Search Results (16)

Polypropylene melt-blown nonwoven fabric (PP MNF) masks can effectively block pathogens in the environment from entering the human body. However, the adhesion of surviving pathogens to masks poses a risk of human infection. Thus, embedding safe and efficient antibacterial materials is the key to solving pathogen infection. In this study, stable chlorinated poly(methacrylamide-N,N′-methylenebisacrylamide) polypropylene melt-blown nonwoven fabrics (PP-P(MAA-MBAA)-Cl MNFs) have been fabricated by a simple UV cross-link and chlorination process, and the active chlorine content can reach 3500 ppm. The PP-P(MAA-MBAA)-Cl MNFs show excellent hydrophilic and antibacterial properties. The PP-P(MAA-MBAA)-Cl MNFs could kill all bacteria (both Escherichia coli and Staphylococcus aureus) with only 5 min of contact. Therefore, incorporating PP-P(MAA-MBAA)-Cl MNF as a hydrophilic antimicrobial layer into a four-layer PP-based mask holds great potential for enhancing protection and comfort. Full article

Melt-blown nonwoven fabrics for filtration are usually manufactured using polypropylene, but after a certain time period the middle layer of the mask may have a reduced effect on adsorbing particles and may not be easily stored. Adding electret materials not only increases storage time, but also shows in this study that the addition of electret can improve filtration efficiency. Therefore, this experiment uses a melt-blown method to prepare a nonwoven layer, and adds MMT, CNT, and TiO2 electret materials to it for experiments. Polypropylene (PP) chip, montmorillonite (MMT) and titanium dioxide (TiO₂) powders, and carbon nanotube (CNT) are blended and made into compound masterbatch pellets using a single-screw extruder. The resulting compound pellets thus contain different combinations of PP, MMT, TiO₂, and CNT. Next, a hot pressor is used to make the compound chips into a high-poly film, which is then measured with differential scanning calorimetry (DSC) and Fourier transform infrared spectroscopy (FTIR). The optimal parameters are yielded and employed to form the PP/MMT/TiO₂ nonwoven fabrics and PP/MMT/CNT nonwoven fabrics. The basis weight, thickness, diameter, pore size, fiber covering ratio, air permeability, and tensile property of different nonwoven fabrics are evaluated in order to have the optimal group of PP-based melt-blown nonwoven fabrics. According to the results of DSC and FTIR measurements, PP and MMT, CNT, and TiO₂ are completely mixed, and the melting temperature (T_m), crystallization temperature (T_c) and endotherm area are changed accordingly. The difference in enthalpy of melting changes the crystallization of PP pellets, which in turn changes the fibers. Moreover, the Fourier transform infrared (FTIR) spectroscopy results substantiate that PP pellets are well blended with CNT and MMT, according to the comparisons of characteristic peaks. Finally, the scanning electron microscopy (SEM) observation suggests that with a spinning die temperature of 240 °C and a spinning die pressure lower than 0.01 MPa, the compound pellets can be successfully formed into melt-blown nonwoven fabrics with a 10-micrometer diameter. The proposed melt-blown nonwoven fabrics can be processed with electret to form long-lasting electret melt-blown nonwoven filters. Full article

The 2019 coronavirus outbreak and worsening air pollution have triggered the search for manufacturing effective protective masks preventing both particulate matter and biohazard absorption through the respiratory tract. Therefore, the design of advanced filtering textiles combining efficient physical barrier properties with antimicrobial properties is more newsworthy than ever. The objective of this work was to produce a filtering electrospun membrane incorporating a biocidal agent that would offer both optimal filtration efficiency and fast deactivation of entrapped viruses and bacteria. After the eco-friendly electrospinning process, polyvinyl alcohol (PVA) nanofibers were stabilized by crosslinking with 1,2,3,4-butanetetracarboxylic acid (BTCA). To compensate their low mechanical properties, nanofiber membranes with variable grammages were directly electrospun on a meltblown polypropylene (PP) support of 30 g/m². The results demonstrated that nanofibers supported on PP with a grammage of around only 2 g/m² presented the best compromise between filtration efficiencies of PM_0.3, PM_0.5, and PM_3.0 and the pressure drop. The filtering electrospun membranes loaded with benzalkonium chloride (ADBAC) as a biocidal agent were successfully tested against E. coli and S. aureus and against human coronavirus strain HCoV-229E. This new biocidal filter based on electrospun nanofibers supported on PP nonwoven fabric could be a promising solution for personal and collective protection in a pandemic context. Full article

Unlike the term sound insulation, which means reducing the penetration of noise into other areas, sound absorption means reducing the reflection and energy of the sound on the surface. It has become a highly noticed issue in recent years because the noise in our daily life is increasing day by day, and it causes some health and comfort disorders. In many areas, textiles have been used for acoustics control and noise absorption purposes. The purpose of this work is to determine the most effective media for sound absorption performance and its relation to thermal conductivity from needle-punched nonwoven, meltblown nonwoven and hybrid forms in different arrangements of these fabrics. To provide comparable samples, both needle-punched nonwoven and meltblown nonwoven samples were produced from 100% Polypropylene fibres. According to sound absorption tests, the hybrid-structured sample having a composition similar to the needle-punched nonwoven sample placed at the bottom of our study, while the meltblown nonwoven sample placed as a face layer outperformed the rest of the samples in terms of sound absorption and thermal conductivity. ‘Meltblown only’ samples had remarkably higher sound absorption efficiency than most of the samples, while the ‘needle-punched nonwoven only’ sample had the lowest sound absorption efficiency in all frequencies. Full article

Meltblown (MB) nonwovens as air filter materials have played an important role in protecting people from microbe infection in the COVID-19 pandemic. As the pandemic enters the third year in this current global event, it becomes more and more beneficial to develop more functional MB nonwovens with special surface selectivity as well as antibacterial activities. In this article, an antibacterial polypropylene MB nonwoven doped with nano silicon nitride (Si₃N₄), one of ceramic materials, was developed. With the introduction of Si₃N₄, both the average diameter of the fibers and the pore diameter and porosity of the nonwovens can be tailored. Moreover, the nonwovens having a single-side moisture transportation, which would be more comfortable in use for respirators or masks, was designed by imparting a hydrophobicity gradient through the single-side superhydrophobic finishing of reactive organic/inorganic silicon coprecipitation in situ. After a nano/micro structural SiO₂ precipitation on one side of the fabric surfaces, the contact angles were up to 161.7° from 141.0° originally. The nonwovens were evaluated on antibacterial activity, the result of which indicated that they had a high antibacterial activity when the dosage of Si₃N₄ was 0.6 wt%. The bacteriostatic rate against E. coli and S. aureus was up to over 96%. Due to the nontoxicity and excellent antibacterial activity of Si₃N₄, this MB nonwovens are promising as a high-efficiency air filter material, particularly during the pandemic. Full article

Large numbers of Single Use Surgical-type Face Masks, used by the public as personal protective equipment during the 2020–2022 COVID-19 pandemic, have been lost or intentionally discarded and have entered the environment rather than the waste management stream. These masks, made from non-woven polypropylene fibers, will undergo environmental decay which will release fiber fragments as microplastics into the environment. While the photochemical process of the decay of polypropylene polymers (photo-oxidation) is well understood, and while there are numerous studies that investigate mask decay and micro-fiber shedding in laboratory settings, there are no observational data that describe the progress and speed of decay on polypropylene face masks in real-life environmental settings. This paper examines the breakdown of single use surgical-type face masks under natural conditions. Masks from three manufacturers were exposed to natural sunlight over a ten-week period and their state of decay was photographically recorded in situ at weekly intervals. Visible decay accelerated after three weeks, with masks made from thinner spunbond fabric decaying more rapidly. Among same-weight fabric, photo-oxidation affected fabric dyed light blue more than undyed fabric, leading to a total breakdown after six weeks. The results are novel as they demonstrate a differential decay between the spunbonded and the melt-blown fabric, which cracks and breaks down much faster due to thinner fibers of shorter length and the lack of thermal bonding points. The resultant extensive micro-fiber generation was accelerated by external physical forces such as wind. This experiment highlights the fact that municipal agencies have only a narrow window of time to remove stray face masks from the urban environment if micro-fiber pollution is to be prevented. Full article

Down fiber is one of the most superior materials, with excellent thermal properties, that can be used in bedding, clothing, and so on. Down products are usually encapsulated in fabrics that are more compact and, therefore, impart an anti-drilling performance. In this study, down fibers were encapsulated in polypropylene melt-blown nonwoven fabric, and also in polyester woven cloth, to form two different kinds of composite waddings. The waddings made of down fiber encapsulated in melt-blown nonwoven fabrics have a superior moisture permeability, thermal insulation, and anti-drilling performance, and a slightly inferior air permeability compared to that of waddings made with traditional woven fabrics. The pore fractal dimensions of melt-blown nonwoven fabrics are larger than that of woven fabrics. The relationship between the fractal dimension and performance of waddings explains the difference. Full article

Manufacturing meltblown nonwoven fabrics requires special grades of resin with very low viscosity, which are not dealt with so much on market and cost quite high compared to the standard grades. We propose a high-shear rate processing method that can quickly and easily produce such low-viscosity resin from the commercial one without using organic peroxides. In this method, we apply high-shear stress to molten resin by using a high-shear extruder, which is a single screw extruder with high screw rotation speed, and the resin is thermally decomposed of its shear-induced heat which is quickly generated. We found that polypropylene with a value of melt flow rate over a thousand, which was required for the meltblown process, was produced from the standard grade with the high-shear extruder at the screw rotation speed of 3600 min${}^{-1}$ and the barrel temperature over 300 ${}^{\circ }$C. Using the degradated polypropylene, a meltblown nonwoven fabric sheet was successfully fabricated. We also developed a numerical simulator of the high-shear extruder which can handle a wide range of the screw rotation speed and barrel temperature by the Nusselt number modulated with the operational conditions. The experimental values of the zero-shear viscosity and temperature at the exit of the extruder agreed well with the simulation results. Our high-shear rate processing method will enable us to quickly and easily produce various meltblown nonwoven fabric sheets at low costs. Full article

Serving as matrices, polypropylene (PP) melt-blown nonwoven fabrics with 4% electrostatic electret masterbatch were incorporated with a 6%, 10%, 14%, or 18% phosphorus-nitrogen flame retardant. The test results indicate that the incorporation of the 6% flame retardant prevented PP melt-blown nonwoven fabrics from generating a molten drop, which, in turn, hampers the secondary flame source while increasing the fiber diameter ratio. With a combination of 4% electrostatic electret masterbatch and the 6% flame retardant, PP melt-blown nonwoven fabrics were grafted with ZIF-8 and Ag@ZIF-8. The antibacterial effect of ZIF-8 and Ag@ZIF-8 was 40% and 85%, respectively. Moreover, four reinforcing measures were used to provide Ag@ZIF-8 PP melt-blown nonwoven fabrics with synergistic effects, involving lamination, electrostatic electret, and Ag@ZIF-8 grafting, as well as a larger diameter because of the addition of phosphorus-nitrogen flame retardants. As specified in the GB2626-2019 and JIS T8151-2018 respiratory resistance test standards, with a constant 60 Pa, Ag@ZIF-8 PP melt-blown nonwoven membranes were tested for a filter effect against PM 0.3. When the number of lamination layers was five, the filter effect was 88 ± 2.2%, and the respiratory resistance was 51 ± 3.6 Pa. Full article

Nonwoven nanofiber webs from polyolefin show great potential in various fields such as nanofilters, high performance membranes and separators in lithium ion batteries (LiB). Although nonwoven microfiber webs can be obtained by the well-established melt-blown method, it is relatively difficult to produce nonwoven nanofiber web using polyolefin (polyethylene and polypropylene). There have been several reports on the preparation of polyolefin nanofibers by melt-electrospinning, although this approach presents several intrinsic disadvantages, i.e., high processing costs, the requirement of complex equipment, and poor control over pore size or fiber diameter. Solution-based electrospinning has the potential to overcome the drawbacks of melt-electrospinning, but the solubility of most polyolefin is poor. In this study, we found that poly-1-butene, a member of the poly(alpha-olefin) family, can be used in the electrospinning process. We set the concentration of the polymeric solution for electrospinning at 0.65–1.7 g/mL. Here, we report on the fabrication of nonwoven fiber webs composed of poly-1-butene and their copolymers. The diameter of the nonwoven fiber mat was 0.2–0.4 μm, which can be applicable for shutdown layer. As a representative application, we prepared a poly-1-butene nanofiber separator with an appropriate pore size by electrospinning for use as the shut-down layer of a next-generation LiB. The PB-based nanofiber mat provided shutdown ability at around 100 to 120 °C. Full article

The combination of the triboelectric effect and static electricity as a triboelectric nanogenerator (TENG) has been extensively studied. TENGs using nanofibers have advantages such as high surface roughness, porous structure, and ease of production by electrospinning; however, their shortcomings include high-cost, limited yield, and poor mechanical properties. Microfibers are produced on mass scale at low cost; they are solvent-free, their thickness can be easily controlled, and they have relatively better mechanical properties than nanofiber webs. Herein, a nano- and micro-fiber-based TENG (NMF-TENG) was fabricated using a nylon 6 nanofiber mat and melt blown nonwoven polypropylene (PP) as triboelectric layers. Hence, the advantages of nanofibers and microfibers are maintained and mutually complemented. The NMF-TENG was manufactured by electrospinning nylon 6 on the nonwoven PP, and then attaching Ni coated fabric electrodes on the top and bottom of the triboelectric layers. The morphology, porosity, pore size distribution, and fiber diameters of the triboelectric layers were investigated. The triboelectric output performances were confirmed by controlling the pressure area and basis weight of the nonwoven PP. This study proposes a low-cost fabrication process of NMF-TENGs with high air-permeability, durability, and productivity, which makes them applicable to a variety of wearable electronics. Full article

This paper presents the method of obtaining poly(propylene) (PP) nonwoven fabrics with antimicrobial properties, using Alafosfalin as the nonwoven modifying agent. Alafosfalin, namely L-alanyl-L-1-aminoethylphosphonic acid, presents representative P-terminal phosphonodipeptide, which possesses a strong, broad spectrum of antimicrobial properties. The analysis of these biofunctionalized nonwoven fabrics processed by the melt-blown technique, included: scanning electron microscopy (SEM), UV/Vis transmittance, FTIR spectrometry, and air permeability. The nonwovens were subjected to microbial activity tests against colonies of Gram-positive (Staphylococcus aureus) and Gram-negative (Escherichia coli) bacteria. Results indicate that the described nonwovens can be successfully used as an antibacterial material. Full article

Particulate airborne pollutants are a big concern to public health, and it brings growing attention about effective filtration devices. Especially, particulate matters smaller than 2.5 µm can reach the thoracic region and the blood stream, and the associated health risk can be exacerbated when pathogenic microbials are present in the air. This study aims at understanding the surface characteristics of nonwoven media that influence filtration performance against solid particles (sodium chloride, NaCl), oily aerosol (dioctyl phthalate, DOP), and Staphylococcus aureus (S. aureus) bacteria. Nonwoven media of polystyrene (PS) fibers were fabricated by electrospinning and its pristine surface energy (38.5 mN/m) was modified to decrease (12.3 mN/m) by the plasma enhanced chemical vapor deposition (PECVD) of octafluorocyclobutane (C₄F₈) or to increase (68.5 mN/m) by the oxygen (O₂) plasma treatment. For NaCl particles and S. aureus aerosol, PS electrospun web showed higher quality factor than polypropylene (PP) meltblown electret that is readily available for commercial products. The O₂ plasma treatment of PS media significantly deteriorated the filtration efficiency, presumably due to the quick dissipation of static charges by the O₂ plasma treatment. The C₄F₈ treated, fluorinated PS media resisted quick wetting of DOP, and its filtration efficiency for DOP and S. aureus remained similar while its efficiency for NaCl decreased. The findings of this study will impact on determining relevant surface treatments for effective particulate filtration. As this study examined the instantaneous performance within 1–2 min of particulate exposure, and the further study with the extended exposure is suggested. Full article

In this paper, a novel electrostatic-assisted melt blown process was reported to produce polypropylene (PP) microfibers with a diameter as fine as 600 nm. The morphology, web structure, pore size distribution, filtration efficiency, and the stress and strain behavior of the PP nonwoven fabric thus prepared were characterized. By introducing an electrostatic field into the conventional melt-blown apparatus, the average diameter of the melt-blown fibers was reduced from 1.69 to 0.96 μm with the experimental setup, and the distribution of fiber diameters was narrower, which resulted in a filter medium with smaller average pore size and improved filtration efficiency. The polymer microfibers prepared by this electrostatic-assisted melt blown method may be adapted in a continuous melt blown process for the production of filtration media used in air filters, dust masks, and so on. Full article

Previous studies on nonwovens used for respiratory protective devices (RPDs) were related to equipment intended for short-term use. There is only limited research on the development of biocidal nonwoven fabrics for reusable RPDs that could be used safely in an industrial work environment where there is a risk of microbial growth. Moreover, a new group of biocides with high antimicrobial activity—gemini surfactants, has never been explored for textile’s application in previous studies. The aim of this study was to develop high-efficiency melt-blown nonwovens containing gemini surfactants with time-dependent biocidal activity, and to validate their antimicrobial properties under conditions simulating their use at a plant biomass-processing unit. A set of porous biocidal structures (SPBS) was prepared and applied to the melt-blown polypropylene (PP) nonwovens. The biocidal properties of the structures were triggered by humidity and had different activation rates. Scanning electron microscopy was used to undertake structural studies of the modified PP/SPBS nonwovens. In addition, simulation of plant biomass dust deposition on the nonwovens was performed. The biocidal activity of PP/SPBS nonwovens was evaluated following incubation with Escherichia coli and Aspergillus niger from the American Type Culture Collection, and with Pseudomonas fluorescens and Penicillium chrysogenum isolated from the biomass. PP/SPBS nonwovens exhibited antimicrobial activity to varying levels. Higher antimicrobial activity was noted for bacteria (R = 87.85–97.46%) and lower for moulds (R = 80.11–94.53%). Full article