Polyvinyl alcohol/silver electrospun nanofibers: Biocidal filter media capturing virus-size particles

Cu-ZnO Embedded in a Polydopamine Shell for the Generation of Antibacterial Surgical Face Masks

A new easy protocol to functionalize the middle layer of commercial surgical face masks (FMs) with Zn and Cu oxides is proposed in order to obtain antibacterial personal protective equipment. Zinc and copper oxides were synthesized embedded in a polydopamine (PDA) shell as potential antibacterial agents; they were analyzed by XRD and TEM, revealing, in all the cases, the formation of metal oxide nanoparticles (NPs). PDA is a natural polymer appreciated for its simple and rapid synthesis, biocompatibility, and high functionalization; it is used in this work as an organic matrix that, in addition to stabilizing NPs, also acts as a diluent in the functionalization step, decreasing the metal loading on the polypropylene (PP) surface. The functionalized middle layers of the FMs were characterized by SEM, XRD, FTIR, and TXRF and tested in their bacterial-growth-inhibiting effect against Klebsiella pneumoniae and Staphylococcus aureus. Among all functionalizing agents, Cu2O-doped-ZnO NPs enclosed in PDA shell, prepared by an ultrasound-assisted method, showed the best antibacterial effect, even at low metal loading, without changing the hydrophobicity of the FM. This approach offers a sustainable solution by prolonging FM lifespan and reducing material waste.

Electrospun nanofibers for medical face mask with protection capabilities against viruses: State of the art and perspective for industrial scale-up

Face masks have proven to be a useful protection from airborne viruses and bacteria, especially in the recent years pandemic outbreak when they effectively lowered the risk of infection from Coronavirus disease (COVID-19) or Omicron variants, being recognized as one of the main protective measures adopted by the World Health Organization (WHO). The need for improving the filtering efficiency performance to prevent penetration of fine particulate matter (PM), which can be potential bacteria or virus carriers, has led the research into developing new methods and techniques for face mask fabrication. In this perspective, Electrospinning has shown to be the most efficient technique to get either synthetic or natural polymers-based fibers with size down to the nanoscale providing remarkable performance in terms of both particle filtration and breathability. The aim of this Review is to give further insight into the implementation of electrospun nanofibers for the realization of the next generation of face masks, with functionalized membranes via addiction of active material to the polymer solutions that can give optimal features about antibacterial, antiviral, self-sterilization, and electrical energy storage capabilities. Furthermore, the recent advances regarding the use of renewable materials and green solvent strategies to improve the sustainability of electrospun membranes and to fabricate eco-friendly filters are here discussed, especially in view of the large-scale nanofiber production where traditional membrane manufacturing may result in a high environmental and health risk.

Determining the filtration effectiveness of non-standard respiratory protective devices by an ad-hoc laboratory methodology

The recent pandemic caused by COVID-19 profoundly changed people's habits. Wearing a face mask has become usual in everyday life to reduce the risk of infection from airborne diseases. At the beginning of the pandemic, the massive request of surgical or filtering face piece (FFP) masks resulted in a global shortage of these devices for the most exposed people, such as healthcare workers. Due to this high demand for respiratory protective devices, many industrial plants have partly converted to the production of face masks using adapted materials and not complying with any specific regulation (non-standard respiratory protective devices or community masks). In this work, an ad-hoc laboratory methodology has been developed to evaluate the filtration efficiency of the materials that compose the community masks using specific instrumentation. The instrumentation consists of three main tools: an aerosol generator, a specifically designed measuring chamber, and an optical particle sizer (OPS) for the measurement of aerosol concentration. The generated aerosol was sent into the measuring chamber, divided into two separate sections by the respiratory mask. The OPS measured the aerosol mass concentration upstream and downstream of the respiratory mask, and from the concentration difference the filtration efficiency was evaluated. The proposed methodology has been validated by evaluating the particle filtration efficiency (PFE) of certified respiratory masks and was then applied for the evaluation of the filtration efficiency of different types of non-standard or community masks to analyze their effectiveness in protecting from the risk of infection of airborne diseases.

Advanced and Smart Textiles during and after the COVID-19 Pandemic: Issues, Challenges, and Innovations

The COVID-19 pandemic has hugely affected the textile and apparel industry. Besides the negative impact due to supply chain disruptions, drop in demand, liquidity problems, and overstocking, this pandemic was found to be a window of opportunity since it accelerated the ongoing digitalization trends and the use of functional materials in the textile industry. This review paper covers the development of smart and advanced textiles that emerged as a response to the outbreak of SARS-CoV-2. We extensively cover the advancements in developing smart textiles that enable monitoring and sensing through electrospun nanofibers and nanogenerators. Additionally, we focus on improving medical textiles mainly through enhanced antiviral capabilities, which play a crucial role in pandemic prevention, protection, and control. We summarize the challenges that arise from personal protective equipment (PPE) disposal and finally give an overview of new smart textile-based products that emerged in the markets related to the control and spread reduction of SARS-CoV-2.

Application of Electrospun Water-Soluble Synthetic Polymers for Multifunctional Air Filters and Face Masks

The worsening of air quality is an urgent human health issue of modern society. The outbreak of COVID-19 has made the improvement of air quality even more imperative, both for the general achievement of major health gains and to reduce the critical factors in the transmission of airborne diseases. Thus, the development of solutions for the filtration of airborne pollutants is pivotal. Electrospinning has gained wide attention as an effective fabrication technique for preparing ultrafine fibers which are specifically tailored for air filtration. Nevertheless, the utilization of harmful organic solvents is the major barrier for the large-scale applicability of electrospinning. The use of water-soluble synthetic polymers has attracted increasing attention as a 'green' solution in electrospinning. We reported an overview of the last five years of the scientific literature on the use of water-soluble synthetic polymers for the fabrication of multifunctional air filters layers. Most of recent studies have focused on polyvinyl alcohol (PVA). Various modifications of electrospun polymers have been also described. The use of water-soluble synthetic polymers can contribute to the scalability of electrospinning and pave the way to innovative applications. Further studies will be required to fully harness the potentiality of these 'greener' electrospinning processes.

High-efficiency retention of ultrafine aerosols by electrospun nanofibers

The versatility of nanofibrous polymeric materials makes them attractive for developing respiratory protective equipment. Ultrafine nanofibers effectively trap the most penetrating aerosols and exhibit consistent performance compared to conventional electret filters. Advanced nanofiber manufacturing technologies such as electrospinning can functionalize filter materials, enhancing them with unique antibacterial, catalytic, sensory, and other properties. Much of the current research in nanofibrous air filtration focuses on using nanofibers for lightweight personal protective equipment such as N95 respirators, but their use for higher levels of respiratory protection required for chemical, biological, radiological, and nuclear (CBRN) protection has not yet been comprehensively explored. In this study, we tested the hypothesis that electrospun filters could provide the particle filtration efficiency and breathing resistance required by the National Institute for Occupational Safety and Health Standard for CBRN air-purifying respirators. Our manufactured nanofibrous filters demonstrated submicron aerosol retention efficiency of > 99.999999%, which is four orders of magnitude better than the requirements of the CBRN standard. They also had a breathing resistance of ~ 26 mmH2O, which is more than twofold lower than the maximum allowable limit. Although the filter material from the gas mask cartridge currently in service with the U.S. military demonstrated a higher quality factor than electrospun filters, the comparative analysis of filter morphology suggested ways of improving nanofibrous filter performance by tuning nanofiber diameter distribution.

Electrospun Nanofibrous Membranes for Controlling Airborne Viruses: Present Status, Standardization of Aerosol Filtration Tests, and Future Development

The global COVID-19 pandemic has raised great public concern about the airborne transmission of viral pathogens. Virus-laden aerosols with small size could be suspended in the air for a long duration and remain infectious. Among a series of measures implemented to mitigate the airborne spread of infectious diseases, filtration by face masks, respirators, and air filters is a potent nonpharmacologic intervention. Compared with conventional air filtration media, nanofibrous membranes fabricated via electrospinning are promising candidates for controlling airborne viruses due to their desired characteristics, i.e., a reduced pore size (submicrometers to several micrometers), a larger specific surface area and porosity, and retained surface and volume charges. So far, a wide variety of electrospun nanofibrous membranes have been developed for aerosol filtration, and they have shown excellent filtration performance. However, current studies using electrospinning for controlling airborne viruses vary significantly in the practice of aerosol filtration tests, including setup configurations and operations. The discrepancy among various studies makes it difficult, if not impossible, to compare filtration performance. Therefore, there is a pressing need to establish a standardized protocol for evaluating the electrospun nanofibrous membranes' performance for removing viral aerosols. In this perspective, we first reviewed the properties and performance of diverse filter media, including electrospun nanofibrous membranes, for removing viral aerosols. Next, aerosol filtration protocols for electrospun nanofibrous membranes were discussed with respect to the aerosol generation, filtration, collection, and detection. Thereafter, standardizing the aerosol filtration test system for electrospun nanofibrous membranes was proposed. In the end, the future advancement of electrospun nanofibrous membranes for enhanced air filtration was discussed. This perspective provides a comprehensive understanding of status and challenges of electrospinning for air filtration, and it sheds light on future nanomaterial and protocol development for controlling airborne viruses, preventing the spread of infectious diseases, and beyond.

Virucidal and Bactericidal Filtration Media from Electrospun Polylactic Acid Nanofibres Capable of Protecting against COVID-19

Electrospun nanofibres excel at air filtration owing to diverse filtration mechanisms, thereby outperforming meltblown fibres. In this work, we present an electrospun polylactide acid nanofibre filter media, FilterLayrTM Eco, displaying outstanding bactericidal and virucidal properties using Manuka oil. Given the existing COVID-19 pandemic, face masks are now a mandatory accessory in many countries, and at the same time, they have become a source of environmental pollution. Made by NanoLayr Ltd., FilterLayrTM Eco uses biobased renewable raw materials with products that have end-of-life options for being industrially compostable. Loaded with natural and non-toxic terpenoid from manuka oil, FilterLayr Eco can filter up to 99.9% of 0.1 µm particles and kill >99% of trapped airborne fungi, bacteria, and viruses, including SARS-CoV-2 (Delta variant). In addition, the antimicrobial activity, and the efficacy of the filter media to filtrate particles was shown to remain highly active following several washing cycles, making it a reusable and more environmentally friendly option. The new nanofibre filter media, FilterLayrTM Eco, met the particle filtration efficiency and breathability requirements of the following standards: N95 performance in accordance with NIOSH 42CFR84, level 2 performance in accordance with ASTM F2100, and level 2 filtration efficiency and level 1 breathability in accordance with ASTM F3502. These are globally recognized facemask and respirator standards.

Fabrication of air filters with advanced filtration performance for removal of viral aerosols and control the spread of COVID-19

COVID-19 is caused via the SARS-CoV-2 virus, a lipid-based enveloped virus with spike-like projections. At present, the global epidemic of COVID-19 continues and waves of SARS-CoV-2, the mutant Delta and Omicron variant which are associated with enhanced transmissibility and evasion to vaccine-induced immunity have increased hospitalization and mortality, the biggest challenge we face is whether we will be able to overcome this virus? On the other side, warm seasons and heat have increased the need for proper ventilation systems to trap contaminants containing the virus. Besides, heat and sweating accelerate the growth of microorganisms. For example, medical staff that is in the front line use masks for a long time, and their facial sweat causes microbes to grow on the mask. Nowadays, efficient air filters with anti-viral and antimicrobial properties have received a lot of attention, and are used to make ventilation systems or medical masks. A wide range of materials plays an important role in the production of efficient air filters. For example, metals, metal oxides, or antimicrobial metal species that have anti-viral and antimicrobial properties, including Ag, ZnO, TiO2, CuO, and Cu played a role in this regard. Carbon nanomaterials such as carbon nanotubes, graphene, or derivatives have also shown their role well. In addition, natural materials such as biopolymers such as alginate, and herbal extracts are employed to prepare effective air filters. In this review, we summarized the utilization of diverse materials in the preparation of efficient air filters to apply in the preparation of medical masks and ventilation systems. In the first part, the employing metal and metal oxides is examined, and the second part summarizes the application of carbon materials for the fabrication of air filters. After examination of the performance of natural materials, challenges and progress visions are discussed.

Electrospun Nanofiber Membranes for Air Filtration: A Review

Nanomaterials for air filtration have been studied by researchers for decades. Owing to the advantages of high porosity, small pore size, and good connectivity, nanofiber membranes prepared by electrospinning technology have been considered as an outstanding air-filter candidate. To satisfy the requirements of material functionalization, electrospinning can provide a simple and efficient one-step process to fabricate the complex structures of functional nanofibers such as core-sheath structures, Janus structures, and other multilayered structures. Additionally, as a nanoparticle carrier, electrospun nanofibers can easily achieve antibacterial properties, flame-retardant properties, and the adsorption properties of volatile gases, etc. These simple and effective approaches have benefited from the significate development of electrospun nanofibers for air-filtration applications. In this review, the research progress on electrospun nanofibers as air filters in recent years is summarized. The fabrication methods, filtration performances, advantages, and disadvantages of single-polymer nanofibers, multipolymer composite nanofibers, and nanoparticle-doped hybrid nanofibers are investigated. Finally, the basic principles of air filtration are concluded upon and prospects for the application of complex-structured nanofibers in the field of air filtration are proposed.

Sustainable Applications of Nanofibers in Agriculture and Water Treatment: A Review

Natural fibers are an important source for producing polymers, which are highly applicable in their nanoform and could be used in very broad fields such as filtration for water/wastewater treatment, biomedicine, food packaging, harvesting, and storage of energy due to their high specific surface area. These natural nanofibers could be mainly produced through plants, animals, and minerals, as well as produced from agricultural wastes. For strengthening these natural fibers, they may reinforce with some substances such as nanomaterials. Natural or biofiber-reinforced bio-composites and nano–bio-composites are considered better than conventional composites. The sustainable application of nanofibers in agricultural sectors is a promising approach and may involve plant protection and its growth through encapsulating many bio-active molecules or agrochemicals (i.e., pesticides, phytohormones, and fertilizers) for smart delivery at the targeted sites. The food industry and processing also are very important applicable fields of nanofibers, particularly food packaging, which may include using nanofibers for active–intelligent food packaging, and food freshness indicators. The removal of pollutants from soil, water, and air is an urgent field for nanofibers due to their high efficiency. Many new approaches or applicable agro-fields for nanofibers are expected in the future, such as using nanofibers as the indicators for CO and NH3. The role of nanofibers in the global fighting against COVID-19 may represent a crucial solution, particularly in producing face masks.

Monitoring and Optimisation of Ag Nanoparticle Spray-Coating on Textiles

An automatic lab-scaled spray-coating machine was used to deposit Ag nanoparticles (AgNPs) on textile to create antibacterial fabric. The spray process was monitored for the dual purpose of (1) optimizing the process by maximizing silver deposition and minimizing fluid waste, thereby reducing suspension consumption and (2) assessing AgNPs release. Monitoring measurements were carried out at two locations: inside and outside the spray chamber (far field). We calculated the deposition efficiency (E), finding it to be enhanced by increasing the spray pressure from 1 to 1.5 bar, but to be lowered when the number of operating sprays was increased, demonstrating the multiple spray system to be less efficient than a single spray. Far-field AgNPs emission showed a particle concentration increase of less than 10% as compared to the background level. This finding suggests that under our experimental conditions, our spray-coating process is not a critical source of worker exposure.

Electrospun Nanofibre Filtration Media to Protect against Biological or Nonbiological Airborne Particles

Electrospun nanofibres can outperform their melt-blown counterparts in many applications, especially air filtration. The different filtration mechanisms of nanofibres are particularly important when it comes to the air filtration of viruses (such as COVID-19) and bacteria. In this work, we present an electrospun nanofibre filter media, FilterLayrTM by NanoLayr Ltd., containing poly(methyl methacrylate)/ethylene vinyl alcohol nanofibres. The outstanding uniformity of the nanofibres was indicated by the good correlation between pressure drop (ΔP) and areal weight with R2 values in the range of 0.82 to 0.98 across various test air velocities. By adjusting the nanofibre areal weight (basis weight), the nanofibre filter media was shown to meet the particle filtration efficiency and breathability requirements of the following internationally accepted facemask and respirator standards: N95 respirator facemask performance in accordance with NIOSH 42CFR84 (filtration efficiency of up to 98.10% at a pressure drop of 226 Pa and 290 Pa at 85 L·min-1 and 120 L·min-1, respectively), Level 2 surgical facemask performance in accordance with ASTM F2299 (filtration efficiency of up to 99.97% at 100 nm particle size and a pressure drop of 44 Pa at 8 L·min-1), and Level 2 filtration efficiency and Level 1 breathability for barrier face coverings in accordance with ASTM F3502 (filtration efficiency of up to 99.68% and a pressure drop of 133 Pa at 60 L·min-1), with Level 2 breathability being achievable at lower nanofibre areal weights.