Chemical engineering of electrospun nanofibrous‐based three‐layered nonwoven polymeric protective mask for enhanced performance

Abstract During the COVID‐19 pandemic, face masks, respirators, and personal protective equipment have become common preventive measures. However, the COVID‐19 pandemic has highlighted the lack of efficient and reusable face masks worldwide. Immense efforts have been dedicated to designing antidust and antidroplet masks to ensure safe breathing. In this context, electrospun nanofibrous layers have attracted considerable attention for the fabrication of antidust and antidroplet masks. During long‐term usage, water droplet layers can lead to pore blockages; this remains a major concern. In this study, a three‐layered sandwich structure comprising a hydrophilic spongy layer, hydrophobic support layer, and antidroplet layer was developed to address this concern. Specifically, the structure comprised polyvinylidene fluoride‐silica nanoparticles‐perfluorooctyl trichlorosilane/polyethylene/polybenzimidazole (PVDF‐Si‐NPs‐PFTOS/PET/PBI) electrospun nanofibrous layers. The PBI layer was utilized as soft, hydrophilic, skin‐friendly layer, as supported by the PET layer for better mechanical stability. In addition, PVDF coated with micro‐nano scale Si‐NPs as modified with a PFTOS nonwoven electrospun layer was used for the antifouling, antidroplet, and splash resistance capabilities. This novel electrospun nanofibrous nonwoven three‐layered sandwich structure (PVDF‐Si‐PFTOS/PET/PBI) exhibited high performance, with competitive antidroplet abilities. Accordingly, this research can be used to fabricate face masks with antidroplet and splash resistance for personal safety and protective equipment.