Large-Scale Centrifugal Multispinning Production of Polymer Micro- and Nanofibers for Mask Filter Application with a Potential of Cospinning Mixed Multicomponent Fibers

High-Temperature-Resistant Dual-Scale Ceramic Nanofiber Films toward Improved Air Filtration

Currently, air pollution primarily arises from industrial emissions, coal combustion, and automobile exhaust, posing significant challenges for mitigation. This highlights the urgent need for advanced and efficient filtration materials with low pressure drop and high-temperature resistance. Traditionally, improving filtration property has involved increasing the thickness of the filtration materials, which consequently leads to higher costs. Here, dual-scale mullite nanofiber (MNF) films containing interwoven thick nanofibers (606 nm) and thin nanofibers (186 nm) are prepared using solution blow spinning. The dual-scale structure design enables the films to maintain a low pressure drop while achieving high filtration efficiency. At an airflow velocity of 5.3 cm s-1, the films with an areal density of 3.8 mg cm-2, achieve a filtration efficiency of 98.23% and a pressure drop of 141 Pa for PM0.3. In addition, the MNF films exhibit excellent flexibility and high-temperature resistance, making them have great potential for use in high-temperature flue gas filtration.

Management of ibuprofen in wastewater using electrospun nanofibers developed from PET and PS wastes

Electrospinning is a promising technique for the beneficial use and recycling of plastic waste polymers using simple methodologies. In this study, plastic bottles and Styrofoam wastes have been used to develop polyethylene terephthalate (PET) and polystyrene (PS) nanofibers using electrospinning technique separately without any further purification. The effect of the concentration onto the nanofiber's morphology was studied. The fabricated nanofibers were characterized using Field Emission Scanning Electron Microscope (FE-SEM), Fourier Transformed Infrared Spectroscopy (ATR-FTIR), N2 adsorption/desorption analysis, and water contact angle (WCA). Furthermore, the prepared nanofibers were applied for the adsorption of ibuprofen (IBU) from wastewater. Some parameters that can influence the adsorption efficiency of nanofibers such as solution pH, wt.% of prepared nanofibers, drug initial concentration, and contact time were studied and optimized. The results show that the equilibrium adsorption capacity was achieved after only 10 min for 12 wt% PET nanofibers which is equivalent to 364.83 mg/g. For 12 wt% PS nanofibers, an equilibrium adsorption capacity of 328.42 mg/g was achieved in 30 min. The experimental data was fitted to five isotherm and four kinetics models to understand the complicated interaction between the nanofibers and the drug. Langmuir-Freundlich isotherm model showed the best fit for experimental data for both PET and PS nanofibers. The adsorption process was characterized by predominantly physical reaction rather than chemical adsorption for both materials. The reusability study revealed that the synthesized nanofibers maintain their ability to adsorb/desorb IBU for up to five cycles. The results obtained demonstrated that fabricated nanofibers from plastic wastes could perform promising adsorbents for the management of IBU in wastewater. However, further research is needed for the scaling-up the fabrication which is required for real-world applications.

The high-throughput atomization of polymer solutions for fiber synthesis in a single step aided with corona ionizers

Polymer microfibers are ubiquitous structures across virtually all technological fields. Their applications include, for instance, filter media, tissue regeneration, wound healing and dressing, and reinforcement materials. The most effective methods for fabrication of fibrous micro and nanomaterials rely on electric fields to spin a liquid jet into an ultrafine thread that rapidly dries up forming a fiber. Continuous spinning and collection leads to formation of fiber mats. Here we report a robust yet simple approach for the massive production of liquid threads, which upon acquiring electrical charges in-flight are collected downstream in the form of fibers. The entire process takes place on-line in a single step. The liquid threads are produced through the fragmentation of a polymer solution bulk due to a turbulent interaction of a gas-liquid interface in the interior of an engineered device, a so-called Flow Blurring atomizer. The particularity of this approach consists precisely in such vigorous interaction, at the micrometer scale, which triggers a bubbly motion in the interior of the device, that is a "micro-mixing". Subsequently, the threads are passed through ionized air currents, at ambient conditions, and then stretched to sub-micrometer dimensions by electric fields. Polyvinylpyrrolidone (PVP) as well as carbon nanotubes (CNTs) or graphene oxide sheets (GOSs)-containing PVP fibers, with diameters in the range 100-900 nm, were synthesized via this approach. In the cases studied herein the method was operated at liquid flow rates (i.e. production rates) of 0.2 mL/min but it could be readily increased up to a few tens of mL/min. The method requires further improvement and optimization, nevertheless it is a promising alternative for mass production of polymer fibers.

Integrating a micro-mixing mechanism and on-line thermal processing for the large-scale ejection of polymeric liquid threads for producing ultrafine fibers

Micro/nanofibers are structures that nowadays have a wide range of cutting-edge applications including energy generation and storage devices, smart textiles, cell growth, and tissue engineering. These fibrous materials are mostly produced from polymer solutions spun, under laminar flow conditions, into nanofibers by external forces. However, the turbulent interaction of gas-liquid interfaces offers an innovative approach for the high-throughput production of nanofibers. Here, we present Flow Blurring (FB), a solely pneumatic approach for the massive production of liquid threads of polymer solutions, which relies on a micro-mixing mechanism that triggers a turbulent motion capable of fragmenting a viscous flow. The as-ejected threads are subsequently processed thermally, on-line in a single-step, thus producing micro/nanofibers that form mats. The method operates with relatively large liquid flow rates, equivalent of a high production rate, and is thus suitable for industrial production of engineered nanomaterials. In this work, we used solutions of poly(vinyl alcohol) (PVA) to study its ejection and fragmentation dynamics through computational fluid dynamics (CFD) simulations. In addition, the physics underlying the regulation of the liquid flow rate in FB atomizers are proposed. Fibers with typical diameters in the range 400-800 nm were produced by online heating of the liquid threads. Liquid ejection experiments were performed under different operating conditions thus verifying the capability of the method for synthesizing submicrometer-sized fibers with high uniformity and production rates suitable for scaling up.

Electrospun nanofibers for medical face mask with protection capabilities against viruses: State of the art and perspective for industrial scale-up

Face masks have proven to be a useful protection from airborne viruses and bacteria, especially in the recent years pandemic outbreak when they effectively lowered the risk of infection from Coronavirus disease (COVID-19) or Omicron variants, being recognized as one of the main protective measures adopted by the World Health Organization (WHO). The need for improving the filtering efficiency performance to prevent penetration of fine particulate matter (PM), which can be potential bacteria or virus carriers, has led the research into developing new methods and techniques for face mask fabrication. In this perspective, Electrospinning has shown to be the most efficient technique to get either synthetic or natural polymers-based fibers with size down to the nanoscale providing remarkable performance in terms of both particle filtration and breathability. The aim of this Review is to give further insight into the implementation of electrospun nanofibers for the realization of the next generation of face masks, with functionalized membranes via addiction of active material to the polymer solutions that can give optimal features about antibacterial, antiviral, self-sterilization, and electrical energy storage capabilities. Furthermore, the recent advances regarding the use of renewable materials and green solvent strategies to improve the sustainability of electrospun membranes and to fabricate eco-friendly filters are here discussed, especially in view of the large-scale nanofiber production where traditional membrane manufacturing may result in a high environmental and health risk.

Advancement of Nonwoven Fabrics in Personal Protective Equipment

While nonwoven fabrics have existed for several decades, their usage in personal protective equipment (PPE) has been met with a rapid surge of demands, in part due to the recent COVID-19 pandemic. This review aims to critically examine the current state of nonwoven PPE fabrics by exploring (i) the material constituents and processing steps to produce fibers and bond them, and (ii) how each fabric layer is integrated into a textile, and how the assembled textiles are used as PPE. Firstly, filament fibers are manufactured via dry, wet, and polymer-laid fiber spinning methods. Then the fibers are bonded via chemical, thermal, and mechanical means. Emergent nonwoven processes such as electrospinning and centrifugal spinning to produce unique ultrafine nanofibers are discussed. Nonwoven PPE applications are categorized as filters, medical usage, and protective garments. The role of each nonwoven layer, its role, and textile integration are discussed. Finally, the challenges stemming from the single-use nature of nonwoven PPEs are discussed, especially in the context of growing concerns over sustainability. Then, emerging solutions to address sustainability issues with material and processing innovations are explored.

Fluid Flow Templating of Polymeric Soft Matter with Diverse Morphologies

It is challenging to find a conventional nanofabrication technique that can consistently produce soft polymeric matter of high surface area and nanoscale morphology in a way that is scalable, versatile, and easily tunable. Here, the capabilities of a universal method for fabricating diverse nano- and micro-scale morphologies based on polymer precipitation templated by the fluid streamlines in multiphasic flow are explored. It is shown that while the procedure is operationally simple, various combinations of its intertwined mechanisms can controllably and reproducibly lead to the formation of an extraordinary wide range of colloidal morphologies. By systematically investigating the process conditions, 12 distinct classes of polymer micro- and nano-structures including particles, rods, ribbons, nanosheets, and soft dendritic colloids (dendricolloids) are identified. The outcomes are interpreted by delineating the physical processes into three stages: hydrodynamic shear, capillary and mechanical breakup, and polymer precipitation rate. The insights into the underlying fundamental mechanisms provide guidance toward developing a versatile and scalable nanofabrication platform. It is verified that the liquid shear-based technique is versatile and works well with many chemically diverse polymers and biopolymers, showing potential as a universal tool for simple and scalable nanofabrication of many morphologically distinct soft matter classes.

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.

Rotary Jet Spinning (RJS): A Key Process to Produce Biopolymeric Wound Dressings

Wounds result from different causes (e.g., trauma, surgeries, and diabetic ulcers), requiring even extended periods of intensive care for healing, according to the patient's organism and treatment. Currently, wound dressings generated by polymeric fibers at micro and nanometric scales are promising for healing the injured area. They offer great surface area and porosity, mimicking the fibrous extracellular matrix structure, facilitating cell adhesion, migration, and proliferation, and accelerating the wound healing process. Such properties resulted in countless applications of these materials in biomedical and tissue engineering, also as drug delivery systems for bioactive molecules to help tissue regeneration. The techniques used to engineer these fibers include spinning methods (electro-, rotary jet-), airbrushing, and 3D printing. These techniques have important advantages, such as easy-handle procedure and process parameters variability (type of polymer), but encounter some scalability problems. RJS is described as a simple and low-cost technique resulting in high efficiency and yield for fiber production, also capable of bioactive agents' incorporation to improve the healing potential of RJS wound dressings. This review addresses the use of RJS to produce polymeric fibers, describing the concept, type of configuration, comparison to other spinning techniques, most commonly used polymers, and the relevant parameters that influence the manufacture of the fibers, for the ultimate use in the development of wound dressings.

A pandemic-induced environmental dilemma of disposable masks: solutions from the perspective of the life cycle

The coronavirus disease 2019 (COVID-19) has swept the world and still afflicts humans. As an effective means of protection, wearing masks has been widely adopted by the general public. The massive use of disposable masks has raised some emerging environmental and bio-safety concerns: improper handling of used masks may transfer the attached pathogens to environmental media; disposable masks mainly consist of polypropylene (PP) fibers which may aggravate the global plastic pollution; and the risks of long-term wearing of masks are elusive. To maximize the utilization and minimize the risks, efforts have been made to improve the performance of masks (e.g., antivirus properties and filtration efficiency), extend their functions (e.g., respiration monitoring and acting as a sampling device), develop new disinfection methods, and recycle masks. Despite that, from the perspective of the life cycle (from production, usage, and discard to disposal), comprehensive solutions are urgently needed to solve the environmental dilemma of disposable masks in both technologies (e.g., efficient use of raw materials, prolonging the service life, and enabling biodegradation) and policies (e.g., stricter industry criteria and garbage sorting).