3.2.1. CMC spinning using PVA.1
In the initial phase of this work, the PVA with a molecular weight (Mn) of ~100,000 g/mol and a hydrolysis degree of 99% was employed. The polymer was solubilized in Milli-Q water (QW). A solution containing 4 wt. % PVA was subjected to electrospinning using previously determined spinning variables. This solution was electrospun along with a 4 wt. % collagen solution, forming the collagen/PVA system, with a collagen:PVA mass ratio of 1:1. [
41].
PCL-type I collagen core-shell electrospun nanofibers for wound healing applications was also effectively obtained using acetic acid as solvent [
41]. However, the solubility of CMC in acetic acid is poor. For this reason, the electrospinning process in this work utilized an aqueous solvent system with 4 wt. % of PVA.1 in Milli-Q water, varying the rate flow in two points (0.1 and 0.5 ml/h). The electrospun PVA.1 and PVA.1/CMC nanofibers under these variables are shown in
Figure 2. The presence of micrometric beads and defects was observed, for two flow rates used while the nanofibers exhibited nanometric diameters. The morphology of electrospun nanofibers is shown, varying the flow rate from 0.1 ml/h and 0.5 ml/h, with average diameters in 86.8 nm ± 37.1 nm and 103. ± 28.6 nm were observed, respectively, indicating a slight increase in diameter with the presence of defects.
The images presented in
Figure 2 indicate that the polymer concentration used was inadequate, as reflected in the obtained morphology. The presence of the thin fibers with more spherical micrometric beads may be attributed to the low viscosities of the studied solution. Liu
et al. (2008) demonstrated that higher polymer concentrations result in a decreased quantity and size of beads produced by electrospinning. Thus, the concentration of 4 wt. % of PVA.1 likely did not exhibit sufficient viscosity for the formation of consistent and fine fibers [
42].
Incorporation CMC into the formulation of PVA.1 at a concentration of 4 wt.% (in an 8:2 mass ratio) altered the morphologies of the nanofibers obtained from neat PVA.1 without CMC (
Figure 2A,B) into bead-like morphologies, as shown in
Figure 2C (ɸ = ~2.99 µm). This corroborates the difficulty of the electrospinning CMC.
Figure 2D highlights the morphological variations observed when the polymer flow rate is increased, confirming that an increase in flow rate enhances the distribution of nanofiber diameters. This can primarily be attributed to the increase in the available polymer mass for fiber formation, which consequently creates greater instability in the formation of the Taylor cone.
Two solutions were prepared to continue the electrospinning of PVA.1 in this study: the 6 wt.% PVA.1 solution and PVA.1/CMC (8:2) solution with 6 wt.% PVA. Both samples were electrospun for 20 minutes using the same parameters. The resulting fibers were characterized by SEM, as shown in
Figure 3.
Figure 3 shows the morphology of electrospun nanofibers using the same processing conditions for a PVA.1 solution and a PVA.1/CMC blend. The nanofiber diameters for these samples were measured, showing similar morphologies for both electrospinning conditions. In other words, the nanofibers obtained from PVA.1 and PVA.1/CMC did not exhibit significant variations in diameter, with an approximate 14% increase observed for PVA.1/CMC nanofibers compared to neat PVA for the 0.5 mL/h of flow rate. The electrospun PVA.1 nanofibers had an average diameter of 192.3 ± 71.1 nm, while PVA.1/CMC nanofibers had an average diameter of 219.2 ± 70.3 nm (
Figure 3A,B), respectively. This behavior was also observed for nanofibers prepared using the flow rate of 0.6 mL/h, as shown in
Figure 3C,D. The variations in the diameter of PVA.1/CMC nanofibers (250.2 ± 74.5 nm) showed an approximate 22% increase compared to pure PVA.1 nanofibers (204.1 ± 65.5 nm).
As demonstrated in
Figure 1, the incorporation of CMC into PVA.1 solution did not generated variation significant in viscosities, however, reflected in nanofibers with larger diameters than those of PVA.1 nanofibers, as expected. Indeed, an increase in the viscosity of the PVA.1/CMC solution was noted, a characteristic that directly influences the diameters of electrospun nanofibers. The variation in the average nanofiber diameter can be attributed to an increase in the surface tension of the solution due to the presence of CMC, as shown in
Figure 1. These characteristics are inherent to CMC in solution, as described in the study by Benchabane and Bekkour (2008), where the rheological properties of neat CMC solutions were investigated [
43]. The study revealed that Newtonian viscosity was observed for low concentrations (~1% w/v); however, above these values, the solutions began to exhibit rheological properties of thixotropic fluids. This fact could be related to greater difficulties in the production of electrospun nanofibers, explaining the increased defects and agglomerates in the nanofibers. Viscosity and surface tension are crucial variables in the electrospinning process, directly influencing the formation of the Taylor cone, as reported in the literature [
44]. Therefore, the increase in the diameter of PVA.1/CMC nanofibers compared to pure PVA.1 can be attributed to these variations in solution properties.
Thus far, electrospun nanofibers with PVA.1 (4 and 6 wt. %) have generated fine nanofibers on a submicrometric scale. However, all samples have shown defects and beads, with a lower quantity for films obtained with PVA.1 concentrations of 6 wt. %. The result suggests that increasing the concentration is providing greater stability to the Taylor cone for the studied variables. However, solutions with this concentration exhibited high viscosity (
Figure 1), which also posed greater challenges for processing, ranging from longer solubilization times to instability in PVA.1/CMC solutions.
To assess whether the increase in solution viscosity could generate defect-free nanofibers, electrospinning of PVA.1 and PVA.1/CMC solutions with a mass concentration of 6% relative to PVA.1 was studied. Some of the obtained results are documented in
Figure 3, which presents SEM micrographs for two electrospun samples, using the same processing variables for PVA.1 solution.
Continuing this study, a PVA.1/CMC solution was electrospun, following the previously described results. For this, variables such as flow rate (1.0 ml/h) and needle tip-collector distance (11 cm) were kept constant. The results are presented in
Figure 4, showing the morphological variation of electrospun PVA.1/CMC nanofibers (6 wt. %) using three different applied voltages (15, 17, and 20 kV).
Under the electrospinning conditions used in this phase of the work, it was observed that voltage variations influenced nanofiber formation (
Figure 4). At 15 kV, the presence of large beads is noticeable, which significantly decreases when a voltage 17 kV is applied, demonstrating a slight improvement in interactions between the polymeric solution and the charges imposed by the applied voltage. This allows electrostatic forces to overcome the surface tension of the solution, enabling the polymer chains to stretch and be ejected at a speed that facilitates the formation of more homogeneous nanofibers. However, some clusters and defects are visible in the micrograph, which may be attributed to insufficient flight time allowing the deposition of polymeric material still containing solvent. On the other hand, results obtained with 20 kV voltage are consistent with those reported in the literature. Liu
et al. (2019) reported that for electrospinning PVA in deionized water, voltages above 20 kV may create instability in the jet and Taylor cone, favoring the formation of multiple jets that induce the formation of coarse defects in nanofiber morphology [
45]. However, at this voltage, an improvement in the morphology of electrospun nanofibers was observed, albeit still with the presence of rounded beads, suggesting that the applied voltage is excessive for the evaluated variables.
In the continuation of the study, solutions with 8 wt. % of PVA.1 and the PVA.1/CMC blend were prepared in the aqueous solution (QW), studying voltage variations at 15 and 20 kV for both PVA.1 and PVA.1/CMC solutions.
In
Figure 5, SEM images of electrospun fibers of PVA.1 and PV.1/CMC are shown as a function of applied voltage. To observe this influence, images with two different magnifications (2k and 10k) are presented to provide a more general view of the produced mats. The solutions used in this part of the investigation had a concentration of 8% w/v of PVA.1.
Figures 5A,B illustrate the morphology of PVA.1 nanofibers obtained at 15 kV and 20 kV, respectively, showcasing the production of nanofibers without beads, with average diameters of 245.9 ± 96.1 nm (
Figure 5A) and 217.9 ± 76.4 nm (
Figure 5B). In these two samples, the formation of beads and/or flattened fibers (ribbons) is observed morphologies characteristic of electrospinning PVA with high viscosity, as described by Koski
et al. (2004) [
34]. These authors demonstrated that obtaining nanofibers with higher winding or twisting indicates a splitting and spreading of the jet due to Taylor cone instability generated by strong polymer-solvent interaction in viscous PVA/water solutions with a high degree of hydrolysis, which also leads to flattened fibers called ribbons.
Figure 5C,D are shown the nanofibers produced under the same electrospinning conditions for the PVA.1/CMC solution. The experiment aimed to provide a comparison of morphologies and the effect of CMC incorporation as a function of applied voltage. As shown in
Figure 5C, electrospinning the PVA.1/CMC blend resulted in an increase in bead presence when a voltage of 15 kV was applied, compared to the PVA.1 sample (
Figure 5A), suggesting a deficiency in the attractive force between the solution and the collector, allowing Taylor cone instability. This behavior was attributed to a possible increase in solution viscosity caused by addition of CMC to PVA, as also observed in
Figure 5D, as described by Hashimi
et al. (2020). They used polyvinylpyrrolidone (PVP) to reduce solution viscosity, obtaining more stable solutions for use in electrospinning [
31].
A study related to the applied flow rate for the PVA.1/CMC solution was conducted. The nanofibers formed by the electrospun samples with this solution are shown in
Figure 6, comparing the morphology of PVA.1/CMC nanofibers as a function of the applied flow rate.
It was observed that even with a small increase in the flow rate of ~0.1 ml/h, the amount of polymeric mass available at the needle tip increased the instability of the Taylor cone, leading to greater bead formation and defects deposited on the collector. This aligns with literature reports, indicating that providing a larger amount of polymer requires more force to stretch the available mass, resulting in larger diameter nanofibers and coarser defects. However, the diameters of the produced nanofibers did not show significant variation, measuring 130.1 ± 48.0 nm for the sample with a flow rate of 0.6 ml/h and 129.9 ± 78.7 nm for the sample obtained with a flow rate of 0.5 ml/h. This demonstrates that neither of the two conditions worked allowed for the formation of nanofibers with homogeneous diameters and defects free. Therefore, it can be concluded that the spinning conditions used for these polymers were not efficient for the formation of fine nanofibers.
As shown in previous studies [
41,
46], it was observed that this parameter did not influence the electrospinning processing, which could be attributed to instabilities in the Taylor Cone resulting from high surface tension of the PVA solution (
Figure 1), this result is according to reports in the literature, which show high surface tension for solutions with a high degree of hydrolysis. Some authors who used this same type of PVA (Mn; 100,000 and degree of hydrolysis: 99%) in electrospinning processes overcame this problem by adding a surfactant to reduce the surface tension of the polymeric solution [
18], it’s not the focus of this study.
On the other hand, the ease of PVA spinning was studied using a second polymer with a lower degree of hydrolysis (partially hydrolysed PVA), which are polymers that are easier to solubilize and have lower surface tension. For this second polymer used, the nomenclature PVA.2 was employed, using a PVA polymer with 88% hydrolysis.
3.2.2. CMC spinning using PVA.2
Similarly, to PVA.1, a study was conducted to investigate the variation in PVA concentration at 6, 8, and 10% (w/v), maintaining the volumetric ratio of 8:2 between PVA and CMC. The flow rate was kept constant at 0.5 ml/h, and the applied voltage was the main variable studied.
This phase of the study began with a PVA.2 solution at a mass concentration of 6 wt. %. The morphology of the nanofibers was assessed for this concentration based on the applied voltage. The micrographs obtained in this study are presented in
Figure 7.
Figure 7 shows the morphology of electrospun nanofibers produced from PVA.2, and PVA.2/CMC starting from a solution with a 6 wt. % mass concentration. However, it is important to note that bead formation in the micrometer scale occurred for all three applied voltages, comparing the micrographs obtained for the PVA.1 under the same processing conditions and concentration. This polymer formed better morphologies compared to the desired ones (nanofibers with smaller defects), related to the lower molecular weight of PVA.2 (Mn: 80,000 g/mol) compared to PVA.1 (Mn: 100,000 g/mol). Thus, on previous studies, it was found that the polymer's molecular weight has a significant influence on processing, as it is directly linked to the viscosity of the spinning solution and the entanglement of polymer chains [
49,
50]. Therefore, it can be said that these conditions were not favorable for promoting the intertwining of polymer chains, favoring the formation of continuous and defect-free nanofibers. The presence of beads with smaller sizes than those seen in the micrographs for 15 and 17 kV is evident. As reported in the literature, voltages above 20 kV in the electrospinning of PVA create unstable jets over time, promoting defect formation [
49].
On the other hand,
Figure 7 (center column) shows the nanofibers obtained from the PVA.2 solutions with CMC. It is possible to observe a potential increase in the number of defects and beads, as well as the average diameter of the nanofibers, compared to the mats obtained under the same processing conditions for pure PVA.2 (
Figure 7, right column). This may be related to the difficulties in spinning caused by CMC and the instability of the Taylor cone that the PVA.2 solution still experiences due to its low molecular interaction stemming from its low viscosity (
Figure 1B). According to the morphology shown in
Figure 7, it can be affirmed that the use of solutions with higher concentrations is necessary.
Therefore, the solution concentration was increased to 8 wt. % by mass of solubilized PVA.2 in Milli-Q water. This aims to evaluate the influence of the molecular weight of this polymer, as well as its spinning capability, since PVA.2 also has a lower degree of hydrolysis. These results are presented in
Figure 8, which shows an overall micrograph of the sample to provide a more comprehensive view of the morphology of the produced nanofibers, as well as an image at a higher magnification to facilitate a more detailed view of the nanofibers.
In the micrographs presented in
Figure 8, the morphologies of electrospun nanofibers from PVA.2 are shown as a function of the applied voltage. The figure shows that for 8 wt. % PVA.2, the formation of the Taylor cone is stable, which resulted in homogeneous defect-free nanofibers for all applied voltages (15, 17, and 20 kV), with average diameters of 466 ± 104.8 nm, 448.6 ± 117.5 nm, and 487.4 ± 72.5 nm. However, the diameters of the nanofibers produced with this polymer are larger than the diameters obtained for PVA.1. The diameters were, however, within the range found in the literature from 100 nm to 2 µm. Studies on electrospun PVA report that the higher the molecular weight of the polymer, the larger the diameter of the produced nanofiber when efficient processing parameters are achieved [
44,
45].
After studying the morphology of the fibers obtained from the PVA.2 (8 wt. %) solution, CMC was added, and the mixture was subjected to electrospinning under the following operational conditions: a flow rate of 0.5 mL/h, an applied voltage of 17 kV, and a distance of 11 cm. Under these parameters, the electrospun sample shown in
Figure 8H was obtained. The incorporation of CMC resulted in the formation of defects, as well as a slight reduction in fiber diameter (270 ± 90 nm) compared to the average diameter of the sample prepared with pure PVA.2 (
Figure 8D). This can be attributed to a lower surface tension of the solution compared to that of PVA.1, which facilitates the formation and stability of the Taylor cone during the spinning process. Furthermore, the negative influence of CMC on the plastic deformation of the solution was evident, potentially leading to the observed defects, which are absent in the neat PVA.2 samples. The viscosity of the solutions for this PVA.2 formulation did not show significant variations, indicating that the presence of defects is merely related to the inclusion of carboxymethyl cellulose.
An additional formulation with 10 wt. % PVA.2 was evaluated to assess the stability of the morphology of the nanofibers produced from a solution with higher concentration and viscosity, following the conditions established for the 8 wt. % PVA.2 solution.
Figure 9 shows the nanofibers obtained from this PVA.2 solution with 10 wt. % mass concentration.
Figure 9A shows the SEM image magnified 2k times with its distribution of fibers obtained with average diameters of 259.9 ± 48.9 nm. This gives a more generalized view of the fiber morphology, showing the presence of nanofibers free from agglomerates and beads. In the micrograph with a magnification of 10,000 times (
Figure 9B), it is shown that despite the homogeneity in the diameters of the fibers, defects caused by fiber coalescence can be seen. This effect can be attributed to solvent residues in the fibers that allowed them to fuse when deposited with high humidity from the solvent, creating some agglomerates as highlighted in
Figure 9C,D.
Once the electrospinning study of CMC was conducted using two different PVAs as spinning supports, this section presents the SEM micrographs of the selected samples of PVA and PVA/CMC previously studied in this paper. The electrospinning conditions are recorded in
Table 1, under which it was possible to obtain mats of nanofibers with minimal defects or none at all.
Once the spinning parameters for the solutions studied in this paper were chosen, the solutions were subjected to electrospinning for 4 hours, followed by characterization of the polymers (CMC, PVAs) and their blends (PVA/CMC).