Influence of rheology and surface properties on morphology of nanofibers derived from islands-in-the-sea meltblown nonwovens

Advances in high-throughput, high-capacity nonwoven membranes for chromatography in downstream processing: A review

Nonwoven membranes are highly engineered fibrous materials that can be manufactured on a large scale from a wide range of different polymers, and their surfaces can be modified using a large variety of different chemistries and ligands. The fiber diameters, surface areas, pore sizes, total porosities, and thicknesses of the nonwoven mats can be carefully controlled, providing many opportunities for creative approaches for the development of novel membranes with unique properties to meet the needs of the future of downstream processing. Fibrous membranes are already finding use in ultrafiltration, microfiltration, depth filtration, and, more recently, in membrane chromatography for product capture and impurity removal. This article summarizes the various methods of manufacturing nonwoven fabrics, and the many methods available for the modification of the fiber surfaces. It also reviews recent studies focused on the use of nonwoven fabric devices in membrane chromatography and provides some perspectives on the challenges that need to be overcome to increase binding capacities, decrease residence times, and reduce pressure drops so that eventually they can replace resin column chromatography in downstream process operations.

Enhancing Mechanical Performance of High-Density Polyethylene at Different Environmental Conditions with Outstanding Foamability through In-Situ Rubber Nanofibrillation: Exploring the Impact of Interface Modification

In this study, we utilized in situ nanofibrillation of thermoplastic polyester ether elastomer (TPEE) within a high-density polyethylene (HDPE) matrix to enhance the rheological properties, foamability, and mechanical characteristics of the HDPE nanocomposite at both room and subzero temperatures. Due to the inherent polarity differences between these two components, TPEE is thermodynamically incompatible with the nonpolar HDPE. To address this compatibility issue, we employed a compatibilizer, styrene/ethylene-butylene/styrene copolymer-grafted maleic anhydride (SEBS-g-MA), to reduce the interfacial tension between the two blend components. In the initial step, we prepared a 10% masterbatch of HDPE/TPEE with and without the compatibilizer using a twin-screw extruder. Subsequently, we processed the 10% masterbatch further through spun bonding to create fiber-in-fiber composites. Scanning electron microscopy (SEM) analysis revealed a significant reduction in the spherical size of HDPE/TPEE particles following the inclusion of SEBS-g-MA, as well as a much smaller TPEE nanofiber size (approximately 60-70 nm for 5% TPEE). Moreover, extensional rheological testing revealed a notable enhancement in extensional rheological properties, with strain-hardening behavior being more pronounced in the compatibilized nanofibrillar composites compared to the noncompatibilized ones. SEM images of the foam structures depicted substantial improvement in the foamability of HDPE in terms of the cell size and density following the nanofibrillation process and the use of the compatibilizer. Ultimately, the in situ rubber fibrillation and enhancement of HDPE and TPEE interface using a compatibilizer led to increasing the HDPE ductility at room and subzero temperatures while maintaining its stiffness.

Electrospinning Nonspinnable Sols to Ceramic Fibers and Springs

Electrospinning has been applied to produce ceramic fibers using sol gel-based spinning solutions consisting of ceramic precursors, a solvent, and a polymer to control the viscosity of the solution. However, the addition of polymers to the spinning solution makes the process more complex, increases the processing time, and results in porous mechanically weak ceramic fibers. Herein, we develop a coelectrospinning technique, where a nonspinnable sol (<10 mPa s) consisting of only the ceramic precursor(s) and solvent(s) is encapsulated inside a polymeric shell, forming core-shell precursor fibers that are further calcined into ceramic fibers with reduced porosity, decreased surface defects, uniform crystal packing, and controlled diameters. We demonstrate the versatility of this method by applying it to a series of nonspinnable sols and creating high-quality ceramic fibers containing TiO2, ZrO2, SiO2, and Al2O3. The polycrystalline TiO2 fibers possess excellent flexibility and a high Young's modulus reaching 54.3 MPa, solving the extreme brittleness problem of the previously reported TiO2 fibers. The single-component ZrO2 fibers exhibit a Young's modulus and toughness of 130.5 MPa and 11.9 KJ/m3, respectively, significantly superior to the counterparts prepared by conventional sol-gel electrospinning. We also report the creation of ceramic fibers in micro- and nanospring morphologies and examine the formation mechanisms using thermomechanical simulations. The fiber assemblies constructed by the helical fibers exhibit a density-normalized toughness of 3.5-5 times that of the straight fibers due to improved fracture strain. This work expands the selection of the electrospinning solution and enables the development of ceramic fibers with more attractive properties.

Evaluation of the degradation of the graphene-polypropylene composites of masks in harsh working conditions

The recent COVID-19 outbreak has led health authorities to recommend at least the use of surgical masks, most preferably respirators (FFP2 or KN95), to prevent the spread of the virus. Non-woven fabrics have been chosen as the best option to manufacture the face masks, due to their filtration efficiency, low cost, and versatility. Modifying the mask filters with graphene has been of great interest due to its potential use as antibacterial and virucidal properties. Indeed, some companies have commercialized face masks in which graphene is coated and/or embedded. However, the Canadian sanitary authorities advised against using the Shandong Shengquan New Materials Co. graphene masks because of the possibility of pulmonary damage produced by graphene inhalation. Thus, we have analyzed the stability of the graphene filter of these masks and compared it with two other commercially available graphene mask filters, evaluating the morphological and spectroscopical change of the fibers, as well as the particles released during the endurance tests. Our work introduces the necessary tools and methodology to evaluate the potential degradation of face masks under extreme working conditions. These methods complement the present standard tests ensuring the security of the new filters based on composites or nanomaterials.

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.

Evidence for bicomponent fibers: A review

Recently, bicomponent fibers have been attracting much attention due to their unique structural characteristics and properties. A common concern was how to characterize a bicomponent fiber. In this review, we generally summarized the classification, structural characteristics, preparation methods of the bicomponent fibers, and focused on the experimental evidence for the identification of bicomponent fibers. Finally, the main challenges and future perspectives of bicomponent fibers and their characterization are provided. We hope that this review will provide readers with a comprehensive understanding of the design and characterization of bicomponent fibers.

Screening of core filter layer for the development of respiratory mask to combat COVID-19

The severe outbreak of respiratory coronavirus disease 2019 has increased the significant demand of respiratory mask and its use become ubiquitous worldwide to control this unprecedented respiratory pandemic. The performance of a respiratory mask depends on the efficiency of the filter layer which is mostly made of polypropylene melt blown non-woven (PP-MB-NW). So far, very limited characterization data are available for the PPE-MB-NW in terms to achieve desired particulate filtration efficiency (PFE) against 0.3 µm size, which are imperative in order to facilitate the right selection of PP-MB-NW fabric for the development of mask. In present study, eight different kinds of PP-MB-NW fabrics (Sample A-H) of varied structural morphology are chosen. The different PP-MB-NW were characterized for its pore size and distribution by mercury porosimeter and BET surface area analyzer was explored first time to understand the importance of blind pore in PFE. The PP-MB-NW samples were characterized using scanning electron microscopy so as to know the surface morphology. The filtration efficiency, pressure drop and breathing resistance of various PP-MB-NW fabric samples are investigated in single and double layers combination against the particle size of 0.3, 0.5 and 1 µm. The samples which are having low pore dia, high solid fraction volume, and low air permeability has high filtration efficiency (> 90%) against 0.3 µm particle with high pressure drop (16.3-21.3 mm WC) and breathing resistance (1.42-1.92 mbar) when compared to rest of the samples. This study will pave the way for the judicial selection of right kind of filter layer i.e., PP-MB-NW fabric for the development of mask and it will be greatly helpful in manufacturing of mask in this present pandemic with desired PFE indicating considerable promise for defense against respiratory pandemic.

Air-Filtering Masks for Respiratory Protection from PM2.5 and Pandemic Pathogens

Air-filtering masks, also known as respirators, protect wearers from inhaling fine particulate matter (PM2.5) in polluted air, as well as airborne pathogens during a pandemic, such as the ongoing COVID-19 pandemic. Fibrous medium, used as the filtration layer, is the most essential component of an air-filtering mask. This article presents an overview of the development of fibrous media for air filtration. We first synthesize the literature on several key factors that affect the filtration performance of fibrous media. We then concentrate on two major techniques for fabricating fibrous media, namely, meltblown and electrospinning. In addition, we underscore the importance of electret filters by reviewing various methods for imparting electrostatic charge on fibrous media. Finally, this article concludes with a perspective on the emerging research opportunities amid the COVID-19 crisis.

Porous Fiber Processing and Manufacturing for Energy Storage Applications

The objective of this article is to provide an overview on the current development of micro- and nanoporous fiber processing and manufacturing technologies. Various methods for making micro- and nanoporous fibers including co-electrospinning, melt spinning, dry jet-wet quenching spinning, vapor deposition, template assisted deposition, electrochemical oxidization, and hydrothermal oxidization are presented. Comparison is made in terms of advantages and disadvantages of different routes for porous fiber processing. Characterization of the pore size, porosity, and specific area is introduced as well. Applications of porous fibers in various fields are discussed. The emphasis is put on their uses for energy storage components and devices including rechargeable batteries and supercapacitors.

Zeolitic Imidazolate Framework-8/Polypropylene-Polycarbonate Barklike Meltblown Fibrous Membranes by a Facile in Situ Growth Method for Efficient PM2.5 Capture

Environmental pollution, especially air pollution, seriously endangers public health globally. Due to severe air pollution, air filters still face many challenges, especially in terms of filtration performance and filtration stability. Herein, a zeolitic imidazolate framework-8/polypropylene-polycarbonate barklike meltblown fibrous membrane (PPC/ZIF-8) was designed through meltblown and an in situ growth method, achieving efficient PM_2.5 capture and high filtration stability under a harsh environment. After in situ growth, the PPC/ZIF-8 membrane could dramatically enhance the PM_2.5 filtration efficiency without increasing the pressure drop; the PM_2.5 filtration efficiency and quality factor were up to 32.83 and 116.86% higher than those of the pure PPC membrane, respectively. Moreover, through five filtration-wash-dry cycles, the PM_2.5 filtration performance is still at a high level. This PPC/ZIF-8 membrane provides a new strategy for the preparation of an air filter with excellent comprehensive filtration performance.

Multifunctional Polymer Composites Produced by Melt-Blown Technique to Use in Filtering Respiratory Protective Devices

In this work, a multifunctional polymer composite is made using melt-blowing technology from polypropylene (88 wt.%) and poly (ethylene terephthalate) (12 wt.%) with the addition of functional modifiers, that is, 3 g of a superabsorbent polymer and 5 g of a biocidal agent (Biohaloysite). The use of modifiers is aimed at obtaining adequate comfort when using the target respiratory protection equipment (RPE) in terms of microclimate in the breathing zone and protection against harmful aerosols including bioaerosols. The developed production method is innovative in that the two powdered modifiers are simultaneously applied in the stream of elementary polymeric fibers by two independent injection systems. Aerosols of the modifiers are supplied via a specially designed channel in the central segment of the die assembly, reducing the amount of materials used in the production process and saving energy. The results show that the proposed method of incorporating additives into the fiber structure did not adversely affect the protective and functional properties of the resulting filtration nonwovens. The produced nonwoven composites are characterized by SEM, FTIR, and differential scanning calorimetry (DSC). Given their high filtration efficiency at 5%, satisfactory airflow resistance (~200 Pa), very good antimicrobial activity, and excellent water absorption capacity, the obtained multifunctional nonwoven composites may be successfully used in filtering respiratory protective devices.

One-Step Bark-Like Imitated Polypropylene (PP)/Polycarbonate (PC) Nanofibrous Meltblown Membrane for Efficient Particulate Matter Removal

A bark-like imitated polypr opylene (PP)/polycarbonate (PC) nanofibrous membrane was constructed by one-step meltblown technique for efficient particulate matter (PM) removal. The effects of PC content (0%, 1%, 3%, 5%, and 7%) on membrane thermal stability, microscopic characteristics, filtration performance, hydrophilicity, and water vapor transmission were investigated. The results demonstrated that using facile design of incompatibility and viscosity difference between PC and PP polymers decreases average fiber diameter, creating a bark-like groove appearance and increasing surface potential, making a new PP/PC membrane with high filtration performance. The resultant PP/PC membrane had finer average fiber diameter of 0.63 μm, which was nearly 89.41% lower than PP membranes (5.95 μm), and its quality factor (0.036 Pa-1) was nearly 2.12 times than that of PP membranes (0.017 Pa-1) with the die hole diameter of 0.5 mm. This fabrication technique of a special meltblown filter membrane saves the cost of die retrofitting and post-processing, which provides an innovative method for particulate efficient removal of high efficient filters.

Lateral Diffusion of a Free Air Jet in Slot-Die Melt Blowing for Microfiber Whipping

In melt blowing, microfibrous nonwoven material is manufactured by using high-speed air to attenuate polymer melt. The melt-blown air jet determines the process of polymer attenuation and fiber formation. In this work, the importance of lateral velocity on the fiber was first theoretical verified. The lateral diffused characteristic of the air flow field in slot-die melt blowing was researched by measuring the velocity direction using a dual-wire probe hot-wire anemometer. Meanwhile, the fiber path was captured by high-speed photography. Results showed that there existed a critical boundary of the lateral diffusion, however, air jets in the x–z plane are a completely diffused field. This work indicates that the lateral velocity in the y–z plane is one of the crucial factors for initiating fiber whipping and fiber distribution.