Ambient Temperature Control Improves Jet Properties and Fiber Thinning in Polyethylene ( PE ) Melt Electrospinning/Blown Hybrid Process

ABSTRACT A melt electrospinning/blown hybrid process was developed for solvent‐free fabrication of polyethylene (PE) nanofiber webs. The effects of hot air pressure, electric field strength, and ambient thermal conditions on polymer jet dynamics and fiber morphology were systematically investigated. A high voltage was applied to a ring electrode positioned between the nozzle and collector to induce electrostatic elongation, and dual heated air streams provided additional thermal drawing forces. An acrylic cylinder was incorporated to stabilize the thermal environment around the jet. Jet area and lateral fluctuations were quantified using charge‐coupled device (CCD) imaging and custom image‐processing algorithms. Morphology of the collected fiber webs was examined by scanning electron microscopy (SEM). Temperature profiles were measured at various tip‐to‐collector distances to assess heat retention performance. Increasing both hot air pressure and electric field strength decreased the fiber diameter, reaching a minimum average of approximately 1.9 μm. While the acrylic cylinder improved thermal stability, it could also introduce internal turbulence that disrupted jet uniformity. Overall, the hybrid melt spinning strategy enables scalable, continuous production of uniform, ultrafine polymer fibers suitable for high‐performance lithium‐ion battery separator applications.