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

Purine-Doped g-C3N4-Modified Fabrics for Personal Protective Masks with Rapid and Sustained Antibacterial Activity

Protective masks are critical to impeding microorganism transmission but can propagate infection via pathogen buildup and face touching. To reduce this liability, we integrated electrospun photocatalytic graphitic carbon nitride (g-C3N4) nanoflakes into standard surgical masks to confer a self-sanitization capacity. By optimizing the purine/melamine precursor ratio during synthesis, we reduced the g-C3N4 band gap from 2.92 to 2.05 eV, eliciting a 4× increase in sterilizing hydrogen peroxide production under visible light. This narrower band gap enables robust photocatalytic generation of reactive oxygen species from environmental and breath humidity to swiftly eliminate accumulated microbes. Under ambient sunlight, the g-C3N4 nanocomposite mask layer achieved a 97% reduction in the bacterial viability during typical use. Because the optimized band gap also allows photocatalytic activity under shadowless lamp illumination, the self-cleaning functionality could mitigate infection risk from residual pathogens in routine hospital settings. Both g-C3N4 and polycaprolactone demonstrate favorable biocompatibility and biodegradability, making this approach preferable over current commercially available metal-based options. Given the abundance and low cost of these components, this scalable approach could expand global access to reusable self-sanitizing protective masks, serving as a sustainable public health preparedness measure against future pandemics, especially in resource-limited settings.

Bicomponent core/sheath melt-blown fibers for air filtration with ultra-low resistance

With the escalating air pollution and frequent outbreaks of airborne diseases, there is a growing demand for personal protective filtration media. Melt-blown nonwovens have proven to be highly effective in capturing tiny particles, but their tightly packed fiber assemblages are more resistant to airflow and less comfortable to breathe. Here, we present a one-step melt-blown spinning process for the production of bicomponent core/sheath (BCS) crimped fibers and their application in high-efficiency, low-resistance air filtration. Fiber curl is caused by unbalanced internal stresses resulting from differences in the structure components, resulting in uneven shrinkage inside and outside the fibers. The resulting CM@S-2 filtration media features a uniform fiber curl and a porous fiber mesh structure, which reduces air filtration resistance. Under the same filtration conditions, the filtration efficiency of CM@S-2 (96.58% vs. 95.58%), filtration resistance (56.1 Pa vs. 108.0 Pa), quality factor (0.061 Pa-1vs. 0.029 Pa-1), and dust holding capacity (10.60 g m-2vs. 9.10 g m-2) were comparable to those of the single-component polypropylene filters. The filtration efficiency of the CM@S-2 remained above 94.0% after 30 days of indoor storage. Computational Fluid Dynamics (CFD) simulation demonstrated that crimped fibers effectively reduce pressure surges on the filter media caused by fiber accumulation. In comparative tests with commercial masks, the CM@S-2 cartridge masks demonstrated superior air permeability compared to commercial masks under similar filtration conditions. In conclusion, the bicomponent core/sheath melt-blown fibers significantly reduce air resistance and show excellent potential for application in protective masks.

One-step fabrication of polylactic acid (PLA) nanofibrous membranes with spider-web-like structure for high-efficiency PM0.3 capture

High-efficiency air filters are in high demand to protect human health from the threat of ultrafine particulate matters (PM). However, most commercial air filters are less effective for PM0.3 capture and/or still suffer from undesirable pressure drops. They are also typically petroleum-based. Herein, a double-jet synchronous electrospinning technology was demonstrated to fabricate spider-web-like polylactic acid (PLA) nanofibrous membranes (SPNM) in one step. The properties of spinning solutions were regulated to construct favorable multi-scale nanofiber and bead structures that mimicked the structural units in spider-webs. The as-prepared SPNM exhibited excellent filtration efficiency (99.87 %) and high quality factor (0.321 Pa-1) against the PM0.3, while presenting an attractively low pressure drop (19 Pa). Additionally, the filtration performance of SPNM was almost completely preserved during 10-cycle tests and the 6-month long-term tests, showing excellent function stability and durability. Benefiting from its good hydrophobicity (WCA = 143.2°), SPNM also presented a satisfactory filtration efficiency (>99.37 %) with low pressure drop (18 Pa) at an environment with humidity at 90 % against PM0.3. Furthermore, the unique structure increased the mechanical strength of SPNM, facilitating the processability for practical applications. Overall, this work may shed light on a promising approach for developing biomass-based, highly efficient filtration materials with hierarchical structures.

Self-Sanitization in a Silk Nanofibrous Network for Biodegradable PM0.3 Filters with In Situ Joule Heating

In the contemporary way of life, face masks are crucial in managing disease transmission and battling air pollution. However, two key challenges, self-sanitization and biodegradation of face masks, need immediate attention, prompting the development of innovative solutions for the future. In this study, we present a novel approach that combines controlled acid hydrolysis and mechanical chopping to synthesize a silk nanofibrous network (SNN) seamlessly integrated with a wearable stainless steel mesh, resulting in the fabrication of self-sanitizable face masks. The distinct architecture of face masks showcases remarkable filtration efficiencies of 91.4, 95.4, and 98.3% for PM0.3, PM0.5, and PM1.0, respectively, while maintaining a comfortable level of breathability (ΔP = 92 Pa). Additionally, the face mask shows that a remarkable thermal resistance of 472 °C cm2 W-1 generates heat spontaneously at low voltage, deactivating Escherichia coli bacteria on the SNN, enabling self-sanitization. The SNN exhibited complete disintegration within the environment in just 10 days, highlighting the remarkable biodegradability of the face mask. The unique advantage of self-sanitization and biodegradation in a face mask filter is simultaneously achieved for the first time, which will open avenues to accomplish environmentally benign next-generation face masks.

Highly Efficient Fabrication of Biomimetic Nanoscaled Tendrils for High-Performance PM0.3 Air Filters

Particulate matter pollution has become a serious public health issue, especially with the outbreak of new infectious diseases. However, most existing air filtration materials face challenges such as being too bulky, having high resistance, and a trade-off between filtration efficiency and air permeability. Here, a unique electro-blown spinning technique is used to prepare an air filter made of biomimetic nanoscaled tendril nonwovens (Nano-TN). The introduction of an airflow field significantly increases the whipping frequency and the strain mismatch of composite jets, achieving large-scale and highly efficient preparation of Nano-TN. The resultant Nano-TN has an ultrahigh porosity (97%) and a small pore size (2.9 μm). At the same filtration level, its air resistance is 37% lower than that of traditional straight nanofibrous nonwovens and has a higher dust-holding capacity. Moreover, compared with traditional three-dimensional air filters, the Nano-TN filter is thinner, offering tremendous application prospects in various environmental purification and personal protection fields.

One-Step Fast Fabrication of Electrospun Fiber Membranes for Efficient Particulate Matter Removal

Rapid social and industrial development has resulted in an increasing demand for fossil fuel energy, which increases particulate matter (PM) pollution. In this study, we employed a simple one-step electrospinning technique to fabricate polysulfone (PSF) fiber membranes for PM filtration. A 0.3 g/mL polymer solution with an N,N-dimethylformamide:tetrahydrofuran volume ratio of 3:1 yielded uniform and bead-free PSF fibers with a diameter of approximately 1.17 μm. The PSF fiber membrane exhibited excellent hydrophobicity and mechanical properties, including a tensile strength of 1.14 MPa and an elongation at break of 116.6%. Finally, the PM filtration performance of the PSF fiber membrane was evaluated. The filtration efficiencies of the membrane for PM2.5 and PM1.0 were approximately 99.6% and 99.2%, respectively. The pressure drops were 65.0 and 65.2 Pa, which were significantly lower than those of commercial air filters. Using this technique, PSF fiber membrane filters can be easily fabricated over a large area, which is promising for numerous air filtration systems.

Ultralight and Superelastic Curly Micro/Nanofibrous Aerogels by Direct Electrospinning Enable High-Performance Warmth Retention

Extremely low temperature has posed huge burden on the public safety concerns and global economics, thereby calling for high-performance warmth retention materials to resist harsh environment. However, most present fibrous warmth retention materials are limited by their large fiber diameter and simple stacking structure, leading to heavy weight, weak mechanical property, and limited thermal insulation performance. Herein, an ultralight and mechanically robust polystyrene/polyurethane fibrous aerogel by direct electrospinning for warmth retention is reported. Manipulation of charge density and phase separation of charged jet allows for the direct assembly of fibrous aerogels consisting of interweaved curly wrinkled micro/nanofibers. The resultant curly wrinkled micro/nanofibrous aerogel possesses low density of 6.8 mg cm-3 and nearly full recovery from 1500-cycle deformations, exhibiting both ultralight feature and superelastic property. The aerogel also shows low thermal conductivity of 24.5 mW m-1  K-1 , making synthetic warmth retention materials superior to down feather possible. This work may shed light on developing versatile 3D micro/nanofibrous materials for environmental, biological, and energy applications.

Bioelectret poly(lactic acid) membranes with simultaneously enhanced physical interception and electrostatic adsorption of airborne PM0.3

Traditional polymeric fibrous membranes have been extensively used to reduce the health risks caused by airborne particulate matter (PM), leading to the dramatically increasing pollution of plastics and microplastics. Although great efforts have been made to develop poly(lactic acid) (PLA)-based membrane filters, they are frequently dwarfed by their relatively poor electret properties and electrostatic adsorptive mechanisms. To resolve this dilemma, a bioelectret approach was proposed in this work, strategically involving the bioinspired adhesion of dielectric hydroxyapatite nanowhiskers as a biodegradable electret to promote the polarization properties of PLA microfibrous membranes. In addition to significant improvements in tensile properties, the incorporation of hydroxyapatite bioelectret (HABE) enabled remarkable increase in the removal efficiencies of ultrafine PM_0.3 in a high-voltage electrostatic field (10 and 25 kV). This was exemplified by the largely increased filtering performance (69.75%, 23.1 Pa) for PLA membranes loaded with 10 wt% HABE at the normal airflow rate (32 L/min) compared to the pristine PLA counterpart (32.89%, 7.2 Pa). Although the filtration efficiency of PM_0.3 for the counterpart dramatically decreased to 21.6% at 85 L/min, the increment was maintained at nearly 196% for the bioelectret PLA, while an ultralow pressure drop (74.5 Pa) and high humidity resistance (RH 80%) were achieved. The unusual property combination were ascribed to the HABE-enabled realization of multiple filtration mechanisms, including the simultaneous enhancement of physical interception and electrostatic adsorption. The significant filtration applications, unattainable with conventional electret membranes, demonstrate the bioelectret PLA as a promising biodegradable platform that allows high filtration properties and humidity resistance.

High-breathable, antimicrobial and water-repellent face mask for breath monitoring

Face masks with multiple functionalities and exceptional durability have attracted increasing interests during the COVID-19 pandemic. How to integrate the antibacterial property, comfortability during long-time wearing, and breath monitoring capability together on a face mask is still challenging. Here we developed a kind of face mask that assembles the particles-free water-repellent fabric, antibacterial fabric, and hidden breath monitoring device together, resulting in the highly breathable, water-repellent, and antibacterial face mask with breath monitoring capability. Based on the rational design of the functional layers, the mask shows exceptional repellency to micro-fogs generated during breathing while maintaining high air permeability and inhibiting the passage of bacteria-containing aerogel. More importantly, the multi-functional mask can also monitor the breath condition in a wireless and real-time fashion, and collect the breath information for epidemiological analysis. The resultant mask paves the way to develop multi-functional breath-monitoring masks that can aid the prevention of the secondary transmission of bacteria and viruses while preventing potential discomfort and face skin allergy during long-period wearing.

The real bacterial filtration efficiency to evaluate the effective protection of facemasks used for the prevention of respiratory diseases

The real protection offered by facemasks to control the transmission of respiratory viruses is still undetermined. Most of the manufacturing regulations, as well as scientific studies, have focused on studying the filtration capacity of the fabrics from which they are made, ignoring the air that escapes through the facial misalignments, and which depends on the respiratory frequencies and volumes. The objective of this work was to define a Real Bacterial Filtration Efficiency for each type of facemask, considering the bacterial filtration efficiency of the manufacturers and the air that passes through them. Nine different facemasks were tested on a mannequin with three gas analyzers (measuring inlet, outlet, and leak volumes) inside a polymethylmethacrylate box. In addition, the differential pressure was measured to determine the resistance offered by the facemasks during the inhalation and exhalation processes. Air was introduced with a manual syringe for 180 s simulating inhalations and exhalations at rest, light, moderate and vigorous activities (10, 60, 80 and 120 L/min, respectively). Statistical analysis showed that practically half of the air entering to the system is not filtered by the facemasks in all intensities (p < 0.001, ηp² = 0.971). They also showed that the hygienic facemasks filter more than 70% of the air, and their filtration does not depend on the simulated intensity, while the rest of the facemasks show an evidently different response, influenced by the amount of air mobilized. Therefore, the Real Bacterial Filtration Efficiency can be calculated as a modulation of the Bacterial Filtration Efficiencies that depends on the type of facemask. The real filtration capacity of the facemasks has been overestimated during last years since the filtration of the fabrics is not the real filtration when the facemask is worn.

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.

Fabrication of Laminated Micro/Nano Filter and Its Application for Inhalable PM Removal

Particulate matter (PM) with a diameter of 0.3 µm is inhalable and brings great threats to human health. Traditional meltblown nonwovens used for air filtration need to be treated by high voltage corona charging, which has the problem of electrostatic dissipation and thus reduces the filtration efficiency. In this work, a kind of composite air-filter with high efficiency and low resistance was fabricated by alternating lamination of ultrathin electronspun nano-layer and melt-blown layer without corona charging treatment. The effects of fiber diameter, pore size, porosity, layer number, and weight on filtration performance were investigated. Meanwhile, the surface hydrophobicity, loading capacity, and storage stability of the composite filter were studied. The results indicate that the filters (18.5 gsm) laminated by 10 layers fiber-webs present excellent filtration efficiency (97.94%), low pressure drop (53.2 Pa), high quality factor (QF 0.073 Pa−1), and high dust holding capacity (9.72 g/m2) for NaCl aerosol particles. Increasing the layers and reducing individual layer weight can significantly improve filtration efficiency and reduce pressure drop of the filter. The filtration efficiency decayed slightly from 97.94% to 96.48% after 80 days storage. The alternate arrangement of ultra-thin nano and melt-blown layers constructed a layer-by-layer interception and collaborative filtering effect in the composite filter, realizing the high filtration efficiency and low resistance without high voltage corona charging. These results provided new insights for the application of nonwoven fabrics in air filtration.

OPPS Fibers with High Temperature Resistance and Excellent Antioxidant Properties by an Oxidation Method

Polyphenylene sulfide (PPS) fiber products have been widely used for separation and filtration in harsh environments due to their excellent chemical resistance and relatively economical price. However, the poor temperature and weak oxidation resistance of PPS significantly shorten its service life under high temperature and strong oxidation environments. Herein, we report a type of oxidation-modified PPS (OPPS) fibers with excellent high temperature and oxidation resistance. This is achieved by oxidizing the thioether sulfide groups in PPS molecular chains into sulfoxide and sulfone groups and cross-linking the intermolecular chains. Both experiments and density functional theory (DFT) calculations indicate that hypochlorous acid (HClO) molecules can rapidly oxidize the PPS fiber surface. In addition, molecular dynamics (MD) simulations prove that there are strong hydrogen bonds and van der Waals interactions between HClO molecules and OPPS molecular chains, which promote the penetration of HClO molecules into the interior of the fiber to complete the layer-by-layer oxidation. The prepared OPPS-20 fibers exhibit excellent structural stability under high temperature and strong oxidant environments. Impressively, the OPPS-20 nonwoven filter still exhibits a high dust filtration efficiency of 99.95% after aging at 320 °C for 12 h, and the corresponding pressure drop is 24 Pa. In addition, the OPPS-20 nonwoven filter also maintains excellent filtration performance after aging in 60% HNO3 solution for 12 h, and the filtration efficiency and pressure drop are 99.96% and 29 Pa, respectively. This work demonstrates that the novel OPPS fibers have excellent application prospects in the field of separation and filtration in harsh environments.