PVA-co-PE Nanofibrous Filter Media with Tailored Three-Dimensional Structure for High Performance and Safe Aerosol Filtration via Suspension-Drying Procedure

Shell Distribution of Vitamin K3 within Reinforced Electrospun Nanofibers for Improved Photo-Antibacterial Performance

Personal protective equipment (PPE) has attracted more attention since the outbreak of the epidemic in 2019. Advanced nano techniques, such as electrospinning, can provide new routes for developing novel PPE. However, electrospun antibacterial PPE is not easily obtained. Fibers loaded with photosensitizers prepared using single-fluid electrospinning have a relatively low utilization rate due to the influence of embedding and their inadequate mechanical properties. For this study, monolithic nanofibers and core-shell nanofibers were prepared and compared. Monolithic F1 fibers comprising polyethylene oxide (PEO), poly(vinyl alcohol-co-ethylene) (PVA-co-PE), and the photo-antibacterial agent vitamin K3 (VK3) were created using a single-fluid blending process. Core-shell F2 nanofibers were prepared using coaxial electrospinning, in which the extensible material PEO was set as the core section, and a composite consisting of PEO, PVA-co-PE, and VK3 was set as the shell section. Both F1 and F2 fibers with the designed structural properties had an average diameter of approximately 1.0 μm, as determined using scanning electron microscopy and transmission electron microscopy. VK3 was amorphously dispersed within the polymeric matrices of F1 and F2 fibers in a compatible manner, as revealed using X-ray diffraction and Fourier transform infrared spectroscopy. Monolithic F1 fibers had a higher tensile strength of 2.917 ± 0.091 MPa, whereas the core-shell F2 fibers had a longer elongation with a break rate of 194.567 ± 0.091%. Photoreaction tests showed that, with their adjustment, core-shell F2 nanofibers could produce 0.222 μmol/L ·OH upon illumination. F2 fibers had slightly better antibacterial performance than F1 fibers, with inhibition zones of 1.361 ± 0.012 cm and 1.296 ± 0.022 cm for E. coli and S. aureus, respectively, but with less VK3. The intentional tailoring of the components and compositions of the core-shell nanostructures can improve the process-structure-performance relationship of electrospun nanofibers for potential sunlight-activated antibacterial PPE.

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

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

HEPA filters for airliner cabins: State of the art and future development

The airliner cabin environment is very important to the health of passengers and crew members, and the use of high-efficiency particulate air (HEPA) filters for recirculated air in the environmental control systems (ECS) is essential for the removal of airborne particles such as SARS CoV-2 aerosols. A HEPA filter should be high efficiency, low-pressure drop, high dust-holding capacity (DHC), lightweight, and strong for use in aircraft. We conducted an experimental study on 23 HEPA filters with glass fiber media that are used in different commercial airliner models. The tested filters had a median filtration efficiency of >99.97% for particles with a diameter of 0.3-0.5 μm, a pressure drop of 134-412 Pa at rated airflow rate, and a DHC of 32.2-37.0 g/m² . The use of nanofiber media instead of glass fiber media can reduce the pressure drop by 66.4%-94.3% and significantly increase the quality factor by analysis of literature data. The disadvantages of poor fire resistance and small DHC can be overcome by the use of flame-retardant polymers and fiber structural design. As a new lightweight and environmentally friendly filter material, nanofiber media could be used as air filters in ECS in the future.

Fabrication and performance of a stable micro/nano composite electret filter for effective PM2.5 capture

Airborne particulate matter (PM) pollution has raised serious concerns over both the global climate and public health. Therefore, there is an urgent need for air filters of high-efficiency and energy-saving. Pore structure optimization and electret enhancement are feasible means to improve their filtration performance. Herein, a novel sandwich-structured electret composite filter with a low pressure drop and robust filtration stability was successfully designed and fabricated. The composite filter was composed of fluffy PS microfibers with large electric resistivity and high porosity, and PAN nanofibers with high polarity and small pore size. Benefiting from the fluffy structure constructed by electrospinning at the right humidity, the tortuous pore channels created by the appropriate mixing of microfibers and nanofibers, and the abundant static charges generated by the hybrid of polar and nonpolar polymer materials, the PS/PAN/PS composite filter possessed a high filtration efficiency of 99.96% for particles of 0.30 μm, a low pressure drop of 54 Pa and a satisfactory quality factor value of 0.1449 Pa^-1 at an airflow velocity of 5.3 cm/s. In particular, the composite filter exhibited better electret stability and PM_2.5 loading performance than the commercial ones, which guarantees its long-term storage and usage.

Highly efficient transparent air filter prepared by collecting-electrode-free bipolar electrospinning apparatus

Electrospinning technology has been used for a long time. A jet from a needle was formed by applying high voltage, and then the nanofibers are deposited onto a collecting electrode (usually metal) and the excess charge is conducted away to complete the electrospinning. Alternatively, it is also possible to prevent charge accumulation from hindering the progress of electrospinning by means of charge neutralization. A bipolar electrospinning technique (B-EEM) was developed to induce jets with different charges through a set of high-voltage power supplies of opposite polarity, and the two jets neutralize each other on the insulating mesh, thus completing the electrospinning process. There is no need for a collecting electrode to complete the electrospinning process. We have found that the filters produced by the new technology have better filtration efficiency while maintaining the same transparency in relative to the original technology, and this optimization is due to the distribution modification of the nanofibers on the mesh.