.

A continuous near-field electrospray process has been developed to deposit micropatterns. Different from traditional electrospray technologies, the nozzle-to-substrate distance was shortened to less than 5 mm, and a glass capillary nozzle with a diameter of tens of microns was used. Steady and continuous ejection was achieved, and patterns with line widths of sub-100 µm were generated. The influence of experimental parameters was investigated. The critical voltage for electrospray increased with nozzle-to-substrate distance and flow rate. The line width of electrosprayed patterns increased with the increases in applied voltage, flow rate, nozzle diameter, and deposition time. This work provides a simple and potential route for on-demand deposition of micro-/nano-patterns in the electrospray process.

Electrospray Deposition of ZnO Thin Films and Its Application to Gas Sensors.

Electrospray is a simple and cost-effective method to fabricate micro-structured thin films. This work investigates the electrospray process of ZnO patterns. The effects of experimental parameters on jet characteristics and electrosprayed patterns are studied. The length of stable jets increases with increasing applied voltage and flow rate, and decreases with increasing nozzle-to-substrate distance, while electrospray angles exhibit an opposite trend with respect to the stable jet lengths. The diameter of electrosprayed particles decreases with increasing applied voltage, and increases with flow rate. Furthermore, an alcohol gas sensor is presented. The ZnAc is calcined into ZnO, which reveals good repeatability and stability of response in target gas. The sensing response, defined as the resistance ratio of R0/Rg, where R0 and Rg are resistance of ZnO in air and alcohol gas, increases with the concentration of alcohol vapors and electrospray deposition time.