Fabrication of nanofiber meltblown membranes and their filtration properties

Progress in the Preparation and Application of Breathable Membranes

Breathable membranes with micropores enable the transfer of gas molecules while blocking liquids and solids, and have a wide range of applications in medical, industrial, environmental, and energy fields. Breathability is highly influenced by the nature of a material, pore size, and pore structure. Preparation methods and the incorporation of functional materials are responsible for the variety of physical properties and applications of breathable membranes. In this review, the preparation methods of breathable membranes, including blown film extrusion, cast film extrusion, phase separation, and electrospinning, are discussed. According to the antibacterial, hydrophobic, thermal insulation, conductive, and adsorption properties, the application of breathable membranes in the fields of electronics, medicine, textiles, packaging, energy, and the environment are summarized. Perspectives on the development trends and challenges of breathable membranes are discussed.

Influence of a Meltblown Die with a Laval Airstream Channel on the Manufacturing Process of a Polymer Fiber Based on an Orthogonal Test and Simulation Analysis

A Laval nozzle is a device that accelerates a low-speed airstream to form a high-speed airstream. In this work, we use a Laval nozzle in the airstream channel design of a meltblown die to improve the tensile properties of the fiber in the airstream field of the meltblown die. The features of the airstream field of the meltblown die are analyzed by numerical simulation. For a given parametrization, six factors may be tuned to optimize the performance of the Laval airstream channel of the meltblown die. We thus use a five-level, six-factor orthogonal test method to optimize the airstream channel of the meltblown die to determine the various factors that influence the airstream field beneath the meltblown die. The results show that the optimized Laval meltblown die performs better than the traditional die and that the widths of the larynx and expansion segment most strongly affect the airstream velocity beneath the Laval meltblown die. Compared with a traditional die, the Laval die optimized by orthogonal testing increases the peak airstream velocity by 17.54%, average velocity by 96.81%, average temperature by 12.32%, and peak pressure by 14.61% and produces weaker turbulence intensity near the spinneret. These characteristics make the airstream beneath the die more stable and uniform and accelerate the attenuation of the fiber diameter, producing more polymer nanofibers. These results demonstrate a valuable approach to the design and optimization of meltblown dies and provide a technical reference for the production and application of the meltblown fiber production equipment.

Effects of Melt-Blown Processing Conditions on Nonwoven Polylactic Acid and Polybutylene Succinate

This research aimed to prepare nonwovens from polylactic acid and polybutylene succinate using the melt-blown process while varying the melt-blown process parameters, including air pressure (0.2 and 0.4 MPa) and die-to-collector distance (15, 30, and 45 cm). Increasing the air pressure and die-to-collector distance resulted in the production of smaller fibers. Simultaneously, the tensile strength was dependent on the polymer, air pressure, and die-to-collector distance used, and the percentage elongation at the break tended to increase with an increasing die-to-collector distance. Regarding thermal properties, the PBS nonwovens exhibited an increased level of crystallinity when the die-to-collector distance was raised, consistent with the degree of crystallinity obtained from X-ray diffraction analysis. Polylactic acid could be successfully processed into nonwovens under all six investigated conditions, whereas nonwoven polybutylene succinate could not be formed at a die-to-collector distance of 15 cm. However, both polymers demonstrated the feasibility of being processed into nonwovens using the melt-blown technique, showing potential for applications in the textile industry.

Effect of Polybutylene Succinate Additive in Polylactic Acid Blend Fibers via a Melt-Blown Process

This work aimed to study the influence of the polybutylene succinate (PBS) content on the physical, thermal, mechanical, and chemical properties of the obtained polylactic acid (PLA)/PBS composite fibers. PLA/PBS blend fibers were prepared by a simple melt-blown process capable of yielding nanofibers. Morphological analysis revealed that the fiber size was irregular and discontinuous in length. Including PBS affected the fiber size distribution, and the fibers had a smoother surface with increased amounts of added PBS. Differential scanning calorimetry analysis (DSC) revealed that the crystallization temperature of the PLA sheet (105.8 °C) was decreased with increasing PBS addition levels down to 91.7 °C at 10 wt.% PBS. This suggests that the addition of PBS may affect PLA crystallization, which is consistent with the X-ray diffraction analysis that revealed that the crystallinity of PLA (19.2%) was increased with increasing PBS addition up to 28.1% at 10 wt% PBS. Moreover, adding PBS increased the tensile properties while the % elongation at break was significantly decreased.

A Fiber Sliding-Orientation Based Micromechanics Failure Model for Melt-Blown Nonwovens

The mechanical model of melt-blown nonwovens (MNs) serves as the foundation for performance optimization, which can offer helpful guidance for product material selection, structural design, and cost control. However, it is challenging to describe the micromechanics failure mechanism of MNs using the traditional mechanical model, which aims to match the model curve with the experimental result at the macrolevel. Herein, a micromechanics failure model for MNs based on sliding-orientation competition is developed. Through in situ observations of fiber position changes and the fluctuation of stress-strain curves, fiber sliding and orientation are introduced into the failure process of MNs. Due to fiber bonding and static friction, only orientation happens during the first stage of stretching. In dramatic contrast, the fibers will slide and orient in the second stage of stretching to change their positions in response to the external force. Sliding friction, fiber bonding, and static friction make up the stress of MNs, and the conflict of fiber sliding and orientation causes variations in the stress. The model has been successfully applied to polylactic acid (PLA) MNs, which proves the effectiveness of the model in MNs.

Anti-influenza Activity of Povidone-Iodine-Integrated Materials

Personal protective equipment (PPE), including medical masks, should be worn for preventing the transmission of respiratory pathogens via infective droplets and aerosols. In medical masks, the key layer is the filter layer, and the melt-blown nonwoven fabric (NWF) is the most used fabric. However, the NWF filter layer cannot kill or inactivate the pathogens spread via droplets and aerosols. Povidone-iodine (PVP-I) has been used as an antiseptic solution given its potent broad-spectrum activity against pathogens. To develop PPE (e.g., medical masks) with anti-pathogenic activity, we integrated PVP-I into nylon-66 NWF. We then evaluated its antiviral activity against influenza A viruses by examining the viability of Madin-Darby canine kidney (MDCK) cells after inoculation with the virus strains exposed to the PVP-I-integrated nylon-66 NWF. The PVP-I nylon-66 NWF protected the MDCK cells from viral infection in a PVP-I concentration-dependent manner. Subsequently, we found to integrate PVP-I into nylon-66 and polyurethane materials among various materials. These PVP-I materials were also effective against influenza virus infection, and treatment with PVP-I nylon-66 NWF showed the highest cell survival among all the tested materials. PVP-I showed anti-influenza A virus activity when used in conjunction with PPE materials. Moreover, nylon-66 NWF integrated with PVP-I was found to be the best material to ensure anti-influenza activity. Therefore, PVP-I-integrated masks could have the potential to inhibit respiratory virus infection. Our results provide new information for developing multi-functional PPEs with anti-viral activity by integrating them with PVP-I to prevent the potential transmission of respiratory viruses.

Post-Pandemic: Investigation of the Degradation of Various Commercial Masks in the Marine Environment

During COVID-19, personal protective equipment such as face masks was in urgent demand in the daily life. As the pandemic may have withdrawn from public attention, the disposal of face masks is a significant issue, especially plastic pollution. To address the degradation of the polymers in the marine environment, seven commercial masks were investigated via artificial weathering procedures in substitute ocean water. A suite of structural and chemical characterization techniques was employed, including scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), Fourier transform infrared spectroscopy (FT-IR), Raman spectroscopy, X-ray diffraction (XRD), and contact angle goniometry, to probe the treatment impact on commercially available N95, surgical, polyurethane, polyester, nylon, silk, and cotton masks. This work provides insights into the comprehensive analysis of material degradation in nature and raises public awareness of environmental issues post-pandemic.

Fabrication and Performance Evaluation of a Cation Exchange Membrane Using Graphene Oxide/Polyethersulfone Composite Nanofibers

Ion exchange membranes, especially cation exchange membranes (CEMs), are an important component in membrane-based energy generation and storage because of their ability to transport cations via the electrochemical potential gradient while preventing electron transport. However, developing a CEM with low areal resistance, high permselectivity, and stability remains difficult. In this study, electrospun graphene oxide/polyethersulfone (GO/PES) composite nanofibers were prepared with varying concentrations of GO. To fabricate a CEM, the pores of the electrospun GO/PES nanofiber substrates were filled with a Nafion ionomer. The pore-filled PES nanofiber loaded with 1% GO revealed a noticeable improvement in hydrophilicity, structural morphology, and mechanical properties. The 1% GO/PES pore-filled CEM was compared to a Nafion membrane of a varying thickness and without a nanofiber substrate. The CEM with a nanofiber substrate showed permselectivity of 85.75%, toughness of 111 J/m³, and areal resistance of 3.7 Ω cm², which were 12.8%, 4.3 times, and 4.0 times better, respectively, than those of the Nafion membrane at the same thickness. The development of a reinforced concrete-like GO/PES nanofiber structure containing stretchable ionomer-enhanced membrane surfaces exhibited suitable areal resistance and reduced the thickness of the composite membrane without compromising the mechanical strength, suggesting its potential application as a cation exchange membrane in electrochemical membrane-based systems.

Polylactic Acid/Calcium Stearate Hydrocharging Melt-Blown Nonwoven Fabrics for Respirator Applications

Non-biodegradable polypropylene, which poses a serious threat to the environment, is the most utilized material in air filtration systems. Moreover, under conditions of high temperature and high humidity, the electrostatic charge in melt-blown nonwoven fabrics treated with traditional corona electrets will quickly dissipate. Here, biodegradable polylactic acid, calcium stearate, and an innovative hydrocharging technique are reported to develop environmentally friendly polylactic acid/calcium stearate hydrocharging melt-blown nonwoven fabrics with high charge stability. Compared with polylactic acid melt-blown nonwoven fabrics, the crystallization structure and charge storage of polylactic acid/calcium stearate melt-blown nonwoven fabrics have been greatly improved due to the presence of calcium stearate. In PM0.3, it exhibited a high filtration efficiency (96.78%), a low pressure drop (65.20 Pa), and a good quality factor (0.053 Pa-1), which can meet the N95 respirator standard. Furthermore, it is worth mentioning that the filtration performance remained at a high level (>95.00%) after 2 months. Importantly, based on the test and analysis of surface electrostatic potential, crystallization, and charge storage and distribution, we proposed plausible charge generation and stable storage mechanisms. It demonstrated more potential for electret air filtration and smart respirators as the further possible step of research in the field.

How do three-layer surgical masks prevent SARS-CoV-2 aerosol transmission?

The three-layer surgical mask was recognized by the World Health Organization as an effective-protection tool for reducing SARS-CoV-2 transmission during the COVID-19 pandemic; however, the contribution of each layer of this mask to the particle size-dependent filtration performance resistance remains unclear. Here, both experimental work and numerical simulation were conducted to study the role of each mask layer in particle size-dependent filtration and respiratory resistance. By using scanning electron microscopy images of a commercial three-layer mask, composed of two spun-bond and one melt-blown nonwoven polypropylene fabric layers, four representative models were constructed, in which the computational fluid dynamics of multiphase flow were performed. The pressure drop of all models under different flow conditions was measured next. Numerical simulation was then verified by comparing the experimental results in the present study and other theoretical works. The filtration efficiency of the spun-bond polypropylene nonwoven fabric layer was much lower than that of the melt-blown nonwoven polypropylene fabric layer for the particle diameter in the range of 0.1-2.0 μm. Both the spun-bond and melt-blown nonwoven polypropylene fabric layers demonstrated extremely low filtration efficiency for particles was<0.3 μm in diameter, with the maximum filtration efficiency being only 30%. The present results may facilitate rational design of mask products in terms of layer number and structural design.

Long-Lasting Electret Melt-Blown Nonwoven Functional Filters Made of Organic/Inorganixc Macromolecular Micron Materials: Manufacturing Techniques and Property Evaluations

Melt-blown nonwoven fabrics for filtration are usually manufactured using polypropylene, but after a certain time period the middle layer of the mask may have a reduced effect on adsorbing particles and may not be easily stored. Adding electret materials not only increases storage time, but also shows in this study that the addition of electret can improve filtration efficiency. Therefore, this experiment uses a melt-blown method to prepare a nonwoven layer, and adds MMT, CNT, and TiO2 electret materials to it for experiments. Polypropylene (PP) chip, montmorillonite (MMT) and titanium dioxide (TiO₂) powders, and carbon nanotube (CNT) are blended and made into compound masterbatch pellets using a single-screw extruder. The resulting compound pellets thus contain different combinations of PP, MMT, TiO₂, and CNT. Next, a hot pressor is used to make the compound chips into a high-poly film, which is then measured with differential scanning calorimetry (DSC) and Fourier transform infrared spectroscopy (FTIR). The optimal parameters are yielded and employed to form the PP/MMT/TiO₂ nonwoven fabrics and PP/MMT/CNT nonwoven fabrics. The basis weight, thickness, diameter, pore size, fiber covering ratio, air permeability, and tensile property of different nonwoven fabrics are evaluated in order to have the optimal group of PP-based melt-blown nonwoven fabrics. According to the results of DSC and FTIR measurements, PP and MMT, CNT, and TiO₂ are completely mixed, and the melting temperature (T_m), crystallization temperature (T_c) and endotherm area are changed accordingly. The difference in enthalpy of melting changes the crystallization of PP pellets, which in turn changes the fibers. Moreover, the Fourier transform infrared (FTIR) spectroscopy results substantiate that PP pellets are well blended with CNT and MMT, according to the comparisons of characteristic peaks. Finally, the scanning electron microscopy (SEM) observation suggests that with a spinning die temperature of 240 °C and a spinning die pressure lower than 0.01 MPa, the compound pellets can be successfully formed into melt-blown nonwoven fabrics with a 10-micrometer diameter. The proposed melt-blown nonwoven fabrics can be processed with electret to form long-lasting electret melt-blown nonwoven filters.

Biodegradable and hydrophobic nanofibrous membranes produced by solution blow spinning for efficient oil/water separation

The development of nanofibrous oil-water separation materials is explosively progressing, but the remarkably low productivity is the main factor hindering their practical application. In this study, biodegradable polybutylene succinate (PBS) nanofibers with excellent productivity (27.0 g/h per nozzle) were successfully fabricated using the solution blow spinning (SBS) process, breaking away from the conventional electrospinning method. The prepared PBS nanofibers exhibited extremely thin fiber diameters (130 nm) with high porosity (97.4%). Without any chemical modification or inorganic/organic hybrid materialization, the PBS nanofibrous membrane showed excellent oil adsorption capacity (minimum: 18.7 g/g and maximum: 38.5 g/g) and separation efficiency; water and oil mixtures (99.4-99.98%) and emulsions (98.1-99.5%) compared to conventional organic polymer-based nanofibers. In terms of disposal after use, this biodegradable nanofibrous membrane was able to return to nature through hydrolysis and biodegradation processes.

Advanced functional nanofibers: strategies to improve performance and expand functions

Nanofibers have a wide range of applications in many fields such as energy generation and storage, environmental sensing and treatment, biomedical and health, thanks to their large specific surface area, excellent flexibility, and superior mechanical properties. With the expansion of application fields and the upgrade of application requirements, there is an inevitable trend of improving the performance and functions of nanofibers. Over the past few decades, numerous studies have demonstrated how nanofibers can be adapted to more complex needs through modifications of their structures, materials, and assembly. Thus, it is necessary to systematically review the field of nanofibers in which new ideas and technologies are emerging. Here we summarize the recent advanced strategies to improve the performances and expand the functions of nanofibers. We first introduce the common methods of preparing nanofibers, then summarize the advances in the field of nanofibers, especially up-to-date strategies for further enhancing their functionalities. We classify these strategies into three categories: design of nanofiber structures, tuning of nanofiber materials, and improvement of nanofibers assemblies. Finally, the optimization methods, materials, application areas, and fabrication methods are summarized, and existing challenges and future research directions are discussed. We hope this review can provide useful guidance for subsequent related work.

Graphical abstract

Multiphase CFD Modeling and Experimental Validation of Polymer and Attenuating Air Jet Interactions in Nonwoven Annular Melt Blowing

In annular melt blowing, fiber formation is achieved by accelerating a molten polymer via drag forces imparted by high velocity air that attenuates the polymer jet diameter. The interactions at the polymer-air interface, which govern the motion of the jets and impact the resulting fiber characteristics, are important but not well understood yet. This work details the development and validation of a multiphase computational fluid dynamics (CFD) model to investigate these interactions and the effects of three key melt blowing process parameters (polymer viscosity and throughput, and air velocity) on two critical fiber attributes - whipping instability and fiber diameter. Simulation results highlighted that whipping instability was driven by the polymer-air velocity differential, and the fiber diameter was primarily modulated by polymer throughput and air velocity. The CFD model was validated by modulating the polymer and air throughputs and analyzing the fiber diameter experimentally. Empirical results showed good agreement between fabricated and model-estimated fiber diameters, especially at lower air velocities. An additional CFD simulation performed using a melt blowing nozzle geometry and process parameters described in literature also confirmed good correlation between model estimates and literature empirical data.

Saving 80% Polypropylene in Facemasks by Laser-Assisted Melt-Blown Nanofibers

The ongoing coronavirus (COVID-19) pandemic requires enormous production of facemasks and related personal protection materials, thereby increasing the amount of nondegradable plastic waste. The core material for facemasks is melt-blown polypropylene (PP) fiber. Each disposable facemask consumes ∼0.7 g of PP fibers, resulting in annual global consumption and disposal of more than 1 150 000 tons of PP fibers annually. Herein, we developed a laser-assisted melt-blown (LAMB) technique to manufacture PP nanofibers with a quality factor of 0.17 Pa^-1 and significantly reduced the filter's weight. We demonstrated that a standard surgical facemask could be made with only 0.13 g of PP nanofibers, saving approximately 80% of the PP materials used in commercial facemasks. Theoretical analysis and modeling were also conducted to understand the LAMB process. Importantly, nanofibers can be easily scaled up for mass production by upgrading traditional melt blown line with scanning laser-assisted melt-blown (SLAMB).

An Overview of Recent Progress in Nanofiber Membranes for Oily Wastewater Treatment

Oil separation from water becomes a challenging issue in industries, especially when large volumes of stable oil/water emulsion are discharged. The present short review offers an overview of the recent developments in the nanofiber membranes used in oily wastewater treatment. This review notes that nanofiber membranes can efficiently separate the free-floating oil, dispersed oil and emulsified oil droplets. The highly interconnected pore structure nanofiber membrane and its modified wettability can enhance the permeation flux and reduce the fouling. The nanofiber membrane is an efficient separator for liquid-liquid with different densities, which can act as a rejector of either oil or water and a coalescer of oil droplets. The present paper focuses on nanofiber membranes' production techniques, nanofiber membranes' modification for flux and separation efficiency improvement, and the future direction of research, especially for practical developments.

High-throughput production of kilogram-scale nanofibers by Kármán vortex solution blow spinning

The interaction between gas flow and liquid flow, governed by fluid dynamic principles, is of substantial importance in both fundamental science and practical applications. For instance, a precisely designed gas shearing on liquid solution may lead to efficacious production of advanced nanomaterials. Here, we devised a needleless Kármán vortex solution blow spinning system that uses a roll-to-roll nylon thread to deliver spinning solution, coupled with vertically blowing airflow to draw high-quality nanofibers with large throughput. A wide variety of nanofibers including polymers, carbon, ceramics, and composites with tunable diameters were fabricated at ultrahigh rates. The system can be further upgraded from single thread to multiple parallel threads and to the meshes, boosting the production of nanofibers to kilogram scale without compromising their quality.

Optimization of the Spinneret Rotation Speed and Airflow Parameters for the Nozzleless Forcespinning of a Polymer Solution

This paper addresses the changing of the process parameters of nozzleless centrifugal spinning (forcespinning). The primary aim of this study was to determine the dependence of the final product on the dosing of the polymer, the rotation speed of the spinneret and the airflow in order to determine the extent of the technological applicability of aqueous polyvinyl alcohol (PVA) and its modifications. PVA was chosen because it is a widely used polymeric solution with environmentally friendly properties and good biodegradability. It is used in the health care and food packaging sectors. The nanofibrous layers were produced by means of a mobile handheld spinning device of our own construction. This mobile application of the spinning machine has several limitations compared to stationary laboratory equipment, mainly due to dimensional limitations. The uniqueness of our device lies in the possibility of its actual use outside the laboratory. In addition to improved mobility, another exciting feature is the combination of nozzleless forcespinning and fiber application using airflow. Dosing, the rotation speed of the spinnerets and the targeted and controlled use of air comprise the fundamental technological parameters for many devices that operate on a centrifugal force system. The rotation rate of the spinnerets primarily affects the production of fibers and their quality, while the airflow acts as a fiber transport and drying medium. The quality of the fibers was evaluated following the preparation of a testing set for the fiber layers. The most suitable combinations of rotation speed and airflow were then used in subsequent experiments to determine the ideal settings for the device. The solution was then modified by reducing the concentration to 16% and adding a surfactant, thus leading to a reduction in the diameters of the resulting fibers. The nanofiber layers so produced were examined using a scanning electron microscope (SEM) in order to analyze the number of defects and to statistically evaluate the fiber diameters.

Comparison of melt-blown and glass-fiber HEPA asbestos filters based on ISO filter classes, filtration efficiency, power consumption, and face velocity

The purpose of this study was to determine the most efficient airborne asbestos filter for use in an HEPA negative air machines through filter performance testing. The filter classes applied conformed with ISO and European standard (EN 1822) regarding fractional efficiency by dust loading amount for filters, fractional efficiency for negative air machines, and consumption of electrical power at filter size 0.3 μm. Class H13 had the highest fractional efficiency among the three experimental filter classes by particle size, at face velocity of (1, 2, and 3) m/s. Melt-blown (MB) filters exhibited higher fractional performance than did glass-fiber filters at all particle sizes tested (0.3, 0.5, and 1.0 µm). The power consumption of glass-fiber filters was higher (at 10 m³/min) than that of melt-blown filters. Therefore, melt blown filters would be more cost-effective than glass fiber filters for use in HEPA negative air machines, for protection against airborne asbestos.Implications: Air cleaner and related systems were developed to control a variety of airborne pollutants in general indoor environments, but there was no certified system for focusing on asbestos fractional efficiency using filter tests. Class H13 had the highest fractional efficiency among the three experimental filter classes by particle size, at face velocity of (1, 2, and 3) m/s. Melt-blown filters exhibited higher fractional performance than did glass-fiber filters at all particle sizes tested (0.3, 0.5, and 1.0 µm). The power consumption of glass-fiber filters was higher (at 10 m³/min) than that of melt-blown filters.

Application of Electrospun Nonwoven Fibers in Air Filters

Air filtration has seen a sizable increase in the global market this past year due to the COVID-19 pandemic. Nanofiber nonwoven mats are able to reach certain efficiencies with a low-pressure drop, have a very high surface area to volume ratio, filter out submicron particulates, and can customize the fiber material to better suit its purpose. Although electrospinning nonwoven mats have been very well studied and documented there are not many papers that combine them. This review touches on the various ways to manufacture nonwoven mats for use as an air filter, with an emphasis on electrospinning, the mechanisms by which the fibrous nonwoven air filter stops particles passing through, and ways that the nonwoven mats can be altered by morphology, structure, and material parameters. Metallic, ceramic, and organic nanoparticle coatings, as well as electrospinning solutions with these same materials and their properties and effects of air filtration, are explored.

Modeling the Triboelectric Behaviors of Elastomeric Nonwoven Fabrics

Theoretical modeling of triboelectric nanogenerators (TENGs) is fundamental to their performance optimization, since it can provide useful guidance on the material selection, structure design, and parameter control of relevant systems. Built on the theoretical model of film-based TENGs, here, an analytical model is introduced for conductor-to-dielectric contact-mode nonwoven-based TENGs, which copes with the unique hierarchical structure of nonwovens and details the correlation between the triboelectric output (maximum transferred charge density) and nonwoven structural parameters (thickness, solidity, and average fiber diameter). A series of styrene-ethylene-butylene-styrene nonwoven samples are fabricated through a melt-blowing process to map nonwoven structural features within certain ranges, while an ion-injection protocol is adopted to quantify the triboelectric output with superior consistency and reproducibility. With a database containing structural features and triboelectric output of 43 nonwoven samples, a good model fitting is achieved via nonlinear regression analysis in Python, which also shows good predictive power and suggests the existing of tribo-output maxima at a specific thickness, solidity, or average fiber diameter when other structural parameters are fixed. The model is also successfully applied to a group of polypropylene meltblown nonwovens, which verifies its universality on meltblown-nonwoven-based TENGs.

Masks for COVID-19

Sustainable solutions on fabricating and using a face mask to block the severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) spread during this coronavirus pandemic of 2019 (COVID-19) are required as society is directed by the World Health Organization (WHO) toward wearing it, resulting in an increasingly huge demand with over 4 000 000 000 masks used per day globally. Herein, various new mask technologies and advanced materials are reviewed to deal with critical shortages, cross-infection, and secondary transmission risk of masks. A number of countries have used cloth masks and 3D-printed masks as substitutes, whose filtration efficiencies can be improved by using nanofibers or mixing other polymers into them. Since 2020, researchers continue to improve the performance of masks by adding various functionalities, for example using metal nanoparticles and herbal extracts to inactivate pathogens, using graphene to make masks photothermal and superhydrophobic, and using triboelectric nanogenerator (TENG) to prolong mask lifetime. The recent advances in material technology have led to the development of antimicrobial coatings, which are introduced in this review. When incorporated into masks, these advanced materials and technologies can aid in the prevention of secondary transmission of the virus.

High-performance Electret and Antibacterial Polypropylene Meltblown Nonwoven Materials Doped with Boehmite and ZnO Nanoparticles for Air Filtration

The current pandemic caused by COVID-19 has intensively triggered the development of high-performance air filters. Polypropylene (PP) is widely used as the raw material of meltblown nonwoven materials and is the core layer in air filters, such as masks. In this study, an electret PP meltblown nonwoven with antibacterial activity was developed, and nano boehmite (AlOOH) and nano-ZnO were employed as electret and antibacterial agents, respectively. AlOOH (0.5–2.0 wt%) and ZnO (1.0 wt%) were doped into the PP matrix using a twin-screw extruder, and the resulting masterbatches were applied as raw materials to produce nonwoven materials via a meltblown process. The as-prepared nonwoven samples were characterized by means of SEM, IR and DSC/TG. After corona charging, the filtration efficiency was determined by a filtration tester, charge decay was measured by an infrared electrostatic tester, and the antibacterial properties were evaluated (evaluation method: AATCC 100–2012). A dosage of AlOOH greater than 1.0 wt% endowed the nonwoven material with high filtration efficiency, and 1.0 wt% ZnO brought about antibacterial activity. Corona charging was an effective means to charge the nonwoven electret, and the charges were quicker to decay in air than in a sealed bag. The as-prepared meltblown nonwoven filter is a remarkably promising filter for air filtration.

Preliminary Study of the Effect of Secondary Airflow on Fiber Attenuation During Melt Blowing

In order to enhance the fiber attenuation during the melt-blown process, a pair of air nozzle, which could erupt airflow as secondary airflow, below the spinning die was arranged and used. Firstly, the effect of applying secondary airflow on the whole airflow was explored by Computational Fluid Dynamics (CFD) simulation. The simulation results demonstrate the interactive relationship between the primary airflow from the spinning die and the secondary airflow. Then, the air velocity of the whole airflow at conditions of with and without secondary airflow was experimental verified. Finally, the effect of secondary airflow on the fiber diameter and the fiber evenness was investigated by a spinning experiment. The spinning results reveals that the application of secondary airflow does not certainly enhance the fiber attenuation. The fiber diameter decreases only when the inlet velocity of secondary airflow is higher than a critical value. In addition, the spinning experiment indicates that the application of secondary airflow improves the evenness of fiber.

Entirely environment-friendly polylactide composites with outstanding heat resistance and superior mechanical performance fabricated by spunbond technology: Exploring the role of nanofibrillated stereocomplex polylactide crystals

This study aims at investigating the manufacturing and characterization of all-polylactide composites prepared by melt spunbond spinning technology. To do so, a series of asymmetric stereocomplex polylactide (SC-PLA) blends (PLLA 95 wt%/PDLA 5 wt%) was melt spun. To examine the impact of molecular structure of PDLA, the blends of linear PLLA, and low and high molecular weight as well as branched PDLAs, were subjected to a single step spunbond process. DSC thermograms of the samples showed two melting temperatures at around 170 °C and 210 °C, which were attributed to the melting of homo and stereocomplex crystals, respectively. The samples were spun at 190 °C, between the homo and stereocomplex crystals' melting temperatures, and at 230 °C, above the stereocomplex crystals' melting temperature. Morphology images showed the formation of fibers in the range of 40-50 μm. Shear rheological measurements revealed that the spun SC-PLA samples had a substantially higher viscosity and storage modulus in the low frequency region, and higher shear thinning behavior, compared to the non-spun samples. Extensional rheology measurements also showed that the spun samples demonstrated strain hardening behavior. Substantial enhancement of rheological properties was noted for the samples containing the branched and high molecular weight PDLA spun at 230 °C. After etching, the spun samples at 190 °C exhibited small spherical crystals with diameters in the range of 80-90 nm, whereas comparatively thin fibers in the size range of 60-70 nm were observed for the samples spun at 230 °C. Remarkable enhancements up to 100% and 60% was noted for the tensile modulus and strength, respectively, of the spun SC-PLA samples. The spun fibers also demonstrated a considerable reduction in boiling water and hot air shrinkage. The distinctive role of nanofibrillated stereocomplex crystals as a rheology modifier and a crystallization nucleating agent makes PLA more sustainable and paves the way for the fabricated all-PLA composites in applications requiring high heat resistance and superior mechanical performance. The present study unequivocally indicates a huge potential for the sustainable entirely all-PLA products manufactured by fiber in fiber and, indeed, unfolds unknown opportunities for PLA-based merchandises in future.

Multifunctional Electrospun Nanofibers Based on Biopolymer Blends and Magnetic Tubular Halloysite for Medical Applications

Tubular halloysite (HNT) is a naturally occurring aluminosilicate clay with a unique combination of natural availability, good biocompatibility, high mechanical strength, and functionality. This study explored the effects of magnetically responsive halloysite (MHNT) on the structure, morphology, chemical composition, and magnetic and mechanical properties of electrospun nanofibers based on polycaprolactone (PCL) and gelatine (Gel) blends. MHNT was prepared via a simple modification of HNT with a perchloric-acid-stabilized magnetic fluid–methanol mixture. PCL/Gel nanofibers containing 6, 9, and 12 wt.% HNT and MHNT were prepared via an electrospinning process, respecting the essential rules for medical applications. The structure and properties of the prepared nanofibers were studied using infrared spectroscopy (ATR-FTIR) and electron microscopy (SEM, STEM) along with energy-dispersive X-ray spectroscopy (EDX), magnetometry, and mechanical analysis. It was found that the incorporation of the studied concentrations of MHNT into PCL/Gel nanofibers led to soft magnetic biocompatible materials with a saturation magnetization of 0.67 emu/g and coercivity of 15 Oe for nanofibers with 12 wt.% MHNT. Moreover, by applying both HNT and MHNT, an improvement of the nanofibers structure was observed, together with strong reinforcing effects. The greatest improvement was observed for nanofibers containing 9 wt.% MHNT when increases in tensile strength reached more than two-fold and the elongation at break reached a five-fold improvement.

Airflow, Fiber Dynamic Whipping, and Final Fiber Diameter in Flush Sharp-Die Melt Blowing with Different Air-Slot Widths

Melt streams were attenuated into microfibers by high-speed airflow during melt blowing. The present work explored the effect of air-slot width on the fiber diameter and diameter evenness in flush sharp-die melt blowing. The airflow in different die melt blowing was first numerically simulated by the CFD approach. Then, the fiber dynamic whipping was captured by high-speed photography. Finally, a spinning experiment was implemented and the fiber diameters were measured. The result reveals that the sharp die with a larger air-slot width produces fibers with a larger diameter, but the uniformity is obviously better. This study reveals that the air flow, fiber whipping, and final fiber diameter are closely related to each other. The quality control of melt-blown fiber can be carried out by controlling the fiber whipping motion.

A Review on Electrospun Nanofibers Based Advanced Applications: From Health Care to Energy Devices

Electrospun nanofibers have been exploited in multidisciplinary fields with numerous applications for decades. Owing to their interconnected ultrafine fibrous structure, high surface-to-volume ratio, tortuosity, permeability, and miniaturization ability along with the benefits of their lightweight, porous nanofibrous structure, they have been extensively utilized in various research fields for decades. Electrospun nanofiber technologies have paved unprecedented advancements with new innovations and discoveries in several fields of application including energy devices and biomedical and environmental appliances. This review article focused on providing a comprehensive overview related to the recent advancements in health care and energy devices while emphasizing on the importance and uniqueness of utilizing nanofibers. A brief description regarding the effect of electrospinning techniques, setup modifications, and parameters optimization on the nanofiber morphology was also provided. The article is concluded with a short discussion on current research challenges and future perspectives.

Bifunctional ZIF-8 Grown Webs for Advanced Filtration of Particulate and Gaseous Matters: Effect of Charging Process on the Electrostatic Capture of Nanoparticles and Sulfur Dioxide

Metal-organic framework (MOF), an emerging class of porous hybrid inorganic-organic crystals, has been applied for various environmental remediation strategies including liquid and air filtration. In this study, the role of the zeolite imidazole framework-8 (ZIF-8) was explored on the charge trapping ability and its contribution to capturing the targeted pollutants of NaCl nanoparticles and SO₂ gas. Poly(lactic acid) fibers with controlled surface pores were electrospun using water vapor-induced phase separation, and the fiber surface was uniformly coated with ZIF-8 crystals via an in situ growth method. As a novel process approach, the corona charging process was applied to the ZIF-8 grown webs. The ZIF-8 promoted the charge trapping in the corona process, and the charged ZIF-8 web showed a significantly improved electrostatic filtration efficiency. Also, the charged ZIF-8 web showed an enhanced SO₂ capture ability, both in the static and dynamic air flow states, demonstrating the applicability as a bifunctional filter for both particulate and gaseous matters. The approach of this study is novel in that both particulate and gas capture capabilities were associated with the charge trapping ability of ZIF-8, implementing the corona charging process to the ZIF-8 webs.

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.

A Current Review on Drug Loaded Nanofibers: Interesting and Valuable Platform for Skin Cancer Treatment

BACKGROUND

Nanofibers are used in topical medication for various skin diseases like wound healing, skin cancer and others. Non-melanoma skin cancers (NMSCs) are the most widely distributed diseases in the world, of which 99% of people are affected by either basal cell carcinomas (BCCs) or squamous cell carcinomas (SCCs) of the skin. Skin malignancy is caused by direct sun exposure and regular application of unsafe restorative items on the skin.

OBJECTIVE

This review presents the use of nanofibers in skin cancer treatment and advances made in skin cancer treatment.

METHODS

There are various methods used in the production of nanofibers such as bicomponent extrusion, phase separation, template synthesis, drawing, electrospinning, and others. Electrospinning is the most widely used technique for nanofiber fabrication. The nanofibers are produced in nanometer size range and mostly used in medication because of their low thickness, large surface area per unit mass and porosity. Nanofibers are also used as drug delivery system for sustaining the action of drugs or medicaments.

RESULTS

Nanofibers enhance the permeation and availability of those drugs having low bioavailability and low permeability. Nanofibers increase the sustainability of the drugs up to 10 days.

CONCLUSION

Skin cancer is the abnormal growth of skin cells in the body influencing people of all colours and skin. In this review paper, the definition and production techniques of nanofibers and drugs used in skin cancer treatment and the relation between skin cancer and nanofiber are illustrated in detail. With the help of different techniques and drugs, the risk of non-melanoma skin cancer is reduced. Lay Summary: The risk of skin cancer and other skin problems is increasing day by day. In a previous study we found that the nanofibers are less used as a topical delivery system. We have studied the nanofibers as a drug delivery system in the treatment of skin cancer by using different drugs. According our study nanofibers are most useful in skin drug delivery and if the nanofiber, are merging with other drug delivery system like nanoparticles, it may maximize the output of drug into skin. The significance of this study is, to explain all information about nanofibers in skin cancer.

In Situ Visualization for Control of Nano-Fibrillation Based on Spunbond Processing Using a Polypropylene/Polyethylene Terephthalate System

In situ generation of polyethylene terephthalate (PET) nanofibrils in polypropylene (PP) microfibers via fiber spinning in a spunbond process was studied in this work. The effects of polymer flow rate and air speed in the drafter on the formation of PET fibrils were investigated using a pilot scale machine. An in-situ visualization technique was applied to examine the fiber evolution events and stretch profile at die exit. A scanning electron microscope was used to analyze and investigate the morphology of the dispersed domain. The PET dispersed phase was fibrillated within the PP matrix such that a nonofibrillated composite containing fibrils with an average size around 100 nm was obtained. It was found that the final fibril size directly depends on the degree of die swell, the air speed and the polymer flow rate. It was also found that the in situ observed size of the micro-scale PP/PET fibers was well correlated to the size of the nano-scale PET fibers formed in the PP matrix. The visualization results revealed that a smaller fibril diameter was obtainable by increasing the stretching on the spin line and/or decreasing the die swell.

Case study into the successful emergency production and certification of a filtering facepiece respirator for Belgian hospitals during the COVID-19 pandemic

The SARS-CoV-2 pandemic presented European hospitals with chronic shortages of personal protective equipment (PPE) such as surgical masks and respirator masks. Demand outstripped the production capacity of certified European manufacturers of these devices. Hospitals perceived emergency local manufacturing of PPE as an approach to reduce dependence on foreign supply. The fact of a pandemic does not circumvent the hospital's responsibility to provide appropriate protective equipment to their staff, so the emergency production needed to result in devices that were certified by testing agencies. This paper is a case study of the emergency manufacturing of respirator masks during the first month of the first wave of SARS-CoV-2 pandemic and is separated into two distinct phases. Phase A describes the three-panel folding facepiece respirator design, material sourcing, performance testing, and an analysis of the folding facepiece respirator assembly process. Phase B describes the redevelopment of individual steps in the assembly process.

Review on Spinning of Biopolymer Fibers from Starch

Increasing interest in bio-based polymers and fibers has led to the development of several alternatives to conventional plastics and fibers made of these materials. Biopolymer fibers can be made from renewable, environmentally friendly resources and can be fully biodegradable. Biogenic resources with a high content of carbohydrates such as starch-containing plants have huge potentials to substitute conventional synthetic plastics in a number of applications. Much literature is available on the production and modification of starch-based fibers and blends of starch with other polymers. Chemistry and structure–property relationships of starch show that it can be used as an attractive source of raw material which can be exploited for conversion into a number of high-value bio-based products. In this review, possible spinning techniques for the development of virgin starch or starch/polymer blend fibers and their products are discussed. Beneficiation of starch for the development of bio-based fibers can result in the sustainable replacement of oil-based high-value materials with cost-effective, environmentally friendly, and abundant products.

Polymer, Additives, and Processing Effects on N95 Filter Performance

The current severe acute respiratory syndrome coronavirus 2 (SARS-COV-2) pandemic has highlighted the need for personal protective equipment, specifically filtering facepiece respirators like N95 masks. While it is common knowledge that polypropylene (PP) is the industry standard material for filtration media, trial and error is often required to identify suitable commercial precursors for filtration media production. This work aims to identify differences between several commercial grades of PP and demonstrate the development of N95 filtration media with the intent that the industry partners can pivot and help address N95 shortages. Three commercial grades of high melt flow index PP were melt blown at Oak Ridge National Laboratory and broadly characterized by several methods including differential scanning calorimetry (DSC), X-ray diffraction (XRD), and neutron scattering. Despite the apparent similarities (high melt flow and isotacticity) between PP feedstocks, the application of corona charging and charge enhancing additives improve each material to widely varying degrees. From the analysis performed here, the most differentiating factor appears to be related to crystallization of the polymer and the resulting electret formation. Materials with higher crystallization onset temperatures, slower crystallization rates, and larger number of crystallites form a stronger electret and are more effective at filtration.

Multi-Layered, Corona Charged Melt Blown Nonwovens as High Performance PM0.3 Air Filters

Particulate matter (PM) and airborne viruses bring adverse influence on human health. As the most feasible way to prevent inhalation of these pollutants, face masks with excellent filtration efficiency and low press drop are in urgent demand. In this study, we report a novel methodology for producing high performance air filter by combining melt blown technique with corona charging treatment. Changing the crystal structure of polypropylene by adding magnesium stearate can avoid charge escape and ensure the stability of filtration performances. Particularly, the influence of fiber diameter, pore size, porosity, and charge storage on the filtration performances of the filter are thoroughly investigated. The filtration performances of the materials, including the loading test performance are also studied. The melt blown materials formed by four layers presented a significant filtration efficiency of 97.96%, a low pressure drop of 84.28 Pa, and a high quality factor (QF) of 0.046 Pa-1 for paraffin oil aerosol particles. Meanwhile, a robust filtration efficiency of 99.03%, a low pressure drop of 82.32 Pa, and an excellent QF of 0.056 Pa-1 for NaCl aerosol particles could be easily achieved. The multi-layered melt blown filtration material developed here would be potentially applied in the field of protective masks.

Synthesis of nano-fibers containing nano-curcumin in zein corn protein and its physicochemical and biological characteristics

Curcumin contains many biological activities as a natural bioactive substance, however, its low solubility stands as a huge bioavailability disadvantage. Recently, different methods have been developed for utilizing the tremendous medicinal properties of this material. In this study, an Oil/Water nano-emulsion of curcumin (Nano-CUR) has been woven in zein polymer at three percentages of 5%, 10%, and 15% (v/v). We have investigated the physicochemical properties of nanofibers (NFs) including FESEM, FTIR, tensile strength, encapsulation efficiency, and release profile, as well as biological properties. According to the data, the NFs have been observed to become significantly thinner and more uniformed as the involved percentage of Nano-CUR had been increased from 5 to 15%. It is considerable that the tensile strength can be increased by heightening the existing Nano-CUR from 5% towards 15%. The resultant NFs of zein/Nano-CUR 15% have exhibited higher in vitro release and lower encapsulation efficiency than the other evaluated zein/Nano-CUR NFs. It has been confirmed through the performed viability and antioxidant studies that zein/Nano-CUR 10% NFs are capable of providing the best conditions for cell proliferation. Considering the mentioned facts, this work has suggested that Nano-CUR can be successfully woven in zein NFs and maintain their biological properties.

Nonwoven Materials Produced by Melt Electrospinning of Polypropylene Filled with Calcium Carbonate

Nowadays, polypropylene-based nonwovens are used in many areas, from filtration to medicine. One of the methods for obtaining such materials is melt electrospinning. In some cases, it is especially interesting to produce composite fibers with a high degree of filling. In this work, the influence of the filling degree of isotactic polypropylene with calcium carbonate on the structure and properties of nonwoven materials obtained by melt electrospinning was studied. It was shown that electrospinning is possible, even at a filler content of 50%, while the average diameter of the fibers increases with the growth in the content of calcium carbonate. The addition of sodium stearate significantly reduces the diameter of the fibers (from 10–65 to 2–10 microns) due to reducing viscosity and increasing the electrical conductivity of the melt. Wide-angle X-ray diffraction analysis and IR spectroscopy reveal that the initial polymer and composites are characterized by the presence of stable α-form crystals, while nonwovens show a predominance of smectic mesophase. The addition of calcium carbonate leads to an increase in the hydrophobicity of the composite films, the addition of sodium stearate results in a decrease of hydrophobicity, while all nonwovens demonstrate superhydrophobic properties.