One-step melt-blowing of multi-scale micro/nano fabric membrane for advanced air-filtration

Production of Ultrafine PVDF Nanofiber-/Nanonet-Based Air Filters via the Electroblowing Technique by Employing PEG as a Pore-Forming Agent

Particles with diameters smaller than 2.5 μm (PM2.5) can penetrate the respiratory system and have negative impacts on human health. Filter media with a porous surface and nanofiber/nanonet structure demonstrate superior filtration performance compared to traditional nano- and microfiber-based filters. In this study, nanostructured filters were produced using the electroblowing method from solutions containing different ratios of poly(vinylidene fluoride) (PVDF) and polyethylene glycol (PEG) polymers for the first time. By increasing the water-soluble PEG ratio in PVDF/PEG blend nanofibers and employing a water bath treatment to the produced mat afterward, a more porous fibrous structure was obtained with a lower average fiber diameter. Notably, the removal of PEG from the PVDF/PEG (3-7) sample, which had the highest PEG content, exhibited clustered nanofiber-/nanonet-like structures with average diameters of 170 and 50 nm at the points where the fibers intersect. Although this process resulted in a slight decrease in the filtration efficiency (-1.3%), the significant reduction observed in pressure drop led to a 3.2% increase in the quality factor (QF). Additionally, by exploiting the polarizability of PVDF under an electric field, the filtration efficiency of the nanostructured PVDF filters enhanced with a ratio of 3.6% after corona discharge treatment leading to a 60% improvement in the QF. As a result, the PVDF/PEG (3-7) sample presented an impressive filtration efficiency of 99.57%, a pressure drop (ΔP) of 158 Pa, and a QF of 0.0345 Pa-1.

Fabrication of PS/PVDF-HFP Multi-Level Structured Micro/Nano Fiber Membranes by One-Step Electrospinning

Recently, the multi-level interwoven structured micro/nano fiber membranes with coarse and fine overlaps have attracted lots of attention due to their advantages of high surface roughness, high porosity, good mechanical strength, etc., but their simple and direct preparation methods still need to be developed. Herein, the multi-level structured micro/nano fiber membranes were prepared novelly and directly by a one-step electrospinning technique based on the principle of micro-phase separation caused by polymer incompatibility using polystyrene (PS) and polyvinylidene fluoride-hexafluoropropylene copolymer (PVDF-HFP) as raw materials. It was found that different spinning fluid parameters and various spinning process parameters will have a significant impact on its morphology and structures. Under certain conditions (the concentration of spinning solution is 18 wt%, the mass ratio of PS to PVDF-HFP is 1:7, the spinning voltage is 30 kV, and the spinning receiving distance is 18 cm), the PS/PVDF-HFP membrane with optimal multi-level structured micro/nano fiber membranes could be obtained, which present an average pore size of 4.38 ± 0.10 μm, a porosity of 78.9 ± 3.5%, and a water contact angle of 145.84 ± 1.70°. The formation mechanism of micro/nano fiber interwoven structures was proposed through conductivity and viscosity tests. In addition, it was initially used as a separation membrane material in membrane distillation, and its performance was preliminarily explored. This paper provides a theoretical and experimental basis for the research and development of an efficient and feasible method for the preparation of multi-level micro/nano fiber membranes.

Functionalized nanofibers in gas sorption process: a critical review on the challenges and prospective research

Air pollution has become the most important environmental and human health threat as it is accounting for about 7 million deaths across the globe every year. Particulate matter (PM) derived from the combustion of fossil fuels, biomass, and other agricultural residues pollutes the atmospheric air which affects the quality of the environment and poses a great threat to human health. Ecological imbalance, climatic variation, and cardiovascular and respiratory problems among humans are significant extortions due to PM pollution. Scientific approaches were initiated to limit the levels of PM in the atmospheric air and the use of nanofiber mats has received wide attention as these possess versatile properties including nanoscale-sized pore structure, homogeneity in their size distribution with high specific surface area, and low basis weight. To exploit their filtration potential towards wide classes of pollutants and also to enhance the capturing efficacy, functionalized nanofibers are currently in practice with tailor-made modifications on the surface. The present review provides a comprehensive report on the different fabrication processes of functionalized nanofibers along with the controlling factors affecting the efficacy of the gas separation process. Also, it provides technical insights on the mass transfer aspects of PM filtration by elucidation their mechanism which can provide vital information on the rate-controlling diffusive flux(es). Conclusively, the practical challenges encountered in the large-scale air filtration systems such as filter cleaning, flow-rate regulation, pressure drop, and extent of reusability are discussed, and the review has identified potential gaps in the current research and can be considered for the prospective research in the area of PM separation process.

Aerosol Filtration Performance of Solution Blown PA6 Webs with Bimodal Fiber Distribution

A bimodal web, where both nanofibers and microfibers are present and distributed randomly across the same web, can deliver high filter efficiency and low pressure drop at the same time since in such a web, filter efficiency is high thanks to small pores created by the presence of nanofibers and the interfiber space created by the presence of microfibers, which is large enough for air to flow through with little resistance. In this work, a bimodal polyamide 6 (PA6) filter web was fabricated via a modified solution blowing (m-SB) technique that produced nanofibers and microfibers simultaneously. Scanning electron microscope (SEM) images of the webs were used to analyze the fiber morphology. Additionally, air permeability, solidity, porosity, filtration performance, and tensile strength of the samples were measured. The bimodal filter web consisted of nanofibers and microfibers with average diameters of 81.5 ± 127 nm and 1.6 ± 0.458 μm, respectively. Its filter efficiency, pressure drop at 95 L min^-1, and tensile strength were 98.891%, 168 Pa, and 0.1 MPa, respectively. Its quality factor (QF) and tensile strength were 0.0268 Pa^-1 and 0.1 MPa, respectively. When compared with commercially available filters, the bimodal web produced had superior filter performance, constituting a suitable alternative for air filter applications.

Decomposition Behavior of Stereocomplex PLA Melt-Blown Fine Fiber Mats in Water and in Compost

This study introduces systematic and comparative investigations of various PLA fine fiber mats prepared by melt blowing. A series of PLLA and PDLA melt-blown fibers from various L and D enantiomers blends were produced. Their morphological, mechanical, and thermal properties were studied, and their decomposition in water and compost was investigated. It was found that the 1:1 ratio blend with stereocomplex crystals had an 80% lower average fiber diameter, 60% higher specific strength and better thermal stability than the PLLA and PDLA fiber mats. In the case of composting, the crystalline peak melting temperature, crystallinity, and thermogravimetric decomposition temperatures marginally decreased after 14 days. The high surface of the fine fiber mats played a crucial role in fast decomposition, as they entirely disintegrated in less than only 40 days. In the case of water, the homocrystalline domains were more susceptible to hydrolysis than the stereocomplex ones. All the PLA fiber mats underwent decomposition and extensive disintegration for 70 days in water. Hydrolysis reduced the amorphous and crystalline fraction of the fibers via surface and bulk erosion, while the decomposition of stereocomplex-crystalline-rich domains mainly exhibited surface erosion. Findings revealed that high porosity and the high surface area of PLA melt-blown fine fiber mats undergo fast decomposition in compost and in water.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s10924-022-02694-w.

Metal-Induced Aminosilica Rigidity Improves Highly Permeable Microporous Membranes via Different Types of Pendant Precursors

In this study, nickel-doped aminosilica membranes containing pendant groups were prepared with 3-aminopropyltriethoxysilane (APTES), trimethoxy[3-(methylamino)propyl]silane (MAPTS), 3 N,N-dimethyl aminopropyltrimethoxysilane (DAPTMS), N-[3-(trimethoxysilylpropyl]ethylene diamine (TMSPED), and 1-[3-(trimethoxysilyl)propyl] urea (TMSPU). Differences in the structures of terminal amine ligands significantly contributed to the formation of a coordinated structural assembly. Ultraviolet-visible spectroscopy (UV-vis), Fourier transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), and N₂ adsorption isotherms revealed that short and rigid pendant amino groups successfully coordinated with nickel to produce subnanopores in the membranes, while an ion-exchange interaction was suggested for longer and sterically hindered aminosilica precursors. Moreover, the basicity of amine precursors affected the affinity of ligands for the development of a coordinated network. A pristine aminosilica membrane showed low levels of H₂ permeance that range from 0.1 to 0.5 × 10^-6 mol m^-2 s^-1 Pa^-1 with a H₂/N₂ permeance ratio that ranges from 15 to 100. On the contrary, nickel coordination increased the H₂ permeance to 0.1-3.0 × 10^-6 mol m^-2 s^-1 Pa^-1 with H₂/N₂ permeance ratios that range from 10 to 68, which indicates the formation of a microporous structure and enlargement of pore sizes. The strong level of coordination affinity between nickel ions and amine groups induced rearrangement of the flexible pendant chain into a more rigid structure.

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.

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.

Carbon Nanotube Mask Filters and Their Hydrophobic Barrier and Hyperthermic Antiviral Effects on SARS-CoV-2

Carbon nanotube face mask filters have strong and uniform hydrophobicity, high durability, and high thermal conductivity and exhibit excellent barrier and antiviral effects against SARS-CoV-2. The nanocarbon filter functions as a superior barrier compared to those in conventional masks owing to the stronger, more uniform, and more durable hydrophobic nature of the carbon nanotubes. A tightly knit carbon nanotube network has a pore size smaller than that of the average coronavirus; nevertheless, the breathability is equal to that of the conventional polypropylene filter. The exceptional thermal conductivity of carbon nanotubes transpires hyperthermic antiviral effects, which offers stronger protection against the virus, as well as reusability. The facile processability, low cost, and light weight of the aerosol-synthesized carbon nanotube filter warrants its viability, reinforcing the fight against the COVID-19 pandemic.

Reusable Self-Sterilization Masks Based on Electrothermal Graphene Filters

Surgical mask is recommended by the World Health Organization for personal protection against disease transmission. However, most of the surgical masks on the market are disposable that cannot be self-sterilized for reuse. Thus, when confronting the global public health crisis, a severe shortage of mask resource is inevitable. In this paper, a novel low-cost electrothermal mask with excellent self-sterilization performance and portability is reported to overcome this shortage. First, a flexible, ventilated, and conductive cloth tape is patterned and adhered to the surface of a filter layer made of melt-blown nonwoven fabrics (MNF), which functions as interdigital electrodes. Then, a graphene layer with premier electric and thermal conductivity is coated onto the MNF. Operating under a low voltage of 3 V, the graphene-modified MNF (mod-MNF) can quickly generate large amounts of heat to achieve a high temperature above 80 °C, which can kill the majority of known viruses attached to the filter layer and the mask surface. Finally, the optimized graphene-modified masks based on the mod-MNF filter retain a relatively high particulate matter (PM) removal efficiency and a low-pressure drop. Moreover, the electrothermal masks can maintain almost the same PM removal efficiency over 10 times of electrifying, suggesting its outstanding reusability.

Electrospun Wrinkled Porous Polyimide Nanofiber-Based Filter via Thermally Induced Phase Separation for Efficient High-Temperature PMs Capture

Benefiting from its superior thermal stability, polyimide (PI) fiber-based composites have attracted wide attention in the field of high-temperature filtration and separation. However, the trade-off between filtration efficiency and pressure drop of traditional PI filters with single morphology and structure still remains challenging. Herein, the electrospun PI high-temperature-resistant air filter was fabricated via thermal-induced phase separation (TIPS), employing polyacrylonitrile (PAN) as a template. The PI nanofibers exhibited special wrinkled porous structure, and the filter possessed a high specific surface area of 304.77 m²/g. The removal of PAN changed the chemical composition of the fiber and induced PI molecules to form complex folds on the surface of the fiber, thus forming the wrinkled porous structure. Additionally, the wrinkled porous PI nanofiber filter displayed a high PM0.3 removal efficiency of 99.99% with a low pressure drop of 43.35 Pa at room temperature, and the filtration efficiency was still over 97% after being used for long time. Moreover, the efficiency of the filter could even reach 95.55% at a high temperature of 280 °C. The excellent filtration performance was attributed to the special wrinkled porous surface, which could limit the Brownian motion of PMs and reinforce the mechanical interception effect to capture the particulate matters (PMs) on the surface of the filter. Therefore, this work provided a novel strategy for the fabrication of filters with special morphology to cope with increasingly serious air pollution in the industrial field.

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.