Surface Energy of Filtration Media Influencing the Filtration Performance against Solid Particles, Oily Aerosol, and Bacterial Aerosol

Electrospun PA6 multi-stage structured nanofiber membrane with high filtration performance for oily particles

Oily particles pollution poses a tremendous threat to people's health, so it is urgent to develop air filtration materials with the ability of removing fine oily particles effectively. In this study, a nylon 6 multi-stage structured nanofiber membrane (PA6 MSNM) for effective air filtration of fine oily particles was designed and fabricated by adding a certain amount of tetrabutylammonium hexafluorophosphate (TBAHP) via one-step electrospinning. The PA6 MSNMs were composed of coarse trunk fibres and fine branching fibres. Benefiting from the properties of small pore size and high porosity, the resulting PA6 MSNMs exhibited high average filtration efficiency of 99.80% for oily aerosol particles of 0.20-4.59 μm, a low pressure drop of 251 Pa, and the high quality factor of 0.0248 Pa-1. More importantly, its filtration efficiencies for oily aerosol particles of 0.25 and 0.30 μm were up to 99.99% and 100.00%, respectively. It is expected that the multi-stage electrospun nanofiber membranes would have wide application prospects in air filtration, particularly for filtering oily particles.

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.

Bacteria Adhesion of Textiles Influenced by Wettability and Pore Characteristics of Fibrous Substrates

Bacteria adhesion on the surface is an initial step to create biofouling, which may lead to a severe infection of living organisms and humans. This study is concerned with investigating the textile properties including wettability, porosity, total pore volume, and pore size in association with bacteria adhesion. As model bacteria, Gram-negative, rod-shaped Escherichia coli and the Gram-positive, spherical-shaped Staphylococcus aureus were used to analyze the adhesion tendency. Electrospun webs made from polystyrene and poly(lactic acid) were used as substrates, with modification of wettability by the plasma process using either O2 or C4F8 gas. The pore and morphological characteristics of fibrous webs were analyzed by the capillary flow porometer and scanning electron microscopy. The substrate's wettability appeared to be the primary factor influencing the cell adhesion, where the hydrophilic surface resulted in considerably higher adhesion. The pore volume and the pore size, rather than the porosity itself, were other important factors affecting the bacteria adherence and retention. In addition, the compact spatial distribution of fibers limited the cell intrusion into the pores, reducing the total amount of adherence. Thus, superhydrophobic textiles with the reduced total pore volume and smaller pore size would circumvent the adhesion. The findings of this study provide informative discussion on the characteristics of fibrous webs affecting the bacteria adhesion, which can be used as a fundamental design guide of anti-biofouling textiles.

Enhancing the filtration efficiency and wearing time of disposable surgical masks using TENG technology

The COVID-19 pandemic has caused an unprecedented human and health crisis. And the shortage of protective equipment, especially the personal protective disposable surgical masks, has been a great challenge. Here, we developed an effective and simple scheme to prolong the lifetime of disposable surgical masks without changing their current structure, which is beneficial to solve the shortage of personal masks. After electrifying the meltblown PP filter by the new-developed single-electrode-based sliding triboelectric nanogenerator (TENG) charge replenishment (NGCR) technology, the processed filter is bipolar charged and has a filtration efficiency beyond 95% for the particulate matter (PM) ranging from PM0.3 to PM10.0. Further, we demonstrate the 80 °C dry heating is an effective decontamination method. This method is compatible with single-electrode-based sliding TENG charge replenishment technology. The 80 °C dry heating and the NGCR technology can make up an effective regeneration procedure for the mask. Even after ten cycles of simulated 4 h wearing process and such regeneration procedure, the filtration efficiency of the disposable surgical masks PM0.3 is still higher than 95%.

Disinfection Treatments of Disposable Respirators Influencing the Bactericidal/Bacteria Removal Efficiency, Filtration Performance, and Structural Integrity

In the outbreak of COVID-19, the extended wear of single-use, disposable respirators was inevitable due to limited supplies. As a respirator is front-line protection against particulate matter, including bioaerosol and droplets, a comprehensive understanding for the reuse strategy is needed. In this study, eight different disinfection methods commonly applied for the reuse of respirators were compared for their influence on the filtration and bactericidal/bacteria removal performance, with in-depth discussion on the cause of effects. Treatments including oven-dry, ultraviolet irradiation (UV), microwaving, laundering with and without detergent, and immersion in hypochlorite, isopropanol, and ethanol were performed to respirators. Immersion in ethanol or isopropanol was effective for inactivation and removal of bacteria, yet such a treatment significantly deteriorated the filtration efficiency in about 20-28%, dissipating the surface charges. Laundering, while effective in removing the attached bacteria, triggered physical damage, leading to a possible reduction of filtration performance. A short-term oven-dry, UV irradiation, and microwaving mostly preserved the filtration performance, yet the drawback lied in the incomplete bactericidal efficiency. This study would contribute to the public health and safety by providing scientific background on the effect of disinfection treatment methods for respirators.

Experimental and Computational Investigation of Intra- and Interlayer Space for Enhanced Depth Filtration and Reduced Pressure Drop

The buildup of pressure drop with mass loading of particles aggravates the breathing resistance and energy consumption of filters. This study investigated the role of intra- and interlayer space of filter media on the pressure drop development with continued particle loading. Five basic morphologies, including microfibers, nanofibers, microbeads-on-strings, and a mix of those morphologies were fabricated via electrospinning. Then the variations of layered constructions were made, to include a total 14 different filter structures. For a single layer filter media, the pore size rather than the percent porosity had a major impact on the pressure drop. For dual layers, the space between the layers and the placement order of webs were important factors affecting the pressure drop and depth loading of particles. Computational modeling was used to interpret the role of the interlayer space on the pressure drop, by monitoring the air flow and particle movement within the filter constructions, where the computational prediction corresponded to the tendency of the experimental findings. The novelty of this study lies in the combined approach of the experimental and computational work to understand the particle capture phenomenon during the mass loading.

Migration Effects of Fluorochemical Melt Additives for Alcohol Repellency in Polypropylene Nonwoven Materials

The use of bulk polymer melt additives provides a facile, industrially relevant approach to tailor properties of polymer surfaces for many different applications. These melt additives, when blended with polymers prior to melt spinning, migrate to the fiber surface and influence surface functionality. While the use of bulk polymer melt additives to impart hydrophilicity or oleophobicity is well studied, the impact of the fiber formation process on additive migration and resultant repellency of nonwoven media products remains largely unexplored. In this study, we produce fluorochemical melt additive containing meltblown nonwovens, and establish methods for characterization of fiber mat surface composition and repellency. Repellency of low surface tension fluids is a significant challenge and is of particular importance in the creation of medical garments such as surgical gowns and masks which must perform as liquid barriers even when exposed to alcohol based solutions. Similarly, melt additives are also used in the production of electret air filtration devices. Electret filters are imbued with charges to enhance particle capture performance, but this charge can be negated through wetting by low surface tension fluids. To address this challenge, the changing composition of fiber surfaces due to the migration of additives is monitored via X-ray Photoelectron Spectroscopy, then related to repellency of alcohol solutions by contact angle analysis. We demonstrate that for the samples tested a fluorine to carbon (F/C) ratio of 0.35 is sufficient to prevent wicking of isopropanol droplets, and higher surface tension fluids could be repelled by fiber mats with lower fluorine content. Through the use of cross-sectional ToF-SIMS analysis, we find that migration of additives is key to the performance of samples with low additive loadings, and that these phenomena are heavily influenced by many nonwoven manufacturing parameters including fiber size, die-to-collector distance, and polymer resin melt flow rates.

Water-Resistant Mechanoluminescent Electrospun Fabrics with Protected Sensitivity in Wet Condition via Plasma-Enhanced Chemical Vapor Deposition Process

Mechanoluminescence (ML), which emits light upon external mechanical stress, was applied to fibrous composites. Herein, ML particles were incorporated into poly(vinylidene fluoride) (PVDF) and polyacrylonitrile (PAN) electrospun webs to prepare ML/PVDF and ML/PAN composite fabrics. The produced fabrics were treated with O2 and C4F8 plasma to modify the wetting properties, then the effects of composite wettability on the light-emitting response in dry and wet conditions were investigated. The light intensity was greatly decreased when the composite fabrics absorbed water. When the composites were hydrophobized by the C4F8 plasma-enhanced chemical vapor deposition process, the original light intensity was protected in wet conditions, while maintaining the water vapor transmission rate. As the clothing material would be exposed to moisture in varied situations, the reduced ML sensitivity in wet conditions may limit the application of ML composite fabrics. The findings suggest a facile strategy to fabricate moisture-resistant, breathable mechanoluminescence composite fabrics.

Advanced Design of Fiber-Based Particulate Filters: Materials, Morphology, and Construction of Fibrous Assembly

With increasing air pollution and sporadic outbreaks of epidemics, there is ramping attention on the filtration devices. The main constituents of airborne pollutants are particulate matters of solid particles, liquid aerosol, bioaerosol/bio-droplets, and gas/vapor. With the growing demand for high-performance filters, novel materials and functionalities are being developed applying advanced technologies. In this paper, recent developments of fiber-based particulate filters are reviewed, with a focus on the important performance parameters and material properties. Trends in technology and research activities are briefly reviewed, and the evaluative measures of filtration performance are reported. Recent studies on the advanced filter materials are reviewed in the aspect of polymers and the fabrication process of fibrous assembly. The characterization method including 3D modeling and simulation is also briefly introduced. Multifunctional filters such as antimicrobial filter and gas and particulate filters are briefly introduced, and efforts for developing environmentally sustainable filters are noted.

Ultrafine, self-crimp, and electret nano-wool for low-resistance and high-efficiency protective filter media against PM0.3

Frequent outbreaks of emerging infectious diseases (EIDs) make personal protective filter media in high demand. Electrospun nanofibrous materials are proved to be very effective in resisting virus-containing fine particles owing to their small fiber diameters; however, hindered by the intrinsic close-packing character of fine fibers, electrospun filters suffer from a relatively high air resistance, thereby poor breathing comfort. Here, we report a biomimetic and one-step strategy to create ultrafine and curly wool-like nanofibers, named nano-wool, which exhibit fluffy assembly architecture and powerful electret effect. By achieving the online self-crimp and in-situ charging of nanofibers, the curly electret nano-wool shows a small diameter of ~0.6 μm (two orders of magnitude lower than natural wool: ~20 μm) and an ultrahigh porosity of 98.7% simultaneously, together with an ultrahigh surface potential of 13260 V (one order of magnitude higher than previous filters). The structural advantages and powerful electret effect enable nano-wool to show excellent filtration efficacy (>99.995% for PM_0.3) and low air resistance (55 Pa). Additionally, nano-wool can be easily scaled up, not only holding great industrial prospect in personal protective respirators, but also paving the way for developing next-generation wool in a cost-efficient and multifunctional form.

Material Properties Influencing the Charge Decay of Electret Filters and their Impact on Filtration Performance

Electret filters as opposed to mechanical filters display the enhanced ability to capture airborne particles with the electrostatic attraction. However, the environmental aging during shelf-life or use may cancel its benefit by dissipating the charges. This work investigates the polymeric attributes influencing the charge decay and the electrostatic filtration of electret filters, employing polymers with different dielectric constants (ε_r) and wettability. As accelerated aging, high temperature (120 °C) or high humidity (25 °C, 90% RH) was applied to the electret filters for 48 h. For the humidity aging, wetting property of material was a critical factor affecting the charge decay and the filtration performance, as the absorbed water increases the electrical conductivity. For the thermal aging, the material with the highest ε_r deteriorated the electric potential and the filtration performance by the largest extent, due to the lower band gap energy for charge transfer. The results of this study implicate that ε_r and wettability are important material parameters influencing the electric conductivity and chain mobility, and they can be used as convenient predictors for charge retention capacity affecting the robust electrostatic filtration performance.

Design of Web-to-Web Spacing for the Reduced Pressure Drop and Effective Depth Filtration

The study aims at lowering the pressure drop and extending the service life at a given set of filter materials implementing a space between the filter layers. As design factors, the web-to-web space was implemented by inserting either a bulk air gap or porous spacer web between the filter webs. The effect of spacing, either by the air gap or by the spacer web, on the pressure drop reduction was apparent for 4-layer constructions, and the effect was greater at the higher face velocity. The use of spacer web was more effective than the air gap in reducing the pressure drop, because the porous, fluffy spacer web acted as an effective air flow channel between the compact filter layers. The loading capacity was also increased with the spacer web implementation, effectively delaying the clogging point and extending the service life. Employing both experimental investigation and numerical simulation, this study intended to provide a practical design solution to the important problem in the field of air filtration. The results of this study can be used as a practical design guide to reduce pressure drop via depth filtration.