Scaling law on particle-to-fiber formation during electrospinning

The development of various morphologies such as beads, beaded fibers, pure fibers and their scaling as a function of solution properties and processing variables in electrospinning is reported. Polyvinyl pyrrolidone (PVP), at various molecular weights and concentrations dissolved in a mixture of water and ethanol, was used to prepare different morphologies and sizes. The morphology of beads and fibers was predicted and measured based on an entanglement number diagram and rheological measurements. A constant-current electrospinning system was employed to control the processing variables. Scaling laws related to solution properties and processing variables (voltage, current and flow rate), and their effect on the fiber/bead diameter, were discussed. Viscosity (η), flow rate (Q), and current (I) were found to play significant roles in the control of morphology during electrospinning. Processing variables involved in electrospinning followed a power scaling that was in agreement with the model. The dependence of fiber diameter (df) on the Q/I for different molecular weights and concentrations also followed a power law, and the scaling varied between 0.11–0.29 for beaded fiber and 0.36–0.51 for pure fiber. In addition, the relationship between viscosity and fiber diameter followed scaling laws: df ∼ η0.98.