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Progress in Chemistry 2023, Vol. 35 Issue (11): 1686-1700 DOI: 10.7536/PC230411 Previous Articles   Next Articles

• Review •

Preparation and Application of Direct Electrospun Fibrous Sponges

Song Yilong, Zhao Shuang, Li Kunfeng, Fei Zhifang, Chen Guobing, Yang Zichun()   

  1. School of Power Engineering, Naval University of Engineering,Wuhan 430033, China
  • Received: Revised: Online: Published:
  • Contact: Yang Zichun
  • Supported by:
    National Natural Science Foundation of China(51802347)
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Electrospun fibrous sponge is a fluffy three-dimensional (3D) material based on one-dimensional fibers. The increase of dimension makes this material have many more prominent advantages than traditional electrospun films, so it has shown great application potential in various fields. With the in-depth study of the three-dimensional structure of electrospinning, it has become a current challenge to obtain stable fibrous sponges directly by electrospinning and improve their performance. In this paper, various new strategies for preparing fibrous sponges by direct electrospinning in recent years are reviewed in detail. Firstly, the mechanism, characteristics and representative research results of different methods are analyzed and summarized. Then the application status of this material in the fields of tissue engineering, environmental governance, safety protection and intelligent equipment is introduced. Finally, the future development trend of electrospinning fibrous sponge is prospected.

Contents

1 Introduction

2 Preparation process of direct electrospinning fibrous sponges

2.1 Sol-controlled self-assembly

2.2 Humidity induced phase separation

2.3 Air-assisted electrospinning

2.4 Near-field electrospinning / 3D printing

2.5 Template-assisted collection

3 Application of direct electrospinning fibrous sponges

3.1 Tissue engineering

3.2 Sound absorption and noise reduction

3.3 Fire protection and heat insulation

3.4 Filtration and separation

3.5 Sensors

4 Conclusion and outlook

Key words: direct electrospinning, three-dimensional structure, fiber curing, tissue engineering, environmental protection
Fig.1 3D electrospun structure of PS. (a) Top-view, (b) side view, (c) finished size and (d) the fibers on the top of 3D stack repel a rod with negative charges, and attract a rod with positive charges[21,28]. Copyright 2012, Elsevier
Fig.2 (a) Schematic illustration for the fabrication of PSFS. (b) The chemical reaction of TTMA during the crosslink treatment process (c) SEM of the lamellar corrugated microstructure. (d,e) Photographs showing that the ultralight PSFS could stand on the tip of a feather and the large scale of PSFS[36]. Copyright 2019, American Chemical Society
Fig.3 (a) Schematic diagram of stepped airflow-assisted electrospinning set-up[48]. (b) Side and bottom views of the spinning unit[48]. (c) Illustration of the turbulent-flow-assisted electrospinning[49]. Copyright 2022, Nature
Fig.4 (a) Schematic setup of the 3D electrospinning process and a close-up schematic of stacked fibers. (b) SEM image of a 10-layer 3D grid structure on paper substrate. (c) SEM image showing the cross-over area of the grid. (d) An optical photo showing a whole grid structure[52]. Copyright 2015, American Chemical Society
Fig.5 (a) Three dimension nanofibrous macrostructures on “dumbbell” collector[61]. (b) The schematic set-up for the production of 3D nanofibrous structures (bulk and aligned) using liquid vortex[67]. (c) Configuration of divergence electrospinning[62]. Copyright 2021, Springer Berlin Heidelberg
Fig.6 (a) Schematic diagram of hydrogel-assisted electrospinning (GelES) with the two sequential processes of molding and electrospinning; (b) photographs of the multi-bifurcated 3D gelatin cylindrical structure and the 3D PCL nanofiber macrostructure; and (c) photographs of various complex 3D macroscopic configurations fabricated by GelES including the bellow-shaped tubular macrostructure, miniaturized human alveoli-like macrostructure, and brain-like shell macrostructure. Copyright 2020, American Chemical Society
Fig.7 (a) Energy of sound is consumed by reflections multilayer in gradient structure fibrous sponge (PSFS). (b) Energy consumed by Helmholtz resonators like structure. (c) Comparison of the macro and microstructure for dense-packed fibers and fluffy PSFS-10. (d) Sound absorption performance of PSFS and dense packed fibers in a similar weight. (e) Sound absorption performance of PSFS with various thicknesses. (f) Comparison of the sound absorption performance for the commercial sound absorption materials and the prepared PSFS[36]. Copyright 2019, American Chemical Society
Table 1 Performance comparison of electrospun fiber sponges applied in the field of fire resistance and thermal insulation
Material Preparation method Working temperature (℃) Thermal conductivity(mW·m-1·K-1) Mechanical property Applications ref
PSU/PU Humidity induced phase separation / 27.08 Elongation at break is 160% Insulation and flame retardant in cold environment 35
Mullite Sol-controlled self-assembly -196~1300 22.8 The tensile strain is 100% Thermal protection system of aircraft 29
ZrO2-TiO2 Sol-controlled self-assembly -196~1200 27 / Insulation at high temperatures 87
PMMA/PU Humidity induced phase separation / 25.28 The tensile stress is 159.02 kPa Thermal insulation material 13
PSU/PU Humidity induced phase separation -196~ 25.8 The tensile stress is 1 MPa Heat preservation in cold environment 37
PPSU/PU/PAI Humidity induced phase separation / 24.6 ~0% plastic deformation after 100 compressions tests at a large compressive strain of 50% Heat preservation in cold environment 32
PSU/ZrC Humidity induced phase separation -100~100 25.2 The material could withstand over 10 000 times its weight Thermal insulation and photothermal conversion in cold environment 40
ZrO2 Air-assisted electrospinning ~1300 26(25℃) Poisson’s ratio and thermal expansion coefficient are almost 0 Thermal insulation at extreme high temperatures 49
104(1000℃)
ZrO2-Al2O3Stack layer by layer~130032.2High compression strength of more than 1100 kPa (at a strain of 90%)Thermal insulation at extreme high temperatures86
Fig.8 Thermal insulation properties of the ZrAlNFAs. (a) Thermal conductivities of the ZrAlNFAs. (b) Thermal conductivity at room temperature versus maximum working temperature for aerogel-like materials. (c) Optical photograph of the front side subjected to a butane blowtorch flame. (d) Infrared images of the back side during the 10 min heating process. (e) Time-dependent temperature profile of the center point on the back side. (f) Optical photograph and SEM image of front side and cross section of the ZrAlNFAs after a 10 min fire resistance test[87]. Copyright 2020, American Chemical Society
Fig.9 Dual-Network structured fibrous sponges. (a) The filtration efficiency and pressure drop when PM 0.3 particles are used and the airflow velocity is 5.33 cm·s-1. (b) Pore size distribution. (c) The porosity and filling density of PAN nanofiber networks with dual network structure prepared at different RH. (d~f) The process diagram of PAN nanofiber filter capturing particles in the air with or without voids. (d' ~f') The pressure field model of airflow passing through these three filters at a surface velocity of 5.33 cm · s-1 [42]. Copyright 2019, Wiley-VCH Verlag
Fig.10 Wearable device assembled from CNFNs for various physiological signal monitoring. (a and b) Real-time resistance response during pronouncing. (c) Photograph of the CNFN sensor fixed on the wrist to measure the pulse. (d) Pulse signal with clear waveforms, indicating 76 beats per min. (e) Respiratory signal caused by air movements for breathing smoothly and hurriedly, respectively. (f) Resistance responses of the CNFN sensor attached to the finger joint for different degrees of bending[26]. Copyright 2019, Royal Society of Chemistry
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