Preparation of Nylon-6 micro-nanofiber composite membranes with 3D uniform gradient structure for high-efficiency air filtration of ultrafine particles

Compared of traditional melt-blown nonwoven materials, micro-nanofiber composite membranes with uniform spatial gradient structure will be the development trend of high efficiency and low resistance filtration materials, especially against ultrafine particles with kinetic diameter less than 0.25 (PM0.25). Herein, Nylon-6 micro-nanofiber composite membranes (Nylon-6 FCMs) with three-dimensional (3D) uniform gradient structure were prepared by air jet spinning under the help of PEO. The fluffy 3D gradient structure possessed a uniform gradual pore gradient from large to small, ensuring the PM0.25 were captured by exact grading under high gas flow due to the form of special "trumpet-like" gas passage inside the membranes. The structure of Nylon-6 FCMs could be controlled and exhibited high tensile strength, good moisture permeability, excellent filtration performance. Among them, the FCM-1 with a uniform gradual pore gradient could achieve the optimal filtering performance with filtration efficiency (99.99 %) and pressure drop (144 Pa). The mask prepared using this Nylon-6 FCMs also displayed good protective effect with comparable air permeability (221.84 mm·s−1) and moisture permeability (181.84 g·m−2·h−1) compared of commercial melt-blown masks. Most importantly, this mask prepared still could maintain good filtration performance even in high temperature and high humidity environment, providing users more comfortable wearing experience and stable protection performance, especially under the current COVID-19 outbreak.