Mass Production of Hierarchically Designed Engine-Intake Air Filters by Multinozzle Electroblow Spinning.

Particulate matter damages engines of vehicles when blown into the ventilation system. Conventional engine-intake filter is cellulose microfiber board with an average diameter larger than ten microns, which has low removal efficiency of ultrafine particular matter. In this work, we apply ultrafine polyurethane nanofibers (∼122.8 nm) onto pleated cellulose board using scalable multinozzle electroblow spinning technology, which improves filtration efficiency of particulate matter with a diameter of less than 0.3 µm PM0.3 greatly. The thermoplastic polyurethane 85A nanofiber membranes are transparent, and display superior filtration performance which meets up with the 95% filtration efficiency standard in GB 19083-2010 technical requirements for protective face mask for medical use. The lightweight pleated thermoplastic polyurethane/cellulose composites intercept ∼90% ultrafine PM0.3 under airflow velocity of 32 L min-1 and possess great resistance to shock. These hierarchically designed filters follow a mechanical mechanism and can be used in on-road and off-road cars in the long run.

Free-Standing Ultrafine Nanofiber Papers with High PM0.3 Mechanical Filtration Efficiency by Scalable Blow and Electro-Blow Spinning.

Particulate matter of 0.3 µm in diameter (PM0.3) poses a serious threat to the environment and human beings. Ultrathin and -light nanofibrous filters with excellent filtration properties can significantly prevent the detrimental effects of these particles. Here, we develop free-standing polyamide PA-66 ultrafine nanofiber papers for PM0.3 filtration using effective and scalable blow and electro-blow spinning techniques. The smallest average fiber diameter is 61.7 nm, which is 2-3 orders of magnitude smaller than that of conventional textiles. Poly(ethylene terephthalate) nonwovens are selected to fabricate free-standing nanofiber papers of various polymers, including polyamide, poly(methyl methacrylate), poly(vinylpyrrolidone), and poly(ethylene oxide) owing to the smooth surfaces of the nonwovens. This underlying principle can be used to create similar free-standing nanofiber papers from other commodity polymers in the future. Mechanisms of capturing particulate matter with different nanofiber morphologies are discussed. Salt and oil particulates are used to characterize the filtration properties. PA-66 papers are promising reusable filters owing to their mechanical particle-capture mechanism. The blow-spun PA-66 papers show filtration performance of 98.75% efficiency and a pressure drop of 125.44 Pa owing to the "slip" effect caused by the ultrasmall diameter. In the electro-blow spinning process, a supplementary voltage supply is conducive to separating nanofiber bundles into random-oriented nanofibers. Electro-blown spun papers possess an ultrahigh efficiency of 99.99% with a reduced areal density of 0.9 g m-2. These PA-66 papers can be used in a variety of applications, such as reusable personal protective equipment, industrial waste gas treatment, and central ventilation purification systems.

One-Step, Large-Scale Blow Spinning to Fabricate Ultralight, Fibrous Sorbents with Ultrahigh Oil Adsorption Capacity.

The cleanup of spilled oil from water has always been a severe and urgent issue, which attracted great attention and interest. In this study, we reported a highly efficient large-scale blow spinning technique to fabricate fibrous oil sorbents including the polystyrene (PS) fibrous sponge and polyvinylidene fluoride (PVDF)/polystyrene (PS) composite package with ultrahigh oil adsorption capacity. The wide diameter distributions and multilevel pore structure of PS fibers were obtained by controlling the precursor solution compositions used in blow spinning. The PS fibrous sponge formed by accumulating naturally exhibited an ultralow density, whose oil adsorption capacity ranged from 74 to 440 g/g for various oils and organic solvents. To enhance the mechanical strength of the PS fibrous sponge, the PVDF/PS composite package with the sandwich structure was fabricated by alternately blow spinning. The PVDF/PS composite package possessed 2.7 times the tensile strength of the PS fibrous sponge while the oil adsorption capacity had merely a slight decrease. Moreover, the fabrication strategy of blow spinning used to produce the fibrous sponge and composite package is highly efficient, cost-effective, and environment-friendly, which is suitable for large-scale industrial production of oil sorbents and oil spill cleanup in environment protection.