Tri-layer gradient structured micro/nanofibrous nonwovens for high filtration efficiency and low air resistance

The coexistence of PM2.5 pollution and the ongoing pandemic poses significant risks to human health. Protective masks incorporating high-efficiency particulate air filters offer adequate protection against PM2.5 particles. Micro/nanofibrous nonwovens, including melt-blown and electrospun nonwovens, are essential filter materials. This study focuses on the filtration mechanism and geometric structure design of multi-level structured micro/nanofibrous nonwovens. A comprehensive investigation was conducted on a filter core material composed of polyacrylonitrile, a polystyrene electrospun membrane, a polypropylene (PP) melt-blown membrane, and a supporting outer layer of a PP spun-bonded membrane. The resulting nonwovens exhibited exceptional filtration efficiency of 99.98% for PM0.3 particles, with a low pressure drop of 60 Pa at 32 L/min inlet air velocity. Filtration efficiencies of 99.99% and 100% were achieved for PM1.0 and PM2.5 particles, respectively. These characteristics make the designed composite nonwovens a very promising filter material for masks. The study contributes to understanding filtration mechanisms and developing advanced high-efficiency filter materials, enhancing protection against airborne pollutants.