Saving 80% Polypropylene in Facemasks by Laser-Assisted Melt-Blown Nanofibers

Abstract

The ongoing coronavirus (COVID-19) pandemic requires enormous production of facemasks and related personal protection materials, thereby increasing the amount of nondegradable plastic waste. The core material for facemasks is melt-blown polypropylene (PP) fiber. Each disposable facemask consumes ∼0.7 g of PP fibers, resulting in annual global consumption and disposal of more than 1 150 000 tons of PP fibers annually. Herein, we developed a laser-assisted melt-blown (LAMB) technique to manufacture PP nanofibers with a quality factor of 0.17 Pa −1 and significantly reduced the filter's weight. We demonstrated that a standard surgical facemask could be made with only 0.13 g of PP nanofibers, saving approximately 80% of the PP materials used in commercial facemasks. Theoretical analysis and modeling were also conducted to understand the LAMB process. Importantly, nanofibers can be easily scaled up for mass production by upgrading traditional melt blown line with scanning laser-assisted melt-blown (SLAMB).

Regulation of polylactic acid using irradiation and preparation of PLA–SiO2–ZnO melt-blown nonwovens for antibacterial and air filtration

“…12 Yang et al adopted a laser-assisted melt-blown (LAMB) technique to manufacture PP MBs, which can substantially alter the viscosity of PP melt and enhance the filtration performance of MBs. 13 However, this method is too expensive for the industrial production of MBs. In contrast, irradiation technology is risk-free, environmentally friendly, and cost-effective.…”

“…Firstly, it is inspired by the fact that irradiation can reduce the viscosity of PLA and further improve its spinnability. 13,14 We studied the effects of different irradiation doses on the molecular weight, viscosity and crystallinity of PLA. Then, by optimizing the weight ratio of irradiated PLA and pristine PLA, the composite MBs were successfully fabricated, and their structural properties, ltration performances and spinnability enhancement mechanism were investigated.…”

P(VDF-TrFE)/BaTiO3 Nanofibrous Membrane with Enhanced Piezoelectricity for High PM0.3 Filtration and Reusable Face Masks

“…With the development of electrospun nanofibers, FFRs made from nanofibrous membranes have been proven to be capable of great PM 0.3 filtration efficiency and low pressure drop ,− because the nanofiber membrane provides a higher specific surface to contact with particles than a microfiber membrane, and the high voltage applied during electrospinning would endow nanofibers with a robust electret effect, which can significantly improve the PM electrostatic adhesion of filters without compromising air permeability. ,− Ding et al fabricated composite electret fabrics using photochromic spiropyran (SP) and polystyrene (PS); the filtration efficiency of PM 0.3 could be maintained at 95% due to its self-polarization-induced electrostatic charge, and the performance was still stable even after 5 times of 75% alcohol washing. Inspired by the electrostatic adhesion, piezoelectric polymers such as poly­(vinylidene fluoride) (PVDF) and its copolymer membranes have attracted attention in the field of air filtration due to their highly self-charging ferroelectric β-phase during electrospinning. , Considering the self-polarized effect is certainly stable without dipole changes and charge dissipation, PVDF-based air filters have been demonstrated with a high PM 0.3 capture capacity and low pressure drop. ,,, However, few studies about piezoelectric filtering membranes that maintain high filtration performance after disinfection with 75% alcohol have been reported.…”

“…Inspired by the electrostatic adhesion, piezoelectric polymers such as poly(vinylidene fluoride) (PVDF) and its copolymer membranes have attracted attention in the field of air filtration due to their highly self-charging ferroelectric β-phase during electrospinning. 29,30 Considering the self-polarized effect is certainly stable without dipole changes and charge dissipation, PVDF-based air filters have been demonstrated with a high PM 0.3 capture capacity and low pressure drop. 8,9,31,32 However, few studies about piezoelectric filtering membranes that maintain high filtration performance after disinfection with 75% alcohol have been reported.…”

Hierarchical PBO Nanofiber/PPS Melt-Blown Mats with a Controllable Porous Microstructure for Thermal Protection under Harsh Conditions

“…Melt-blowing is a commercial process that directly converts polymer resins into nonwoven mats with ultrafine fibers, high porosity, and small pore sizes. , These characteristics make melt-blown mats (MBMs) possess low thermal conductivity and are widely used in thermal insulation clothing for special staff in cold conditions. Several approaches have been reported for decreasing the diameter, such as reducing the viscosity of the melt, decreasing the orifice size, and using electrostatic and laser-assisted melt-blowing techniques. − However, MBMs are rarely used as TPC in harsh conditions due to the tremendous difficulty in reducing the fiber diameter to less than 200 nm and the low thermal stability of the commonly used polymers, such as polypropylene (PP) and polylactic acid (PLA). , Therefore, developing mechanically robust, heat-resistant fabrics with well-designed pore structures for TPC is desired yet challenging.…”