Nanofiber is a fiber with a diameter measuring less than 1 micrometer (1000 nanometers). Microfibers have unique properties compared to larger fibers as their small diameter and extremely large specific surface area lend them properties ideal for many applications.
Production of Nanofibers
There are various methods for producing microfibers but the most common are electrospinning and meltblowing. In electrospinning, a polymer solution or melt is pumped through a capillary tube by a syringe pump. A high voltage electric field is applied between the tip of the tube and a collector plate. This creates electrically charged jets of polymer solution which accelerates towards the collector and leaves randomly oriented microfibers on the plate as the solvent evaporates. Meltblowing uses gravity, centrifugal force and high-velocity air to produce continuous non-woven microfiber mats as molten polymer is extruded through a die and encounters converging hot air streams.
Properties of Nanofibers
Due to their small diameter and high surface area to volume ratio, microfibers have a number of unique properties making them very useful in many applications. Their small pore size allows for ideal filtration of particles down to virus size. High tensile strength allows for reinforcement in lightweight composites. Porosity permits high gas permeability needed for wound dressings. Surface functionality can be tailored using different polymers and surface treatments. Biocompatibility also opens up uses in biomedical and healthcare.
Filtration
A key use of Nanofiber mats is in high performance air and liquid filtration. Their small pore size of less than 100 nm allows removal of submicron particles like viruses, bacteria and fine dust. Electrospun microfiber mats have over 95% filtration efficiency and can filter particles 100 times smaller than HEPA filters. This makes them ideal for respirator masks, cleanroom air filters and water purification. Some are able to capture pathogens like coronaviruses. Commercial uses include air filters for buildings, vehicles and industrial processes.
Protective Clothing and Equipment
Electrospun microfiber nonwovens provide barrier protection with high breathability needed for protective suits, masks and respirator filters. The tiny pores allow moisture vapor to pass through while blocking smaller pathogens, chemicals and aerosols. Combining microfibers with other materials results in fabrics lighter and more comfortable than existing alternatives. Major industries using microfiber protective textiles include healthcare, military, industrial safety and hazardous material handling. Leading producers supply PPE globally in response to pandemic needs.
Wound Care and Tissue Engineering
Electrospun microfiber mats mimic the characteristics of natural extracellular matrix promoting cell growth and wound healing. Their high porosity, gas permeability and ability to absorb fluids and blood make them ideal scaffolds for burns and chronic wounds. Incorporating drugs and growth factors leads to advanced wound dressings aiding regeneration. Researchers are also exploring use of microfiber scaffolds in tissue engineering of skin, blood vessels and load-bearing tissues to replace damaged body parts. Commercial products include bandages, grafts and materials for regenerative medicine therapies.
Drug Delivery and Controlled Release
Nanofibers provide unique platforms for controlled release applications. Electrospun microfiber mats possess tuneable porosity and high encapsulation efficiency. Combining drugs within the polymer fibers enables sustained release over prolonged periods as the fiber degrades or through diffusion. Targeted release profiles can be achieved through modifications to fiber composition, dimensions and external stimuli like light, ultrasound or change in pH. This allows drug delivery patches, implants and wound dressings for conditions like inflammation, infection, cancer and more.
Energy Storage
Nanofibers are gaining importance as building blocks for next-generation batteries, supercapacitors and fuel cells due to their high specific surface area, porosity and potential for property enhancements. Electrospun carbon microfibers boost performance and stability of lithium-ion batteries as anode materials and separators. Conducting polymer microfibers are researched for pseudocapacitors able to charge extremely fast. Microfiber composite electrodes also show promise for sodium-ion and other alternate battery chemistries. Wider commercial application in portable electronics and electric vehicles depends on scalable manufacturing of microfiber energy storage materials.
Composites and Packaging
Polymer microfibers facilitate reinforcement and property enhancement in composite materials. Glass, carbon and Kevlar microfibers significantly boost tensile strength and stiffness of plastics, cement and concrete when incorporated at low loadings of 1-5% by weight. Nanocomposites find uses as lightweight construction materials, ballistic armor, aircraft parts and sporting goods. Electrospun microfiber mats are also emerging as biobased food packaging with antimicrobial effects and selective barrier properties ideal for fresh produce and meat. More research aims to utilize agricultural and food industry wastes in such green composites.
Outlook
With continuous progress in scalable and economical production techniques, widespread applications of electrospun nanofibers are on the horizon in sectors from healthcare, energy and environment to aerospace, automotive and consumer. Ongoing research expansion is further unlocking their potential through control over morphology, composition and properties. Recent years have seen new developments and commercial growth amid pandemic demand highlighting microfibers' importance. The field promises new materials, products and technology advancements to tackle global challenges in coming decades.
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