Nanofiber
Nanofibers are fibers with diameters in the nanometer range. Nanofibers can be generated from different polymers and hence have different physical properties and application potentials. Examples of natural polymers include collagen, cellulose, silk fibroin, keratin, gelatin and polysaccharides such as chitosan and alginate. Examples of synthetic polymers include poly, polycaprolactone, polyurethane, poly, poly, and poly. Polymer chains are connected via covalent bonds. The diameters of nanofibers depend on the type of polymer used and the method of production. All polymer nanofibers are unique for their large surface area-to-volume ratio, high porosity, appreciable mechanical strength, and flexibility in functionalization compared to their microfiber counterparts.
There exist many different methods to make nanofibers, including drawing, electrospinning, self-assembly, template synthesis, and thermal-induced phase separation. Electrospinning is the most commonly used method to generate nanofibers because of the straightforward setup, the ability to mass-produce continuous nanofibers from various polymers, and the capability to generate ultrathin fibers with controllable diameters, compositions, and orientations. This flexibility allows for controlling the shape and arrangement of the fibers so that different structures can be fabricated depending on intended application purposes.
Nanofibers have many possible technological and commercial applications. They are used in tissue engineering, drug delivery, seed coating material, cancer diagnosis, lithium-air battery, optical sensors, air filtration, redox-flow batteries and composite materials.
History of nanofiber production
Nanofibers were first produced via electrospinning more than four centuries ago. Beginning with the development of the electrospinning method, English physicist William Gilbert first documented the electrostatic attraction between liquids by preparing an experiment in which he observed a spherical water drop on a dry surface warp into a cone shape when it was held below an electrically charged amber. This deformation later came to be known as the Taylor cone. In 1882, English physicist Lord Rayleigh analyzed the unstable states of liquid droplets that were electrically charged, and noted that the liquid was ejected in tiny jets when equilibrium was established between the surface tension and electrostatic force. In 1887, British physicist Charles Vernon Boys published a manuscript about nanofiber development and production. In 1900, American inventor John Francis Cooley filed the first modern electrospinning patent.Anton Formhals was the first person to attempt nanofiber production between 1934 and 1944 and publish the first patent describing the experimental production of nanofibers. In 1966, Harold Simons published a patent for a device that could produce thin and light nanofiber fabrics with diverse motifs.
Only at the end of the 20th century have the words electrospinning and nanofiber become common language among scientists and researchers. Electrospinning continues to be developed today.
Synthesis methods
Many chemical and mechanical techniques for preparing nanofibers exist.Electrospinning
Electrospinning is the most commonly used method to fabricate nanofibers.The instruments necessary for electrospinning include a high voltage supplier, a capillary tube with a pipette or needle with a small diameter, and a metal collecting screen. One electrode is placed into the polymer solution and the other electrode is attached to the collector. An electric field is applied to the end of the capillary tube that contains the polymer solution held by its surface tension and forms a charge on the surface of the liquid. As the intensity of the electric field increases, the hemispherical surface of the fluid at the tip of the capillary tube elongates to form a conical shape known as the Taylor cone. A critical value is attained upon further increase in the electric field in which the repulsive electrostatic force overcomes the surface tension and the charged jet of fluid is ejected from the tip of the Taylor cone. The discharged polymer solution jet is unstable and elongates as a result, allowing the jet to become very long and thin. Charged polymer fibers solidifies with solvent evaporation. Randomly-oriented nanofibers are collected on the collector. Nanofibers can also be collected in a highly aligned fashion by using specialized collectors such as the rotating drum, metal frame, or a two-parallel plates system. Parameters such as jet stream movement and polymer concentration have to be controlled to produce nanofibers with uniform diameters and morphologies.
The electrospinning technique transforms many types of polymers into nanofibers. An electrospun nanofiber network resembles the extracellular matrix well. This resemblance is a major advantage of electrospinning because it opens up the possibility of mimicking the ECM with regards to fiber diameters, high porosity, and mechanical properties. Electrospinning is being further developed for mass production of one-by-one continuous nanofibers.
Thermal-induced phase separation
Thermal-induced phase separation separates a homogenous polymer solution into a multi-phase system via thermodynamic changes. The procedure involves five steps: polymer dissolution, liquid-liquid or liquid-solid phase separation, polymer gelation, extraction of solvent from the gel with water, and freezing and freeze-drying under vacuum. Thermal-induced phase separation method is widely used to generate scaffolds for tissue regeneration.The homogenous polymer solution in the first step is thermodynamically unstable and tends to separate into polymer-rich and polymer-lean phases under appropriate temperature. Eventually after solvent removal, the polymer-rich phase solidifies to form the matrix and the polymer-lean phase develops into pores. Next, two types of phase separation can be carried out on the polymer solution depending on the desired pattern. Liquid-liquid separation is usually used to form bicontinuous phase structures while solid-liquid phase separation is used to form crystal structures. The gelation step plays a crucial role in controlling the porous morphology of the nanofibrous matrices. Gelation is influenced by temperature, polymer concentration, and solvent properties. Temperature regulates the structure of the fiber network: low gelation temperature results in formation of nanoscale fiber networks while high gelation temperature leads to the formation of a platelet-like structure. Polymer concentration affects fiber properties: an increase in polymer concentration decreases porosity and increases mechanical properties such as tensile strength. Solvent properties influence morphology of the scaffolds. After gelation, gel is placed in distilled water for solvent exchange. Afterwards, the gel is removed from the water and goes through freezing and freeze-drying. It is then stored in a desiccator until characterization.
Drawing
The drawing method makes long single strands of nanofibers one at a time. The pulling process is accompanied by solidification that converts the dissolved spinning material into a solid fiber. A cooling step is necessary in the case of melt spinning and evaporation of solvent in the case of dry spinning. A limitation, however, is that only a viscoelastic material that can undergo extensive deformations while possessing sufficient cohesion to survive the stresses developed during pulling can be made into nanofibers through this process.Template synthesis
The template synthesis method uses a nanoporous membrane template composed of cylindrical pores of uniform diameter to make fibrils and tubules. This method can be used to prepare fibrils and tubules of many types of materials, including metals, semiconductors and electronically conductive polymers. The uniform pores allow for control of the dimensions of the fibers so nanofibers with very small diameters can be produced through this method. However, a drawback of this method is that it cannot make continuous nanofibers one at a time.Self-assembly
The self-assembly technique is used to generate peptide nanofibers and peptide amphiphiles. The method was inspired by the natural folding process of amino acid residues to form proteins with unique three-dimensional structures. The self-assembly process of peptide nanofibers involves various driving forces such as hydrophobic interactions, electrostatic forces, hydrogen bonding and van der Waals forces and is influenced by external conditions such as ionic strength and pH.Polymer materials
Due to their high porosity and large surface area-to-volume ratio, nanofibers are widely used to construct scaffolds for biological applications. Major examples of natural polymers used in scaffold production are collagen, cellulose, silk fibroin, keratin, gelatin and polysaccharides such as chitosan and alginate. Collagen is a natural extracellular component of many connective tissues. Its fibrillary structure, which varies in diameter from 50-500 nm, is important for cell recognition, attachment, proliferation and differentiation. Using type I collagen nanofibers produced via electrospinning, Shih et al. found that the engineered collagen scaffold showed an increase in cell adhesion and decrease in cell migration with increasing fiber diameter. Using silk scaffolds as a guide for growth for bone tissue regeneration, Kim et al. observed complete bone union after 8 weeks and complete healing of defects after 12 weeks whereas the control in which the bone did not have the scaffold displayed limited mending of defects in the same time period. Similarly, keratin, gelatin, chitosan and alginate demonstrate excellent biocompatibility and bioactivity in scaffolds.However, cellular recognition of natural polymers can easily initiate an immune response. Consequently, synthetic polymers such as poly, polycaprolactone, polyurethane, poly, poly, and poly have been developed as alternatives for integration into scaffolds. Being biodegradable and biocompatible, these synthetic polymers can be used to form matrices with a fiber diameter within the nanometer range. Out of these synthetic polymers, PCL has generated considerable enthusiasm among researchers. PCL is a type of biodegradable polyester that can be prepared via ring-opening polymerization of ε-caprolactone using catalysts. It shows low toxicity, low cost and slow degradation. PCL can be combined with other materials such as gelatin, collagen, chitosan, and calcium phosphate to improve the differentiation and proliferation capacity. PLLA is another popular synthetic polymer. PLLA is well known for its superior mechanical properties, biodegradability and biocompatibility. It shows efficient cell migration ability due to its high spatial interconnectivity, high porosity and controlled alignment. A blend of PLLA and PLGA scaffold matrix has shown proper biomimetic structure, good mechanical strength and favorable bioactivity.