Multifunctional Chitosan Nanofiber-Based Sponge Materials Using Freeze-Thaw and Post-Cross-Linking Method

The fabrication of porous sponge materials with stable structures via cross-linking diverse polymers presents significant challenges due to the simultaneous requirements for phase separation as a pore-forming step and cross-linking reactions during the fabrication process. To address these challenges, we developed a sponge material solely from natural-based polymers, specifically chitosan nanofibers (CSNFs) and dialdehyde carboxymethyl cellulose (DACMC), employing a straightforward, eco-friendly technique. This technique integrates a facile freeze-thaw method with subsequent cross-linking between CSNFs and DACMC. This method effectively addresses the difficulties associated with pore formation in materials, which typically arise from the rapid formation and precipitation of polyionic complexes during the mixing of anionic and cationic polymers, using ice crystals as a rigid template. The resultant sponge materials exhibit remarkable shape recoverability in their wet state and maintain light, stable porosity in the dry state. Furthermore, in comparison to commonly used commercial foams, this composite porous material demonstrates superior fire retardancy and thermal insulation properties in its dry state. Additionally, it shows effective adsorption capacities for both cationic and anionic dyes and metal ions. This method of using biobased polymers to produce porous composites offers a promising avenue for creating multifunctional materials, with potential applications across various industries.

Solvent Vapor Strengthened Polyimide Nanofiber-Based Aerogels with High Resilience and Controllable Porous Structure

Owing to the hierarchically three-dimensional (3D) network, ultralow density, and high porosity, nanofiber-based aerogels (NFAs) have drawn great attention recently. However, precise control of the porous structure and mechanical properties of NFAs, which have been proved to be extremely essential to the applications, still remains a major challenge. Herein, electrospun polyimide (PI) nanofibers were utilized as building blocks to construct NFAs through the solid-templating technique. The porous structure of PI nanofiber-based aerogels (PI-NFAs) could be adjusted by changing the processing parameters. By further welding the adjacent nanofibers at the contact sites with solvent vapor, high-resilience PI-NFAs were successfully prepared with comparable or higher recoverable, under compression, folding and torsion relative to other NFAs. The welded PI-NFAs showed ultralow density (minimum of 0.96 mg/cm³), high porosity (maximum of 99.93%), and tunable hierarchical structure. Therefore, this study brought a new perspective on the simple preparation of high-resilience nanofiber-based aerogels with tunable porous structures.

Noninvasive characterization (EPR, μCT, NMR) of 3D PLA electrospun fiber sponges for controlled drug delivery

Highly porous 3D-scaffolds, made from cut, electrospun PLA fibers, are relatively new and promising systems for controlled drug-delivery applications. Because knowledge concerning fundamental processes of drug delivery from those scaffolds is limited, we noninvasively characterized drug-loading and drug-release mechanisms of these polymer-fiber sponges (PFS). We screened simplified PFS-implantation scenarios with EPR and μCT to quantify and 3D-visualize the absorption of model-biofluids and an oil, a possible drug-loading liquid. Saturation of PFS (6 × 8 mm, h x d) is governed by the high hydrophobicity of the material and air-entrapment. It required up to 45 weeks for phosphate-buffered saline and 11 weeks for a more physiological, surface-active protein-solution, indicating the slow fluid-uptake of PFS as an effective mechanism to substantially prolong the release of a drug incorporated within the scaffold. Medium-chain triglycerides, as a good wetting liquid, saturated PFS within seconds, suggesting PFS potential to serve as carrier-vessels for immobilizing hydrophobic drug-solutions to define a liquid's 3D-interface. Oil-retention under mechanical stress was therefore investigated. ¹H NMR permitted insights into PFS-oil interaction, confirming surface-relaxation and restricted diffusion; both did not influence drug release from oil-loaded PFS. Results facilitate better understanding of PFS and their potential use in drug delivery.

A Green Approach to Modify Surface Properties of Polyurethane Foam for Enhanced Oil Absorption

The non-selective property of conventional polyurethane (PU) foam tends to lower its oil absorption efficiency. To address this issue, we modified the surface properties of PU foam using a rapid solvent-free surface functionalization approach based on the chemical vapor deposition (CVD) method to establish an extremely thin yet uniform coating layer to improve foam performance. The PU foam was respectively functionalized using different monomers, i.e., perfluorodecyl acrylate (PFDA), 2,2,3,4,4,4-hexafluorobutyl acrylate (HFBA), and hexamethyldisiloxane (HMDSO), and the effect of deposition times (1, 5 and 10 min) on the properties of foam was investigated. The results showed that all the modified foams demonstrated a much higher water contact angle (i.e., greater hydrophobicity) and greater absorption capacities compared to the control PU foam. This is due to the presence of specific functional groups, e.g., fluorine (F) and silane (Si) in the modified PU foams. Of all, the PU/PHFBA_i foam exhibited the highest absorption capacities, recording 66.68, 58.15, 53.70, and 58.38 g/g for chloroform, acetone, cyclohexane, and edible oil, respectively. These values were 39.19–119.31% higher than that of control foam. The promising performance of the PU/PHFBA_i foam is due to the improved surface hydrophobicity attributed to the original perfluoroalkyl moieties of the HFBA monomer. The PU/PHFBA_i foam also demonstrated a much more stable absorption performance compared to the control foam when both samples were reused for up to 10 cycles. This clearly indicates the positive impact of the proposed functionalization method in improving PU properties for oil absorption processes.

High-density Fibrous Polyimide Sponges with Superior Mechanical and Thermal Properties

A relatively low compressive strength significantly limits the practical application of sponges made from electrospun fibers because of an ultralow density <10 mg/cm³. To solve this problem, fibrous polyimide sponges with high density (HDPISG) were prepared using a "self-gluing" concept. The HDPISG have a density of up to 280 mg/cm³ and porosity >80%, and showed good breathability. The compressive strength increased significantly as the sponge densities increased. The HDPISG with a density of 280 mg/cm³ has the highest compressive strength of 5190 and 35,900 kPa under 50 and 80% compression, respectively. The small HDPISG can even hold weights more than ten thousand times of the weight of the sponge. The HDPISG also possess excellent mechanical properties after thermal treatments and no loss of compressive strength can be seen after heating at 300 °C for 30 h. Further study indicates that the HDPISG can maintain their main shape after carbonization.

Durable Light-Driven Three-Dimensional Smart Switchable Superwetting Nanotextile as a Green Scaled-Up Oil-Water Separation Technology

Stimuli-responsive polymer architectures are attracting a lot of interest, but it still remains a great challenge to develop effective industrial-scale strategies. A single-stage and cost-effective approach was applied to fabricate a three-dimensional (3D) smart responsive surface with fast and reversibly switchable wetting between superhydrophobicity and superhydrophilicity/underwater superoleophobicity properties induced by photo and heat stimuli. Commercially available PVDF and P25TiO₂ as starting materials fabricated with a scaled-up electrospinning approach were applied to prepare 3D smart switchable PVDF-P25TiO₂ nanotextile superwetted by both UV and solar light that is simply recovered by heat at a reasonable time. The superhydrophilic/underwater superoleophobic photo-induced nanotextile will act in "water-removing" mode in which water quickly passes through and the oil is blocked on the surface. An acceptable recycling, reusing, and superior antifouling and self-cleaning performance arising from a TiO₂ photocatalytic effect makes it highly desired in a green scaled-up industry oily wastewater treatment technology. With these advantages, a large-scale industrial production process can be simply simulated by applying a conducting mesh-like collector substrate.

Bacterial cellulose sponges obtained with green cross-linkers for tissue engineering

Three-dimensional (3D) porous structures with controlled pore size and interconnected pores, good mechanical properties and biocompatibility are of great interest for tissue engineering. In this work we propose a new strategy to obtain highly porous 3D structures with improved properties using bacterial cellulose (BC) and eco-friendly additives and processes. Glucose, vanillin and citric acid were used as non-toxic and cheap cross-linkers and γ-aminopropyltriethoxysilane was used to partially replace the surface OH groups of cellulose with amino groups. The efficiency of grafting and cross-linking reactions was confirmed by Fourier transform infrared spectroscopy and X-ray photoelectron spectroscopy. The morphological investigation of BC sponges revealed a multi-hierarchical organization after functionalization and cross-linking. Micro-computed tomography analysis showed 80-90% open porosity in modified BC sponges. The thermal and mechanical properties of the sponges were influenced by the cross-linker type and concentration. The strength-to-weight ratio of BC sponges cross-linked with glucose and citric acid was 150% and 120% higher compared to that of unmodified BC sponge. In vitro assays revealed that the modified BC sponges are non-cytotoxic and do not trigger an inflammatory response in macrophages. This study provides a simple and green method to obtain highly porous cellulose sponges with hierarchical design, biocompatibility and good mechanical properties.

Virtually Wall-Less Tubular Sponges as Compartmentalized Reaction Containers

Sponges are open cellular materials with numerous interesting features. However, the potential of compartmentalized sponges has not been explored although many new properties and applications could be envisioned. We found that compartmentalized fibrous ultraporous polymer sponges with superhydrophobic surfaces could be designed as virtually wall-less reaction containers. With this, for example, the efficient removal of CO₂ from water and the controlled mineralization of calcium carbonate are possible. The high porosity (>99%) and superhydrophobicity make these sponges ideal candidates to hold alkanolamine solution for absorbing CO₂ and exchange gas through the walls of the sponges. The tubular sponge exhibits a much higher evaporation rate than a glass tube with the same diameter due to the much larger contact area between water and air. Therefore, the spongy reaction container also possesses a much faster adsorption rate, smaller equilibration time and higher efficiency for CO₂ adsorption than the glass tube container. In addition, these tubular sponges are also utilized to precipitate calcium carbonate by ammonium carbonate decomposition, which can control the deposition rates and products by tailoring the porosity and surface chemistry in the future. These new sponges provide an ideal basis for numerous new applications, for example, as breathable pipe lines for gas-liquid exchange, slag slurry carbonization, humidifier, and blood enricher.

Ultralight, superelastic and bendable lashing-structured nanofibrous aerogels for effective sound absorption

Low-density nanofibrous aerogels enable various applications but are often hindered by their fragile bendability and poor tensile strength. Herein, we report a strategy to design nanofibrous aerogels with robust bendability and superelastic property, which has been achieved by fabricating bamboo lashing-like structures through a freeze-drying method. The obtained reinforced nanofibrous aerogels (RNFAs) can maintain their structural integrity after 100 bending-recovery cycles at a bending angle of about 100°. Particularly, the RNFAs can completely revive from large deformation with a fast recovery speed (∼834 mm s-1). Significantly, the internal hierarchical porous structures and hydrophobicity of the materials provide them with ultralight properties (density <11 mg cm-3), efficient sound absorption capability (noise reduction coefficient of 0.41) and good moisture resistance; thus, they are promising options in cabins, vehicles, and the regulation of indoor reverberation.

Fibrous polymer nanomaterials for biomedical applications and their transport by fluids: an overview

Over the past few decades, there has been strong interest in the development of new micro- and nanomaterials for biomedical applications. Their use in the form of capsules, particles or filaments suspended in body fluids is associated with conformational changes and hydrodynamic interactions responsible for their transport. The dynamics of fibres or other long objects in Poiseuille flow is one of the fundamental problems in a variety of biomedical contexts, such as mobility of proteins, dynamics of DNA or other biological polymers, cell movement, tissue engineering, and drug delivery. In this review, we discuss several important applications of micro and nanoobjects in this field and try to understand the problems of their transport in flow resulting from material-environment interactions in typical, crowded, and complex biological fluids. Our aim is to elucidate the relationship between the nano- and microscopic structures of elongated polymer particles and their flow properties, thus opening the possibility to design nanoobjects that can be efficiently transported by body fluids for targeted drug release or local tissue regeneration.

Ultraporous, Compressible, Wettable Polylactide/Polycaprolactone Sponges for Tissue Engineering

Ultraporous, degradable sponges made of either polylactide or of blends of polylactide/poly(ε-caprolactone) are prepared by freeze-drying of dispersions of short electrospun fibers and subsequent thermal annealing. The sponges feature ultrahigh porosity (99.6%), a hierarchical cellular structure, and high reversible compressibility with fast recovery from deformation in the dry as well as in the wet state. The sponge properties depend on the fiber dispersion concentration and the annealing temperature. Sponge characteristics like fiber density (2.5-20 mg/cm³), size, shape, crystallinity, mechanical strength, wetability, and structural integrity are user adjustable. Cell culture experiments were successfully performed with Jurkat cells with Confocal Laser Scanning Microscopy and MTT staining showing rapid cell proliferation. Live/Dead staining demonstrated high viability of the seeded cells. The sponge characteristics and modifications investigated and presented here reveal that these sponges are highly promising for tissue engineering applications.

Exploration of Ultralight Nanofiber Aerogels as Particle Filters: Capacity and Efficiency

Ultralight nanofiber aerogels (NFAs) or nanofiber sponges are a truly three-dimensional derivative of the intrinsically flat electrospun nanofiber mats or membranes (NFMs). Here we investigated the potential of such materials for particle or aerosol filtration because particle filtration is a major application of NFMs. Ultralight NFAs were synthesized from electrospun nanofibers using a solid-templating technique. These materials had a tunable hierarchical cellular open-pore structure. We observed high filtration efficiencies of up to 99.999% at the most penetrating particle size. By tailoring the porosity of the NFAs through the processing parameters, we were able to adjust the number of permeated particles by a factor of 1000 and the pressure drop by a factor of 9. These NFAs acted as a deep-bed filter, and they were capable of handling high dust loadings without any indication of performance loss or an increase in the pressure drop. When the face velocity was increased from 0.75 to 6 cm s^-1, the filtration efficiency remained high within a factor of 1.1-10. Both characteristics were in contrast to the behavior of two commercial NFM particle filters, which showed significant increases in the pressure drop with the filtration time as well as a susceptibility against high face velocities by a factor of 105.

Electrospun nanofiber reinforced composites: a review

High performance electrospun nanofibers could be used to fabricate nanofiber reinforced composites.

Low-Density Open Cellular Sponges as Functional Materials

Low-density macroporous sponges with densities less than 100 mg cm^-3 are both a challenge and an opportunity for advanced chemistry and material science. The challenge lies in the precise preparation of the sponges with property combinations that lead to novel applications. Bottom-up and top-down chemical and engineering methods for the preparation of sponges are a major focus of this Review, with an emphasis on carbon and polymer materials. The light weight, sustainability, breathability, special wetting characteristics, large mass transfer, mechanical stability, and large pore volume are typical characteristics of sponges made of advanced materials and could lead to novel applications. Some selected sponge properties and potential applications are discussed.

Ultralight, Thermally Insulating, Compressible Polyimide Fiber Assembled Sponges

Tunable density, thermally and mechanically stable, elastic, and thermally insulating sponges are required for demanding applications. Hierarchically structured sponges with bimodal interconnected pores, porosity more than 99%, and tunable densities (between 7.6 and 10.1 mg/cm³) are reported using polyimide (PI) as high temperature stable polymer. The sponges are made by freeze-drying a dispersion of short PI fibers and precursor polymer, poly(amic acid) (PAA). The concept of "self-gluing" the fibrous network skeleton of PI during sponge formation was applied to achieve mechanical stability without sacrificing the thermal properties. The sponges showed initial degradation above 400 and 500 °C in air and nitrogen, respectively. They have low thermal conductivity of 0.026 W/mK and thermal diffusivity of 1.009 mm²/s for a density of 10.1 mg/cm³. The sponges are compressible for at least 10 000 cycles and good thermal insulators even at high compressions. These fibrous PI sponges are promising candidates for potential applications in thermal insulation, lightweight construction, high-temperature filtration, sensors, and catalyst carrier for high-temperature reactions.

Exploration of Macroporous Polymeric Sponges As Drug Carriers

Achieving high drug loading capacity and controlling drug delivery are two main challenges related to drug carriers. In this study, polymeric macroporous sponges with very high pore volume and large porosity are introduced as a new-type of drug carrier. Due to the high pore volume (285 and 166 cm³/g for the sponges with densities of 3.5 and 6.0 mg/cm³, respectively), the sponges exhibit very high drug loading capacities with average values of 1870 ± 114 and 2697 ± 73 mg/g in the present study, which is much higher than the meso and microporous drug carriers (<1500 mg/g). In order to control the release profiles, an additional poly(p-xylylene) (PPX) coating was deposited by chemical vapor deposition on the drug loaded sponge. Consequently, Artemisone (ART) release in the aqueous medium could be retarded, depending on the density of the sponge and the thickness of the coating. In future, the new 3D polymeric sponges would be highly beneficial as drug carriers for the programmed release of drugs for treatment of chronic diseases.

Ultralight sponges of poly(para-xylylene) by template-assisted chemical vapour deposition

Particle foams and open cell sponges play nowadays an important role in academia and industrial research. The fabrication of new high-performance foams is one of the challenges. Until now, it is impossible to visualise the quality of particle foams, and the quantification is only possible with expensive analytical methods like scanning electron microscopy. In this work, we demonstrate a simple method for the visualisation of void sizes and defects inside particle foams on the basis of expanded polystyrene. The concept was transferred to porous materials, which work as templates for the formation of ultralight poly(para-xylylene) foams with stunning properties.

Spongy Gels by a Top-Down Approach from Polymer Fibrous Sponges

Ultralight cellular sponges offer a unique set of properties. We show here that solvent uptake by these sponges results in new gel-like materials, which we term spongy gels. The appearance of the spongy gels is very similar to classic organogels. Usually, organogels are formed by a bottom-up process. In contrast, the spongy gels are formed by a top-down approach that offers numerous advantages for the design of their properties, reproducibility, and stability. The sponges themselves represent the scaffold of a gel that could be filled with a solvent, and thereby form a mechanically stable gel-like material. The spongy gels are independent of a time-consuming or otherwise demanding in situ scaffold formation. As solvent evaporation from gels is a concern for various applications, we also studied solvent evaporation of wetting and non-wetting liquids dispersed in the sponge.