Processing method and apparatus for micro-structured rope-like material

A method of making a continuous fiber thread or rope, comprising:

• initiating electrodeposition by feeding a polymer solution through an electrospray nozzle into a gap between a first electrode and a second electrode of an apparatus comprising:
• a base comprising an electric lead electrically-connected to a power source providing a voltage suitable for electrodeposition;
• a first rotating head rotatably connected to the base and electrically-connected to the electric lead of the base, wherein the first rotating head rotates about an axis of rotation, the first rotating head comprising:
• a first fiber collection spool;
• a motor configured to rotate the first fiber collection spool;
• a first electrode having a distal end and a proximal end attached to the first fiber collection spool and electrically-connected to the electric lead;
• and
• a first guide at the axis of rotation of the first rotating head configured to rotatably-retain the first electrode and through which the distal end of the first electrode is extended or extendable on action of the first fiber collection spool, and wherein the distal end of the first electrode extends through the first guide;
• a second electrode having a distal end spaced apart from the distal end of the first electrode and defining a gap between the first electrode and the second electrode, and connected at its proximal end to the electric lead or to a second electric lead connected to a power source providing a voltage;
• a motor configured to rotate the first rotating head about the axis of rotation;
• and
• an electrospinning nozzle configured to deposit a polymer composition in the gap between the first electrode and the second electrode and electrically-connected to an electric lead and a power source providing a voltage to the electrospinning nozzle that produces an electrical field with the first and second electrode for electrodeposition of the polymer composition in the gap between the distal ends of the first electrode and second electrode,
• thereby forming nascent thread or rope, and attaching the nascent thread or rope to the first electrode and to the second electrode;
• and
• rotating the first fiber collection spool during electrodeposition of the polymer solution at a rate to first draw the first electrode, and then the nascent electrodeposited thread or rope connected to the distal end of the first electrode, through the first guide and onto the first fiber collection spool, such that polymer fibers are electrodeposited onto and between nascent thread or rope attached to the first electrode and the second electrode, thereby extending the length of the thread or rope and winding the nascent thread or rope about the first fiber collection spool.