Fabrication of Laminated Micro/Nano Filter and Its Application for Inhalable PM Removal

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.

One-Step Fast Fabrication of Electrospun Fiber Membranes for Efficient Particulate Matter Removal

Rapid social and industrial development has resulted in an increasing demand for fossil fuel energy, which increases particulate matter (PM) pollution. In this study, we employed a simple one-step electrospinning technique to fabricate polysulfone (PSF) fiber membranes for PM filtration. A 0.3 g/mL polymer solution with an N,N-dimethylformamide:tetrahydrofuran volume ratio of 3:1 yielded uniform and bead-free PSF fibers with a diameter of approximately 1.17 μm. The PSF fiber membrane exhibited excellent hydrophobicity and mechanical properties, including a tensile strength of 1.14 MPa and an elongation at break of 116.6%. Finally, the PM filtration performance of the PSF fiber membrane was evaluated. The filtration efficiencies of the membrane for PM2.5 and PM1.0 were approximately 99.6% and 99.2%, respectively. The pressure drops were 65.0 and 65.2 Pa, which were significantly lower than those of commercial air filters. Using this technique, PSF fiber membrane filters can be easily fabricated over a large area, which is promising for numerous air filtration systems.

Preparation of fluffy bimodal conjugated electrospun poly(lactic acid) air filters with low pressure drop

Electrospun nanofiber membranes have been extensively studied as air filters. However, their limited filtration efficiency for submicron inhalable particulate matter (PM), high resistance to filtration, and limited capacity to hold dust have hindered their widespread use. The majority of materials come from petroleum, and the use of organic solvents during the spinning process has a significant negative impact on the environment. In this work, a sustainable method has been proposed for producing filters using poly(lactic acid) (PLA) with a bimodal diameter distribution through conjugated electrospinning. This technique allows for the continuous production of interconnected micro/nano hybrid porous membranes, resulting in reduced resistance and improved dust holding capacity. The filtration efficiency, pressure drop, long-term filtration performance, and actual performance of the conjugated bimodal membrane (CBM) were extensively investigated. The results indicate that the filter has a high capacity for retaining particles, with filtration efficiencies of 99.94% for PM 0.3 and 99.96% for PM 2.5. It also demonstrates a high quality factor (0.078 Pa-1 for PM 0.3 and 0.084 Pa-1 for PM 2.5), long-term stability (a decrease of 2.35% for PM 0.3 and 0.05% for PM 2.5 over a period of 60 days) and outstanding dust holding capacity (9.17 g m-2). The conjugated bimodal membrane (CBM) shows a 22.64% decrease in resistance compared to the non-conjugated bimodal membrane (BM). In general, the approach outlined in this work provides valuable insights into the development of high-performance biodegradable air filters. These filters have improved filtration efficiency and reduced resistance.

Preparation of Self-Curling Melt-Blown Fibers with Crimped Masterbatch (CM) and Its Application for Low-Pressure Air Filtration

Particulate matter (PM) and airborne viruses pose significant threats to both the environment and public health. As the most viable solution to prevent the inhalation of these pollutants, there is an urgent demand for face masks with excellent filtration efficiency and low-pressure drop. In this study, a crimped masterbatch (CM) is added to polypropylene feedstocks to produce curling fibers through melt-blown spinning. These curled fibers exhibit low filtration resistance and effective dust-holding performances when used for air filtration. The effect of adding CM on fiber diameter, pore size, crimp, porosity, roughness, and surface potential was studied. The filtration performance of the materials, including the PM filtration capabilities, recirculation filtration, and loading test performance, were also investigated. The results demonstrate that the degree of fiber crimp can be adjusted by incorporating varying amounts of CM. This curling was caused by the uneven shrinkage that occurred due to variations in thermal contraction between these polymers. The curled fibers created a fluffy structure in the fiber network and modified the distribution of pore sizes within it. Under the same filtration conditions as sodium chloride aerogel, CM-2 (PP:CM 8:2) exhibited similar filtration efficiency (95.54% vs. 94.74%), lower filtration resistance (88.68 Pa vs. 108.88 Pa), higher quality factor (0.035 Pa-1 vs. 0.028 Pa-1) and better dust holding capacity (10.39 g/m2 vs. 9.20 g/m2) compared to CM-0 (PP:CM 10:0). After 30 days of indoor storage, the filtration efficiency of CM-2 remained above 94%. The self-curling melt-blown filtration material developed here could potentially be applied in the field of protective masks.