In this work, a multifunctional polymer composite is made using melt-blowing technology from polypropylene (88 wt.%) and poly (ethylene terephthalate) (12 wt.%) with the addition of functional modifiers, that is, 3 g of a superabsorbent polymer and 5 g of a biocidal agent (Biohaloysite). The use of modifiers is aimed at obtaining adequate comfort when using the target respiratory protection equipment (RPE) in terms of microclimate in the breathing zone and protection against harmful aerosols including bioaerosols. The developed production method is innovative in that the two powdered modifiers are simultaneously applied in the stream of elementary polymeric fibers by two independent injection systems. Aerosols of the modifiers are supplied via a specially designed channel in the central segment of the die assembly, reducing the amount of materials used in the production process and saving energy. The results show that the proposed method of incorporating additives into the fiber structure did not adversely affect the protective and functional properties of the resulting filtration nonwovens. The produced nonwoven composites are characterized by SEM, FTIR, and differential scanning calorimetry (DSC). Given their high filtration efficiency at 5%, satisfactory airflow resistance (~200 Pa), very good antimicrobial activity, and excellent water absorption capacity, the obtained multifunctional nonwoven composites may be successfully used in filtering respiratory protective devices.

Filtering nonwovens loaded with activated carbon are among the most popular materials used in the construction of filtering facepiece respirators (FFRs) with anti-odour properties that can be used for respiratory protection at workplaces where the occupational exposure limits of harmful substances are not exceeded. Such FFRs, in addition to a polymer filter material of varying effectiveness, also contain a layer of activated-carbon-loaded nonwoven filter, which limits the quantity of chemical compounds entering the breathing zone. The aim of this work was to analyse the influence of challenge concentration (20–120 ppm), relative humidity (2–70%), flow rate (20–55 L/min), and flow pattern (steady-state and pulsating) on the breakthrough of polymer/carbon nonwovens. A commercial activated-carbon-loaded nonwoven filter was used in this study. Its morphology and textural parameters were determined using optical microscopy, image processing, and nitrogen adsorption/desorption measurements at 77 K. Breakthrough experiments were carried out using cyclohexane vapours to assess adsorption characteristics of polymer/carbon media. The results showed that the breakthrough times decreased with increasing challenge concentration (up to 30%), relative humidity (up to 73%), and flow rate (up to 72%). The pulsating flow pattern was found to be more favourable in terms of odour reduction efficiency (up to 30%). The results indicate that all of these factors should be considered during selection and performance assessment of respirators used for odour relief.

Zeolites are micro- and mesoporous aluminosilicate minerals (both natural and industrially produced) widely used as catalysts and sorbents in domestic and commercial water purification and separation technologies. Their ability to selectively adsorb gases (i.e., water vapor, carbon dioxide, and sulfur dioxide removal) from an air stream makes them suitable for applications in odor reducing media used in filtering facepiece respirators (FFRs). FFRs are multilayer products in which the most important role is played by high-performance melt-blown electret nonwovens modified with activated carbon to adsorb malodorous compounds. Replacing carbon sorbents with zeolites could increase the efficiency of odor abatement, thus alleviating work-related hazards for individuals exposed to malodorous substances with adverse effects on human well-being. The objective of the present work was to analyze the influence of the textural parameters of zeolite and mesoporous silica materials on the protective and functional properties of polymeric nonwoven composites containing them. In our experiments, the longest breakthrough time against ammonia vapor was found for a nonwoven composite containing the inorganic mesoporous silica material type MCM-41. It was also characterized by high filtration efficiency against aerosols with solid and liquid dispersed phases (97% and 99% for sodium chloride and paraffin oil mist, respectively) at an airflow resistance of approximately 330 Pa. In turn, the composites containing the molecular sieve (SM-zeolite ZSM-5) exhibited the longest breakthrough time for acetone and cyclohexane vapors at the maximum allowable concentrations of 235 ppm and 81 ppm, respectively. Basic filtration tests showed that the composite was 97% effective against both test aerosols at an airflow resistance of 283.5 Pa.

In this article, we present polymer non-woven fabrics with the addition of carbon sorbents being tested to estimate the breakthrough time and efficient protection against vapors present in smog. For this purpose, three substances were selected, which constitute an inhalation hazard and are smog components: cyclohexane, toluene, and sulfur dioxide. It was demonstrated that an increased quantity of carbon sorbent in polymeric filters significantly prolongs the breakthrough time. However, high sorbent quantities may increase the filter surface mass and air flow resistance. To optimize the protective parameters with functionality, a compromise between the two has to be found. By comparing the breakthrough times for different carbon sorbent quantities, the optimal filter composition was elaborated. The analyzed non-woven fabrics were manufactured by the melt-blown process and filled with ball-milled carbon sorbents supplied directly into the fabric blowing nozzle. Both protective performance and textural properties were analyzed for two commercially available carbon sorbents. Furthermore, it was proven that high values of sorbent-specific surface area translates directly into greater filter performance.

The paper presents various dispersive systems developed for sensing toxic substance—ammonia. Polycarbonate dissolved in methylene chloride was used as a polymer matrix, which was enriched with: multi-walled carbon nanotubes (MWCNs), reduced graphene oxide (rGO) and conductive polymer (polyaniline—PANi). Dispersive systems were applied to the prefabricated substrates with comb electrodes by two methods: spraying and drop-casting, forming an active chemosensitive to ammonia vapours films. The spraying method involved applying the dispersion to the substrate by an aerograph for a specific time, whereas drop-casting involves depositing of the produced dispersive systems using a precision automatic pipette. The electrical responses of the obtained films were examined for nominal concentrations of ammonia vapours. Different types of dispersions with various composition were tested, the relationships between individual compounds and ammonia were analysed and the most promising dispersions were selected. Sensor containing rGO deposited by drop-casting revealed the highest change in the resistance (14.21%).

The developed chemosensitive layers consisted of multi-walled carbon nanotubes (MWCNTs), reduced graphene oxide (rGO), and a conductive polymer (polyaniline—PANI) in a polymeric matrix (a polystyrene solution in methylene chloride). The layers were challenged with a test gas to determine the optimum variant in terms of sensitivity to the selected analyte and the repeatability of results. In terms of individual components, the greatest percentage change in resistance (32%) and the best repeatability were found for chemosensitive layers containing a PANI salt in the polymeric matrix. Even greater changes in resistance were exhibited by sensors containing more than one active component in the matrix: 45% for PANI + MWCNTs and 75% for PANI + rGO. The presented method of thin-layer deposition was shown to be suitable for the production of sensitive and functional sensors of ammonia vapors. The developed sensors were characterized by high repeatability and sensitivity to a harmful substance that constitutes an inhalation hazard to workers. The sensors were also analyzed for their durability and recovery as well as the ability to function under varying temperature and humidity conditions.