Highly Integrated Polysulfone/Polyacrylonitrile/Polyamide-6 Air Filter for Multilevel Physical Sieving Airborne Particles

Biomimetic Grooved Ribbon Aerogel Inspired by the Structure of Pinus sylvestris var. mongolica Needles for Efficient Air Purification

Air pollutants, such as particulate matter (PM) and ammonia (NH3), generated by intensive animal farming pose considerable threats to human health, animal welfare, and ecological balance. Conventional materials are often ineffective at simultaneously removing multiple pollutants, maintaining a low pressure drop, and ensuring durability in heavily polluted environments. Inspired by the dust-retention properties of Pinus sylvestris var. mongolica (PS) needles, this study developed a biomimetic grooved ribbon fiber using electrospinning technology. These fibers were further assembled into a three-dimensional bioinspired aerogel structure through freeze-forming technology to achieve efficient dust capture. Additionally, the introduction of UiO-66-NH2 nanoparticles significantly enhanced the properties of the aerogels for NH3 adsorption. Among the various prepared aerogels (PG, UPG-5, UPG-10, UPG-15, and UPG-20), UPG-10 demonstrated the best performance, achieving a filtration efficiency of 99.24% with a pressure drop of 95 Pa. Notably, it exhibited a remarkable dust-holding capacity of 147 g/m2, and its NH3 adsorption capacity reached 99.89 cm3/g, surpassing PG aerogel by 31.46 cm3/g. Additionally, UPG-10 exhibited outstanding elasticity, maintaining over 80% of its original shape after 30 compression cycles. This biomimetic aerogel presents a promising solution for air purification, contributing to improved agricultural efficiency and environmental sustainability.

Construction and Particulate Filtration Performance of Bacterial Cellulose-Derived Aerogels Optimized by Plant Polysaccharides

Air pollution has emerged as a global challenge, posing significant threats to public health and human well being. This issue has garnered substantial attention from researchers focused on developing environmentally friendly and sustainable materials. This study synthesizes bacterial cellulose (BC)-derived aerogels based on plant polysaccharides and BC using a directional freeze-drying technique, followed by surface modification with methyltrimethoxysilane (MTMS). The physicochemical characteristics of these BC-derived aerogels are thoroughly investigated to elucidate the interaction mechanisms between plant polysaccharides and bacterial cellulose at the molecular level, and their capabilities for particulate matter filtration are explored. The results demonstrate that incorporating plant polysaccharides and MTMS into BC aerogels results in synergistic mechanical properties characterized by a unique combination of softness and rigidity. Notably, sodium alginate shows the highest affinity for bacterial cellulose and MTMS, leading to optimal reinforcement effects. An oriented honeycomb structure forms internally within the aerogels, potentially reducing pressure drop. Furthermore, these aerogels exhibit a "fiber+pore" multi-filtration mechanism, achieving up to 97% filtration efficiency specifically for PM2.5 particles. These findings suggest bacterial cellulose-derived aerogels could be a sustainable alternative for mitigating air pollution.

Cellulose Acetate Membranes: Antibacterial Strategy and Application-A Review

Developing antibacterial and biodegradable cellulose acetate (CA) membrane materials is one of the main challenges in multiple application fields. CA membrane materials are widely used in gas purification, water purification, and biomedical fields due to their environmental friendliness, high chemical and mechanical stability, excellent processability, and low cost. However, antibacterial modification of CA membrane materials to enhance their utilization value in the application process has always been the direction of researchers' efforts. This review focuses on the preparation and application of antibacterial CA and its derivatives membranes, especially the types and introduction methods of antibacterial agents. First, a brief introduction of CA-based polymer membranes is presented, followed by an overview of the antibacterial agent types and their introduction methods, and antibacterial mechanisms. After that, various membranes prepared using CA-based polymers as the main matrix or as additives are discussed. Then, specific applications of antibacterial CA-based membrane materials in water purification, gas purification, biomedical, food packaging, and other fields are outlined.

Hyperbranched Polymer Induced Antibacterial Tree-Like Nanofibrous Membrane for High Effective Air Filtration

The air filtration materials with high efficiency, low resistance, and extra antibacterial property are crucial for personal health protection. Herein, a tree-like polyvinylidene fluoride (PVDF) nanofibrous membrane with hierarchical structure (trunk fiber of 447 nm, branched fiber of 24.7 nm) and high filtration capacity is demonstrated. Specifically, 2-hydroxypropyl trimethyl ammonium chloride terminated hyperbranched polymer (HBP-HTC) with near-spherical three-dimensional molecular structure and adjustable terminal positive groups is synthesized as an additive for PVDF electrospinning to enhance the jet splitting and promote the formation of branched ultrafine nanofibers, achieving a coverage rate of branched nanofibers over 90% that is superior than small molecular quaternary ammonium salts. The branched nanofibers network enhances mechanical properties and filtration efficiency (99.995% for 0.26 µm sodium chloride particles) of the PVDF/HBP-HTC membrane, which demonstrates reduced pressure drop (122.4 Pa) and a quality factor up to 0.083 Pa-1 on a 40 µm-thick sample. More importantly, the numerous quaternary ammonium salt groups of HBP-HTC deliver excellent antibacterial properties to the PVDF membranes. Bacterial inhibitive rate of 99.9% against both S. aureus and E. coli is demonstrated in a membrane with 3.0 wt% HBP-HTC. This work provides a new strategy for development of high-efficiency and antibacterial protection products.

Advancing Breathability of Respiratory Nanofilter by Optimizing Pore Structure and Alignment in Nanofiber Networks

Respiratory masks are the primary and most effective means of protecting individuals from airborne hazards such as droplets and particulate matter during public engagements. However, conventional electrostatically charged melt-blown microfiber masks typically require thick and dense membranes to achieve high filtration efficiency, which in turn cause a significant pressure drop and reduce breathability. In this study, we have developed a multielectrospinning system to address this issue by manipulating the pore structure of nanofiber networks, including the use of uniaxially aligned nanofibers created via an electric-field-guided electrospinning apparatus. In contrast to the common randomly collected microfiber membranes, partially aligned dual-nanofiber membranes, which are fabricated via electrospinning of a random 150 nm nanofiber base layer and a uniaxially aligned 450 nm nanofiber spacer layer on a roll-to-roll collector, offer an efficient way to modulate nanofiber membrane pore structures. Notably, the dual-nanofiber configuration with submicron pore structure exhibits increased fiber density and decreased volume density, resulting in an enhanced filtration efficiency of over 97% and a 50% reduction in pressure drop. This leads to the highest quality factor of 0.0781. Moreover, the submicron pore structure within the nanofiber networks introduces an additional sieving filtration mechanism, ensuring superior filtration efficiency under highly humid conditions and even after washing with a 70% ethanol solution. The nanofiber mask provides a sustainable solution for safeguarding the human respiratory system, as it effectively filters and inactivates human coronaviruses while utilizing 130 times fewer polymeric materials than melt-blown filters. This reusability of our filters and their minimum usage of polymeric materials would significantly reduce plastic waste for a sustainable global society.

Production of Ultrafine PVDF Nanofiber-/Nanonet-Based Air Filters via the Electroblowing Technique by Employing PEG as a Pore-Forming Agent

Particles with diameters smaller than 2.5 μm (PM2.5) can penetrate the respiratory system and have negative impacts on human health. Filter media with a porous surface and nanofiber/nanonet structure demonstrate superior filtration performance compared to traditional nano- and microfiber-based filters. In this study, nanostructured filters were produced using the electroblowing method from solutions containing different ratios of poly(vinylidene fluoride) (PVDF) and polyethylene glycol (PEG) polymers for the first time. By increasing the water-soluble PEG ratio in PVDF/PEG blend nanofibers and employing a water bath treatment to the produced mat afterward, a more porous fibrous structure was obtained with a lower average fiber diameter. Notably, the removal of PEG from the PVDF/PEG (3-7) sample, which had the highest PEG content, exhibited clustered nanofiber-/nanonet-like structures with average diameters of 170 and 50 nm at the points where the fibers intersect. Although this process resulted in a slight decrease in the filtration efficiency (-1.3%), the significant reduction observed in pressure drop led to a 3.2% increase in the quality factor (QF). Additionally, by exploiting the polarizability of PVDF under an electric field, the filtration efficiency of the nanostructured PVDF filters enhanced with a ratio of 3.6% after corona discharge treatment leading to a 60% improvement in the QF. As a result, the PVDF/PEG (3-7) sample presented an impressive filtration efficiency of 99.57%, a pressure drop (ΔP) of 158 Pa, and a QF of 0.0345 Pa-1.

Nanopatterned Electroactive Polylactic Acid Nanofibrous MOFilters for Efficient PM0.3 Filtration and Bacterial Inhibition

Biodegradable polylactic acid (PLA) nanofibrous membranes (NFMs) hold great potential to address the increasing airborne particulate matter (PM) and dramatic accumulation of plastic/microplastic pollution. However, the field of PLA NFM-based filters is still in its infancy, frequently dwarfed by the bottlenecks regarding relatively low surface activity, poor electroactivity, and insufficient PM capturing mechanisms. This effort discloses a microwave-assisted approach to minute-level synthesis of dielectric ZIF-8 nanocrystals with high specific surface area (over 1012 m2/g) and ultrasmall size (∼240 nm), which were intimately anchored onto PLA nanofibers (PLA@ZIF-8) by a combined "electrospinning-electrospray" strategy. This endowed the PLA@ZIF-8 NFMs with largely increased electroactivity in terms of elevated dielectric coefficient (an increase of 202%), surface potential (up to 5.8 kV), and triboelectric properties (output voltage of 30.8 V at 10 N, 0.5 Hz). Given the profound control over morphology and electroactivity, the PLA@ZIF-8 NFMs exhibited efficient filtration of PM0.3 (97.1%, 85 L/min) with a decreased air resistance (592.5 Pa), surpassing that of the pure PLA counterpart (88.4%, 650.9 Pa). This was essentially ascribed to realization of multiple filtration mechanisms for PLA@ZIF-8 NFMs, including enhanced physical interception, polar interactions, and electrostatic adsorption, and the unique self-charging function triggered by airflow vibrations. Moreover, perfect antibacterial performance was achieved for PLA@ZIF-8, showing ultrahigh inhibition rates of 99.9 and 100% against E. coli and S. aureus, respectively. The proposed hierarchical structuring strategy, offering the multifunction integration unattainable with conventional methods, may facilitate the development of biodegradable long-term air filters.

Development of an asymmetric composite PPS-based bag-filter material through membrane laminating and superfine fiber blending: Lab test, field application and development of numerical models

Dedusting is crucial for air pollution control, and nonwoven needle felt (NWNF) bag-filters are widely applied for this purpose. Surface treatment of the filter materials can enhance NWNF's performance, but the large discrepancy in pore size between the surface and NWNF layers causes interface effects, impairing reverse cleaning and shortening service life. In this study, a novel PTFE membrane-laminated asymmetrical composite bag-filter was developed, by blending superfine polyphenylene sulfide fiber (PPS) in the original NWNF structure. Image analysis shows a gradual increase in pore size from the surface to the downstream layer. In standard lab-scale tests, the novel M-PPSF-S filter showed moderately higher resistance, significantly longer service life, higher dedusting efficiencies and better cleaning performance, compared to filters without surface laminating and/or superfine fiber blending. Numerical modelling was performed, and the flow fields and pressure distribution in these filter materials were visualized, confirming that M-PPSF-S' unique structure facilitated the alleviation of interface effect and non-steady flow. M-PPSF-S was further scaled up to treat real flue gas from a coal-fired power plant, where constant good performance was observed over 5 months. This study offers a novel and practical way to develop low-cost, high-performance filter materials for high temperature flue gas treatment.

Electrospun PA6 Nanofibers Bearing the CeO2 Dephosphorylation Catalyst

Two types of CeO₂ nanoparticles (CeNPs) prepared by low-temperature (<100 °C) precipitation methods in water were successfully immobilized in a matrix of electrospun PA6 nanofibers. The colloidal solutions of CeNPs in AcOH were directly mixed with the polymer solution before the needle electrospinning process, thereby achieving their good dispersion in the nanofibers. CeNPs embedded in the structure and on the surface of nanofibers exposing their reactive surfaces showed robust dephosphorylation catalytic activity, as demonstrated by monitoring the hydrolytic cleavage of three phosphodiester molecules (p-NP-TMP, p-NPPC, BNPP) in water by the HPLC method. This procedure allowed us to study the kinetics and mechanism of the hydrolytic cleavage and the ability of immobilized CeNPs to cleave different types of P-O bonds. One of the main hydrolysis products, p-nitrophenol, was effectively adsorbed on PA6 nanofibers, which may allow the selective separation of the degradation products after hydrolysis.

Nanofibers in Respiratory Masks: An Alternative to Prevent Pathogen Transmission

Recent global outbreak of COVID-19 has raised serious awareness about our abilities to protect ourselves from hazardous pathogens and volatile organic compounds. Evidence suggests that personal protection equipment such as respiratory masks can radically decrease rates of transmission and infections due to contagious pathogens. To increase filtration efficiency without compromising breathability, application of nanofibers in production of respiratory masks have been proposed. The emergence of nanofibers in the industry has since introduced a next generation of respiratory masks that promises improved filtration efficiency and breathability via nanometric pores and thin fiber thickness. In addition, the surface of nanofibers can be functionalized and enhanced to capture specific particles. In addition to conventional techniques such as melt-blown, respiratory masks by nanofibers have provided an opportunity to prevent pathogen transmission. As the surge in global demand for respiratory masks increases, herein, we reviewed recent advancement of nanofibers as an alternative technique to be used in respiratory mask production.

Electroactive, Antibacterial, and Biodegradable Poly(lactic acid) Nanofibrous Air Filters for Healthcare

Poly(lactic acid) (PLA)-based nanofibrous membranes (NFMs) hold great potential in the field of biodegradable filters for air purification but are largely limited by the relatively low electret properties and high susceptibility to bacteria. Herein, we disclosed a facile approach to the fabrication of electroactive and antibacterial PLA NFMs impregnated with a highly dielectric photocatalyst. In particular, the microwave-assisted doping (MAD) protocol was employed to yield Zn-doped titanium dioxide (Zn-TIO), featuring the well-defined anatase phase, a uniform size of ∼65 nm, and decreased band gap (3.0 eV). The incorporation of Zn-TIO (2, 6, and 10 wt %) into PLA gave rise to a significant refinement of the electrospun nanofibers, decreasing from the highest diameter of 581 nm for pure PLA to the lowest value of 264 nm. More importantly, dramatical improvements in the dielectric constants, surface potential, and electret properties were simultaneously achieved for the composite NFMs, as exemplified by a nearly 94% increase in surface potential for 3-day-aged PLA/Zn-TIO (90/10) compared with that of pure PLA. The well regulation of morphological features and promotion of electroactivity contributed to a distinct increase in the air filtration performance, as demonstrated by 98.7% filtration of PM_0.3 with the highest quality factor of 0.032 Pa^-1 at the airflow velocity of 32 L/min for PLA/Zn-TIO (94/6), largely surpassing pure PLA (89.4%, 0.011 Pa^-1). Benefiting from the effective generation of reactive radicals and gradual release of Zn²⁺ by Zn-TIO, the electroactive PLA NFMs were ready to profoundly inactivate Escherichia coli and Staphylococcus epidermidis. The exceptional combination of remarkable electret properties and excellent antibacterial performance makes the PLA membrane filters promising for healthcare.

PTFE/PVA-PVDF Conjugated Electrospun Nanofiber Membrane with Triboelectric Effect Used in Face Mask

COVID-19 broke out all over the world, and the medical protective mask is an important epidemic prevention equipment. Traditional medical protective masks use electret polypropylene melt-blown cloth as the core filter material. However, it relies heavily on electrostatic filtration and has high filtration resistance. The one-time electret makes the static charge decay rapidly with the water vapor generated by breathing, which affects the service life of the mask. In this paper, PTFE/PVA fiber and PVDF fiber were fabricated by conjugate electrospinning method, and the PTFE/PVA-PVDF layer blending fluffy fiber membrane was obtained by on-line mixing. Under the action of air slip effect and triboelectric secondary electret, the fiber membrane has higher filtration efficiency, lower filtration resistance and longer service life. The initial filtration efficiency of the fiber membrane is above 95%, the filtration efficiency is near to 100% after 24 times of cyclic filtration, the filtration resistance is about 110 Pa, the air permeability of the fiber membrane is 262.88–370.70 mm/s, and the moisture permeability is as high as 7721–8471 g/ (m2·24 h).

A Novel Vision of Reinforcing Nanofibrous Masks with Metal Nanoparticles: Antiviral Mechanisms Investigation

Prevention of spreading viral respiratory disease, especially in case of a pandemic such as coronavirus disease of 2019 (COVID-19), has been proved impossible without considering obligatory face mask-wearing protocols for both healthy and contaminated populations. The widespread application of face masks for long hours and almost everywhere increases the risks of bacterial growth in the warm and humid environment inside the mask. On the other hand, in the absence of antiviral agents on the surface of the mask, the virus may have a chance to stay alive and be carried to different places or even put the wearers at risk of contamination when touching or disposing the masks. In this article, the antiviral activity and mechanism of action of some of the potent metal and metal oxide nanoparticles in the role of promising virucidal agents have been reviewed, and incorporation of them in an electrospun nanofibrous structure has been considered an applicable method for the fabrication of innovative respiratory protecting materials with upgraded safety levels.

Graphical Abstract

Simple fabrication of an electrospun polystyrene microfiber filter that meets N95 filtering facepiece respirator filtration and breathability standards

During the global spread of COVID-19, high demand and limited availability of melt-blown filtration material led to a manufacturing backlog of N95 Filtering Facepiece Respirators (FFRs). This shortfall prompted the search for alternative filter materials that could be quickly mass produced while meeting N95 FFR filtration and breathability performance standards. Here, an unsupported, nonwoven layer of uncharged polystyrene (PS) microfibers was produced via electrospinning that achieves N95 performance standards based on physical parameters (e.g., filter thickness) alone. PS microfibers 3-6 μm in diameter and deposited in an ~5 mm thick filter layer are favorable for use in FFRs, achieving high filtration efficiencies (≥97.5%) and low pressure drops (≤15 mm H2O). The PS microfiber filter demonstrates durability upon disinfection with hydroxyl radicals (•OH), maintaining high filtration efficiencies and low pressure drops over six rounds of disinfection. Additionally, the PS microfibers exhibit antibacterial activity (1-log removal of E. coli) and can be modified readily through integration of silver nanoparticles (AgNPs) during electrospinning to enhance their activity (≥3-log removal at 25 wt% AgNP integration). Because of their tunable performance, potential reusability with disinfection, and antimicrobial properties, these electrospun PS microfibers may represent a suitable, alternative filter material for use in N95 FFRs.

Multi-Unit Needleless Electrospinning for One-Step Construction of 3D Waterproof MF-PVA Nanofibrous Membranes as High-Performance Air Filters

The airborne particulate matter (PM) seriously threatens people's health. Personal protective equipment with electrospun nanofibers is an effective method to make people away from air pollutants. Herein, 3D waterproof melamine-formaldehyde polyvinyl alcohol (MF-PVA) nanofibrous membranes are fabricated by a one-step method combining multi-unit needleless electrospinning and a thermal treatment device in a line. 3D nanofibrous structures can be controlled by adjusting the solution concentration of each unit. The PVA nanofibrous membranes become waterproof after cross-linking with MF resin in the following thermal treatment device. The optimized MF-PVA nanofibrous membrane shows excellent air filtration performance (97.3% for PM_0.3 , 100% for PM_1.0 , and 100% for PM_2.5 ) and low air resistance (76 Pa). These 3D waterproof MF-PVA nanofibrous membranes exhibit ultra-stable performance in various practical environments.

Nude and Modified Electrospun Nanofibers, Application to Air Purification

Air transports several pollutants, including particulate matter (PM), which can produce cardiovascular and respiratory diseases. Thus, it is a challenge to control pollutant emissions before releasing them to the environment. Until now, filtration has been the most efficient processes for removing PM. Therefore, the electrospinning procedure has been applied to obtain membranes with a high filtration efficiency and low pressure drop. This review addressed the synthesis of polymers that are used for fabricating high-performance membranes by electrospinning to remove air pollutants. Then, the most influential parameters to produce electrospun membranes are indicated. The main results show that electrospun membranes are an excellent alternative to having air filters due to the versatility of the process, the capacity for controlling the fiber diameter, porosity, high filtration efficiency and low-pressure drop.

Aerosol Filtration Performance of Solution Blown PA6 Webs with Bimodal Fiber Distribution

A bimodal web, where both nanofibers and microfibers are present and distributed randomly across the same web, can deliver high filter efficiency and low pressure drop at the same time since in such a web, filter efficiency is high thanks to small pores created by the presence of nanofibers and the interfiber space created by the presence of microfibers, which is large enough for air to flow through with little resistance. In this work, a bimodal polyamide 6 (PA6) filter web was fabricated via a modified solution blowing (m-SB) technique that produced nanofibers and microfibers simultaneously. Scanning electron microscope (SEM) images of the webs were used to analyze the fiber morphology. Additionally, air permeability, solidity, porosity, filtration performance, and tensile strength of the samples were measured. The bimodal filter web consisted of nanofibers and microfibers with average diameters of 81.5 ± 127 nm and 1.6 ± 0.458 μm, respectively. Its filter efficiency, pressure drop at 95 L min^-1, and tensile strength were 98.891%, 168 Pa, and 0.1 MPa, respectively. Its quality factor (QF) and tensile strength were 0.0268 Pa^-1 and 0.1 MPa, respectively. When compared with commercially available filters, the bimodal web produced had superior filter performance, constituting a suitable alternative for air filter applications.

High-performance multifunctional electrospun fibrous air filter for personal protection: A review

With the increasingly serious air pollution and the rampant coronavirus disease 2019 (COVID–19), preparing high–performance air filter to achieve the effective personal protection has become a research hotspot. Electrospun nanofibrous membrane has become the first choice of air filter because of its small diameter, high specific surface area and porosity. However, improving the filtration performance of the filter only cannot meet the personal needs: it should be given more functions based on high filtration performance to maximize the personal benefits, called, multifunctional, which can also be easily realized by electrospinning technology, and has attracted much attention. In this review, the filtration mechanism of high–performance electrospun air filter is innovatively summarized from the perspective of membrane. On this basis, the specific preparation process, advantages and disadvantages are analyzed in detail. Furthermore, other functions required for achieving maximum personal protection benefits are introduced specifically, and the existing high–performance electrospun air filter with multiple functions are summarized. Finally, the challenges, limitations, and development trends of manufacturing high–performance air filter with multiple functions for personal protection are presented.

Nanoporous Atomically Thin Graphene Filters for Nanoscale Aerosols

Filtering nanoparticulate aerosols from air streams is important for a wide range of personal protection equipment (PPE), including masks used for medical research, healthcare, law enforcement, first responders, and military applications. Conventional PPEs capable of filtering nanoparticles <300 nm are typically bulky and sacrifice breathability to maximize protection from exposure to harmful nanoparticulate aerosols including viruses ∼20-300 nm from air streams. Here, we show that nanopores introduced into centimeter-scale monolayer graphene supported on polycarbonate track-etched supports via a facile oxygen plasma etch can allow for filtration of aerosolized SiO₂ nanoparticles of ∼5-20 nm from air steams while maintaining air permeance of ∼2.28-7.1 × 10^-5 mol m^-2 s^-1 Pa^-1. Furthermore, a systematic increase in oxygen plasma etch time allows for a tunable size-selective filtration of aerosolized nanoparticles. We demonstrate a new route to realize ultra-compact, lightweight, and conformal form-factor filters capable of blocking sub-20 nm aerosolized nanoparticles with particular relevance for biological/viral threat mitigation.

HEPA filters for airliner cabins: State of the art and future development

The airliner cabin environment is very important to the health of passengers and crew members, and the use of high-efficiency particulate air (HEPA) filters for recirculated air in the environmental control systems (ECS) is essential for the removal of airborne particles such as SARS CoV-2 aerosols. A HEPA filter should be high efficiency, low-pressure drop, high dust-holding capacity (DHC), lightweight, and strong for use in aircraft. We conducted an experimental study on 23 HEPA filters with glass fiber media that are used in different commercial airliner models. The tested filters had a median filtration efficiency of >99.97% for particles with a diameter of 0.3-0.5 μm, a pressure drop of 134-412 Pa at rated airflow rate, and a DHC of 32.2-37.0 g/m² . The use of nanofiber media instead of glass fiber media can reduce the pressure drop by 66.4%-94.3% and significantly increase the quality factor by analysis of literature data. The disadvantages of poor fire resistance and small DHC can be overcome by the use of flame-retardant polymers and fiber structural design. As a new lightweight and environmentally friendly filter material, nanofiber media could be used as air filters in ECS in the future.

Biomimetic Fibrous Leaf-Vein Membrane Enabling Unidirectional Water Penetration and Effective Antibacterial PM Filtration

Air pollution induced by pathogenic particulate matter (PM) has posed a serious threat to public health worldwide. Advanced air filters are thus required, not only exhibiting high PM capture efficiency, low breathing resistance, and high internal moisture transferring performance but also isolating and inactivating external pathogenic aerosols. In this study, we demonstrated a facile approach to construct a biomimetic fibrous leaf-vein membrane with unidirectional water penetration and effective antibacterial PM filtration by one-step electrospinning of poly(vinylidene fluoride) (PVDF)-based multilayer nanofibers. With ultrathin fibers penetrating the skeletal framework of bimodal thick fibers, the membranes showed gradient interconnected porous structures and achieved a highly efficient and stable (in an acid and alkali environment) PM_0.3 interception (>99.98%) with low air drag (51-71 Pa). In addition, the gradient narrow pores of the membranes contributed to a gradient higher hydrophilicity. The subsequent unidirectional water motion effectively isolates pathogenic aerosols typically generated by external individuals or ultrafast water penetration from the inverse face. Moreover, the membranes demonstrated an antibacterial efficacy (>99.99%) in a 5 min contact, inactivating the intercepted airborne pathogens efficiently. The test results proved that the proposed membranes were promising advanced air filters for respirator applications.

Multilevel structured PASS nanofiber filter with outstanding thermal stability and excellent mechanical property for high-efficiency particulate matter removal

Particulate matter (PM) pollution from industrialization poses a great threat to people's health. Although fiber-based filters are used effectively to capture PM, the traditional filters with large diameter suffer from low filtration efficiency, high pressure drop and low temperature resistance. In this study, multilayer poly arylene sulfide sulfone (M-PASS) composite filter was designed and fabricated via electrospinning technology. The M-PASS composite filter is sandwich-structure. Due to the unique structure and composition, the M-PASS filter exhibited outstanding removal efficiency of 99.97 ± 0.0050%, extremely low air resistance of 44.3 ± 0.7 Pa, excellent quality factor (QF) of 0.19 ± 0.0019 Pa^-1, and desirable mechanical strength of 7.0 ± 0.2 MPa. Furthermore, the as-prepared M-PASS filter can remain outstanding filtration performance at 200.0 ℃ due to the high thermal stability of PASS and the removal efficiency was still above 95.2 ± 0.4% after long-term filtration test. These results demonstrate that the structure of filter is the important one for air filtration and the M-PASS nanofiber filters have great potential in PM removal, especially under high temperature conditions.

2D Polymer Nanonets: Controllable Constructions and Functional Applications

Two-dimensional (2D) polymer nanonets have demonstrated great potential in various application fields due to their integrated advantages of ultrafine diameter, small pore size, high porosity, excellent interconnectivity, and large specific surface area. Here, a comprehensive overview of the controlled constructions of the polymer nanonets derived from electrospinning/netting, direct electronetting, self-assembly of cellulose nanofibers, and nonsolvent-induced phase separation is provided. Then, the widely researched multifunctional applications of polymer nanonets in filtration, sensor, tissue engineering, and electricity are also given. Finally, the challenges and possible directions for further developing the polymer nanonets are also intensively highlighted. This article is protected by copyright. All rights reserved.

Functional Mesostructured Electrospun Polymer Nonwovens with Supramolecular Nanofibers

Functional, hierarchically mesostructured nonwovens are of fundamental importance because complex fiber morphologies increase the active surface area and functionality allowing for the effective immobilization of metal nanoparticles. Such complex functional fiber morphologies clearly widen the property profile and enable the preparation of more efficient and selective filter media. Here, we demonstrate the realization of hierarchically mesostructured nonwovens with barbed wire-like morphology by combining electrospun polystyrene fibers, decorated with patchy worm-like micelles, with solution-processed supramolecular short fibers composed of 1,3,5-benzenetricarboxamides with peripheral N,N-diisopropylaminoethyl substituents. The worm-like micelles with a patchy microphase-separated corona were prepared by crystallization-driven self-assembly of a polyethylene based triblock terpolymer and deposited on top of the polystyrene fibers by coaxial electrospinning. The micelles were designed in a way that their patches promote the directed self-assembly of the 1,3,5-benzenetricarboxamide and the fixation of the supramolecular nanofibers on the supporting polystyrene fibers. Functionality of the mesostructured nonwoven is provided by the peripheral N,N-diisopropylaminoethyl substituents of the 1,3,5-benzenetricarboxamide and proven by the effective immobilization of individual palladium nanoparticles on the supramolecular nanofibers. The preparation of hierarchically mesostructured nonwovens and their shown functionality demonstrate that such systems are attractive candidates to be used for example in filtration, selective separation and heterogenous catalysis. This article is protected by copyright. All rights reserved.

Electrical conductivity and thermal stability of surface-modified multiwalled carbon nanotubes/polysulfone/poly(p-phenylenediamine) composites

Multiwalled carbon nanotubes (MWCNTs) were functionalized with acid then coated with poly(p-phenylenediamine) (PpPD). Various concentrations of modified multiwalled carbon nanotubes (MWCNTs@PpPD) were introduced to a polysulfone (PSU) and poly(p-phenylenediamine) (PpPD) blend providing nanocomposites in form of sheets. Chemical oxidative polymerization was used to polymerize p-phenylenediamine. PpPD is then applied as a compatibilizer in such heterogeneous system to facilitate a successful percolation for MWCNTs in the polymeric matrix as an enhanced conductive filler. The morphological investigations showed homogeneous distribution for MWCNTs in the polymeric matrix. The prepared composites were investigated demonstrating favorable thermal and electrical properties. Thermogravimetric analysis (TGA) emphasized that MWCNTs@PpPD contributed in enhancing the thermal stability of the prepared sheets. The electrical conductivity of PSU/PpPD/MWCNTs@PpPD nanocomposites boosted upon raising the magnitude of loaded MWCNTs. The existence of MWCNTs@PpPD in the polymeric matrix extended the interfacial polarization effects with elevating the conductance. The loaded composite with (7.5 wt%) MWCNTs@PpPD showed the optimum electrical conductivity values. It was then treated with HCl to protonate the amine groups in PpPD showing higher conductivity value than its corresponding untreated one. PpPD and MWCNTs contributed synergistically in modifying the insulation feature of PSU to a favorable electrical conductivity one.

Efficacy of facemasks in mitigating respiratory exposure to submicron aerosols

We designed a novel experimental set-up to pseudo-simultaneously measure size-segregated filtration efficiency (η_F), breathing resistance (η_P) and potential usage time (t_B) for 11 types of face protective equipment (FPE; four respirators; three medical; and four handmade) in the submicron range. As expected, the highest η_F was exhibited by respirators (97 ± 3%), followed by medical (81 ± 7%) and handmade (47 ± 13%). Similarly, the breathing resistance was highest for respirators, followed by medical and handmade FPE. Combined analysis of efficiency and breathing resistance highlighted trade-offs, i.e. respirators showing the best overall performance across these two indicators, followed by medical and handmade FPE. This hierarchy was also confirmed by quality factor, which is a performance indicator of filters. Detailed assessment of size-segregated aerosols, combined with the scanning electron microscope imaging, revealed material characteristics such as pore density, fiber thickness, filter material and number of layers influence their performance. η_F and η_P showed an inverse exponential decay with time. Using their cross-over point, in combination with acceptable breathability, allowed to estimate t_B as 3.2-9.5 h (respirators), 2.6-7.3 h (medical masks) and 4.0-8.8 h (handmade). While relatively longer t_B of handmade FPE indicate breathing comfort, they are far less efficient in filtering virus-laden submicron aerosols compared with respirators.

Multi-layered micro/nanofibrous nonwovens for functional face mask filter

The worldwide COVID-19 pandemic has led to an attention on the usage of personal protective face masks. However, the longevity and safety of the commercial face masks are limited due to the charge dissipation of the electret meltblown nonwovens, which are dominate in the face mask filters. Herein, we design a type of multi-layer structured nonwovens using meltblowing and electrospinning technologies. The complex nonwovens involving meltblown and electrospun fibers are designed to possess multilevel fiber diameters and pore sizes. The micro/nanofibers with porous and wrinkled surface morphologies can well capture particulate matters (PMs), and the multilevel pore sizes contribute to low air resistance under high filtration efficiency. Airflow field simulation was carried out to understand the pressure distribution within the nonwovens in the filtration process. Meanwhile, by adding Ag nanoparticles (AgNPs) as additives, the nonwovens exhibit excellent antibacterial performance. The resultant nonwovens exhibit filtration efficiency of 99.1% for PM_0.3 and low pressure drop of 105 Pa under the 10.67 cm/s inlet air velocity, and antibacterial rate of > 99.99% for Escherichia coli. These performances and functions make the designed complex nonwovens a promising filter core for face masks.

ELECTRONIC SUPPLEMENTARY MATERIAL

Supplementary material (Fig. S1. The filtration efficiencies of a brand of surgical mask changes with the storage time under the condition of 100% humidity. Fig. S2. The FE-SEM images of the fibers after blocking PMs. Fig. S3. Illustration of 3D structure models of the nonwovens. Fig. S4. Diameter distribution of AgNPs. Table S1. The structure parameters and filtration performances of the PP-M fibers with and without pores and wrinkles. Table S2. Filtration performance of PP-M/PLA-M/PLA-N nonwovens and commercial face masks. Table S3. The structural parameters for the nonwovens. Table S4. The filtration efficiencies and pressure drops of the PP, PE spunbonded nonwovens, and PP-M/PLA-M/PLA-N@AgNPs nonwovens) is available in the online version of this article at 10.1007/s12274-022-4350-2.

Sequential Multiscale Simulation of a Filtering Facepiece for Prediction of Filtration Efficiency and Resistance in Varied Particulate Scenarios

This study explores a novel approach of multiscale modeling and simulation to characterize the filtration behavior of a facepiece in varied particulate conditions. Sequential multiscale modeling was performed for filter media, filtering facepiece, and testing setup. The developed virtual models were validated for their morphological characteristics and filtration performance by comparing with the data from the physical experiments. Then, a virtual test was conducted in consideration of a time scale, simulating diverse particulate environments with different levels of particle size distribution, particle concentration, and face velocity. An environment with small particles and high mass concentration resulted in a rapid buildup of resistance, reducing the service life. Large particles were accumulated mostly at the entrance of the filter layer, resulting in a lower penetration and slower buildup of resistance. This study is significant in that the adopted virtual approach enables the prediction of filtration behavior and service life, applying diverse environmental conditions without involving the costs of extra setups for the physical experiments. This study demonstrates a novel and economic research method that can be effectively applied to the research and development of filters.

Bicomponent PLA Nanofiber Nonwovens as Highly Efficient Filtration Media for Particulate Pollutants and Pathogens

Herein, a novel form of bicomponent nanofiber membrane containing stereo-complex polylactic acid (SC-PLA) was successfully produced by the side-by-side electrospinning of Poly (L-lactic acid) (PLLA) and Poly (D-lactic acid) (PDLA). We demonstrate that through these environmentally sustainable materials, highly efficient nanofiber assemblies for filtration can be constructed at very low basis weight. The physical and morphological structure, crystalline structure, hydrophobicity, porous structure, and filtration performance of the fibrous membranes were thoroughly characterized. It was shown that the fabricated polylactic acid (PLA) side-by-side fiber membrane had the advantages of excellent hydrophobicity, small average pore size, high porosity, high filtration efficiency, low pressure drop as well as superior air permeability. At the very low basis weight of 1.1 g/m², the filtration efficiency and pressure drop of the prepared side-by-side membrane reached 96.2% and 30 Pa, respectively. Overall, this biomass-based, biodegradable filtration material has the potential to replace the fossil fuel-based polypropylene commercial meltblown materials for the design and development in filtration, separation, biomedical, personal protection and other fields.

Porous Fibers Templated by Melt Blowing Cocontinuous Immiscible Polymer Blends

We report a scalable melt blowing method for producing porous nonwoven fibers from model cocontinuous polystyrene/high-density polyethylene polymer blends. While conventional melt compounding of cocontinuous blends typically produces domain sizes ∼1-10 μm, melt blowing these blends into fibers reduces those dimensions up to 35-fold and generates an interpenetrating domain structure. Inclusion of ≤1 wt % of a block copolymer compatibilizer in these blends crucially enables access to smaller domain sizes in the fibers by minimizing thermodynamically-driven blend coarsening inherent to cocontinuous blends. Selective solvent extraction of the sacrificial polymer phase yielded a network of porous channels within the fibers. Fiber surfaces also exhibited pores that percolate into the fiber interior, signifying the continuous and interconnected nature of the final structure. Pore sizes as small as ∼100 nm were obtained, suggesting potential applications of these porous nonwovens that rely on their high surface areas, including various filtration modules.

Effect of Nanoclay Addition on the Morphology, Fiber Size Distribution and Pore Size of Electrospun Polyvinylpyrrolidone (PVP) Composite Fibers for Air Filter Applications

The fabrication of Polyvinylpyrrolidone (PVP) electrospun layers for air filter applications is the target of this study. Solutions of 10% PVP containing 0, 3, 10 and 25 wt% nanoclay were used to fabricate electrospun fibers. Scanning electron microscopy showed that the fibers’ roughness increased by increasing the nanoclay content, and it was maximum at the nanoclay concentration of 25 wt%. Concurrently, nanoclay decreased the pore size considerably and increased the range of the fibers’ size distribution up to 100%. In addition, as the nanoclay concentration increased, the frequency distribution decreased abruptly for the larger fiber sizes and increased dramatically for the small fiber sizes. This phenomenon was correlated to the effect of nanoclay concentration on the conductivity of the solution. The solution’s conductivity increased from 1.7 ± 0.05 µS/cm for the PVP solution without nanoclay to 62.7 ± 0.19 µS/cm for the solution containing 25 wt% nanoclay and destabilized the electrospun jet, increasing the range of fiber size distribution. Therefore, the PVP solution containing 25 wt% nanoclay has potential characteristics suitable for air-filter applications, owing to its rougher fibers and combination of fine and thicker fibers.

Multistructured Electrospun Nanofibers for Air Filtration: A Review

Air filtration materials (AFMs) have gradually become a research hotspot on account of the increasing attention paid to the global air quality problem. However, most AFMs cannot balance the contradiction between high filtration efficiency and low pressure drop. Electrospinning nanofibers have a large surface area to volume ratio, an adjustable porous structure, and a simple preparation process that make them an appropriate candidate for filtration materials. Therefore, electrospun nanofibers have attracted increased attention in air filtration applications. In this paper, first, the preparation methods of high-performance electrospun air filtration membranes (EAFMs) and the typical surface structures and filtration principles of electrospun fibers for air filtration are reviewed. Second, the research progress of EAFMs with multistructures, including nanoprotrusion, wrinkled, porous, branched, hollow, core-shell, ribbon, beaded, nets structure, and the application of these nanofibers in air filtration are summarized. Finally, challenges with the fabrication of EAFMs, limitations of their use, and trends for future developments are presented.

Filtering efficiency measurement of respirators by laser-based particle counting method

Respirators are one of the most useful personal protective equipment which can effectively limit the spreading of coronavirus (COVID-19). There are a worldwide shortage of respirators, melt-blown non-woven fabrics, and respirator testing possibilities. An easy and fast filtering efficiency measurement method was developed for testing the filtering materials of respirators. It works with a laser-based particle counting method, and it can determine two types of filtering efficiencies: Particle Filtering Efficiency (PFE) at given particle sizes and Concentration Filtering Efficiency (CFE) in the case of different aerosols. The measurement method was validated with different aerosol concentrations and with etalon respirators. Considerable advantages of our measurement method are simplicity, availability, and the relatively low price compared to the flame-photometer based methods. The ability of the measurement method was tested on ten different types of Chinese KN95 respirators. The quality of these respirators differs much, only two from ten reached 95% filtering efficiency.

Three-dimensional composite electrospun nanofibrous membrane by multi-jet electrospinning with sheath gas for high-efficiency antibiosis air filtration

Three-dimensional (3D) composite polyvinylidene fluoride (PVDF)/polyacrylonitrile (PAN) electrospun nanofibrous membranes combining both thick and thin nanofibers have been fabricated by the method of multi-jet electrospinning with sheath gas to realize high-efficiency air filtration under a low pressure drop. The thin PAN nanofibers form a dense membrane, with a strong capturing ability on the ultra-fine particles, while the thick PVDF nanofibers play a 3D supporting effect on the thin PAN nanofibers. In this case, the combination results in a fluffy membrane with higher porosity, which could achieve the airflow passing through the membrane without the air pressure drop. The effects of the composite manner of thick nanofibers and thin nanofibers are investigated, in order to optimize the air filtration performance of the 3D composite nanofibrous membrane. As a result, the maximum quality factor for air filtration could reach up to 0.398 Pa^-1. The particle-fiber interaction model was used to simulate the air filtration process as well, and the simulation results were fairly consistent with the experimental results, providing a guidance method for the optimization of composite nanofibrous membrane for high-efficiency air filtration. More interestingly, a cationic poly[2-(N,N-dimethyl amino) ethyl methacrylate] (PDMAEMA) was added in the PVDF solution to obtain a composite air filtration membrane with excellent antibiosis performance, which achieved the highest inhibition rate of approximately 90%. In short, this work provides an effective way to promote antibiosis air filtration performance by using an electrospun nanofibrous membrane, and might also effectively accelerate the biological protection application of current air filtration membranes.

Biodegradable, Efficient, and Breathable Multi-Use Face Mask Filter

The demand for face masks is increasing exponentially due to the coronavirus pandemic and issues associated with airborne particulate matter (PM). However, both conventional electrostatic- and nanosieve-based mask filters are single-use and are not degradable or recyclable, which creates serious waste problems. In addition, the former loses function under humid conditions, while the latter operates with a significant air-pressure drop and suffers from relatively fast pore blockage. Herein, a biodegradable, moisture-resistant, highly breathable, and high-performance fibrous mask filter is developed. Briefly, two biodegradable microfiber and nanofiber mats are integrated into a Janus membrane filter and then coated by cationically charged chitosan nanowhiskers. This filter is as efficient as the commercial N95 filter and removes 98.3% of 2.5 µm PM. The nanofiber physically sieves fine PM and the microfiber provides a low pressure differential of 59 Pa, which is comfortable for human breathing. In contrast to the dramatic performance decline of the commercial N95 filter when exposed to moisture, this filter exhibits negligible performance loss and is therefore multi-usable because the permanent dipoles of the chitosan adsorb ultrafine PM (e.g., nitrogen and sulfur oxides). Importantly, this filter completely decomposes within 4 weeks in composting soil.

Formation and Photoluminescence Properties of ZnO Nanoparticles on Electrospun Nanofibers Produced by Atomic Layer Deposition

The unique combination of optical, chemical, and structural properties of one-dimensional zinc oxide (1D ZnO) makes it one of the most attractive materials in a wide range of research and applications. In the present study, 1D ZnO nanomaterials were fabricated using a combination of two independent methods: electrospinning and atomic layer deposition (ALD). The electrospinning technique was used to produce 1D electrospun fibers consisting of four types of polymers: polylactic acid (PLLA), polyvinylidene fluoride (PVDF), polyvinyl alcohol (PVA), and polyamide 6 (PA6). The ALD technology, in turn, was selected as an excellent candidate for the synthesis of a ZnO thin layer over polymer fibers for the production of 1D ZnO/polymer nanofiber composites (PLLA/ZnO, PVDF/ZnO, PVA/ZnO, PA6/ZnO). Structural and optical properties of the produced nanofibers were studied by means of scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), diffuse reflectance, and photoluminescence (PL) spectroscopy. It was found that only PVDF/ZnO nanofibers exhibit stable room temperature PL that may be the result of a higher ZnO content in the sample. In addition, PL measurements were conducted as a function of excitation power and temperature in order to establish the main PL mechanisms and parameters for the PVDF/ZnO sample, as a most promising candidate for the biophotonic application.

Sustainable Personal Protective Clothing for Healthcare Applications: A Review

Personal protective equipment (PPE) is critical to protect healthcare workers (HCWs) from highly infectious diseases such as COVID-19. However, hospitals have been at risk of running out of the safe and effective PPE including personal protective clothing needed to treat patients with COVID-19, due to unprecedented global demand. In addition, there are only limited manufacturing facilities of such clothing available worldwide, due to a lack of available knowledge about relevant technologies, ineffective supply chains, and stringent regulatory requirements. Therefore, there remains a clear unmet need for coordinating the actions and efforts from scientists, engineers, manufacturers, suppliers, and regulatory bodies to develop and produce safe and effective protective clothing using the technologies that are locally available around the world. In this review, we discuss currently used PPE, their quality, and the associated regulatory standards. We survey the current state-of-the-art antimicrobial functional finishes on fabrics to protect the wearer against viruses and bacteria and provide an overview of protective medical fabric manufacturing techniques, their supply chains, and the environmental impacts of current single-use synthetic fiber-based protective clothing. Finally, we discuss future research directions, which include increasing efficiency, safety, and availability of personal protective clothing worldwide without conferring environmental problems.