Electrospun medical hygiene and antimicrobial materials: filtration, liquid management, and research progress in functional fibers

01What functional combinations are required for medical hygiene materials?

Hygiene materials are not intended for a single use. The filtration layer in respiratory protection must retain airflow channels while capturing particles; materials contacting the skin or areas around wounds place greater emphasis on liquid migration, flexibility, and biocompatibility; after incorporating antimicrobial components, it is also necessary to understand the contact conditions under which they act. These issues can be studied within the same fiber system but should also be evaluated separately.^{1,2,3,4,5,6,7}

For new projects, specifying what should be blocked, what should be allowed to pass, and which side of the material will contact the user is usually more helpful than deciding on a particular nano-additive first. Complete products also include support layers, seams, and structural designs; results from a single electrospun membrane represent only one part of the overall system.

02How does electrospinning alter filtration and surface structures?

Fiber diameter, porosity, surface density, and interlayer combinations jointly affect airflow and particle pathways. Combining finer fibers with support fibers allows separate arrangement of capture and support functions; adding functional components through surface deposition or blending can further modify wetting, charge, and microbial contact behavior.^1,2,3,4

Structural design involves trade-offs that must be observed together: depositing more fibers may enhance capture but could also increase pressure drop; increasing surface coverage may add contact sites but could also alter porosity and durability. Therefore, a clear fiber image or a single filtration efficiency figure is insufficient to demonstrate that a sample is suitable for its intended use.^1,2,3

03Filtration Fibrous Membranes: Research on Multiscale Structures and Needleless Preparation

PLA Multiscale Fiber Structures

In a study published in 2022, Wang et al. combined fine-scale PLA fibers with a more open fibrous support network to investigate the relationships among surface density, porosity, and airflow resistance, while also examining particle filtration and degradation under specific environmental conditions. This work demonstrates that filtration layer design can be achieved through functional division of fibers at different scales, rather than relying solely on increasing membrane thickness.¹

The particle filtration tests were conducted under specified experimental conditions; these data cannot be directly used to infer the fit, liquid splash protection, or clinical protective performance of finished masks. The degradation tests also correspond to designated media and environments. Describing a material as degradable does not mean it will degrade at the same rate in any usage or disposal environment.¹

Layering of Cellulose Acetate and Quaternized Chitosan

In 2023, Yan et al. employed hybrid needleless spinning to combine a cellulose acetate support layer with a quaternized chitosan functional layer, investigating fiber aggregate structures, particle filtration, airflow resistance, and in vitro antibacterial activity. This work links two spinning formats with layered materials, providing a process example for projects aiming to form multifunctional fiber layers on continuous substrates.³

04Antibacterial and Antiviral Research Requires Specification of Target Organisms

Silver Nanowire Surface Deposition and Bioaerosols

In 2021, Korean researchers Park et al. first prepared PAN electrospun fibers and then deposited silver nanowires via electrostatic spraying. The study separately examined filtration of tested bacteria and MS2 phage particles, as well as changes in microbial activity after capture. A key feature is the separate measurement of “captured” particles and “reduced activity”; the results from MS2 cannot directly substitute for tests involving all human viruses.²

Light-Responsive Composite Fibers Require Corresponding Illumination Conditions

In 2022, Chen et al. incorporated plant extracts, silver, and silver-doped carbon nitride into PAN fibers, investigating particle filtration, antibacterial activity under different illumination conditions, and in vitro activity against H3N2 influenza virus. The paper also includes molecular docking of COVID-19-related proteins; this constitutes computational analysis and should not be presented as completed verification of SARS-CoV-2 inactivation.⁴

Such research encourages developers to incorporate functional activation conditions into material specifications. If antibacterial activity depends on light exposure, the light source, contact time, and humidity should be verified against intended usage conditions; results obtained under laboratory illumination should not be described as effects that continuously occur during daily wear.⁴

Expanding from Particle Tests to Multiple Bioaerosols

In 2021, Thai researchers Saikaew and Intasanta studied multifunctional fibrous filtration materials, reporting laboratory evaluations of fine particles, bioaerosols, and multiple microorganisms, including tests related to mycobacteria. This demonstrates that filtration materials intended for health applications can be evaluated across multiple parameters based on clearly defined targets; however, these tests still do not equate to infection risk studies in real-world populations.⁷

05Unidirectional Liquid Transport and Antibacterial Composites in Care Materials

In 2022, Li et al. combined a hydrophobic TPU layer with a hydrophilic PVA/ chitosan derivative layer to prepare a Janus fibrous membrane with different properties on its two sides. The study examined unidirectional liquid transport, tensile properties, in vitro antibacterial activity, and cytocompatibility, exploring material structures that enable liquid migration along a predetermined path.⁵

For developers of care layers, dressing components, and related materials, the value of this work lies in considering liquid transport together with softness and interlayer bonding. Liquid transport is not merely another term for water absorption: the material must also maintain its designed transport path during repeated contact, compression, and bending. This paper provides material- and in vitro-based evidence; unidirectional liquid transport metrics alone cannot be used to infer reduced skin irritation or improved infection outcomes.⁵

06Functional Fillers: Understanding the Scope of Applicability of Results

In 2024, Deng et al. formed a composite component using ZIF-8 and chitosan, then incorporated it into PLA electrospun membranes to study particle filtration, bacterial contact, and changes in aqueous and soil environments. This research addresses both surface functionality and post-use material behavior, suggesting that additives may simultaneously affect multiple properties.⁶

However, antibacterial rates obtained under specific culture conditions do not demonstrate that the material is suitable for skin contact or use in close proximity to the respiratory tract. The immobilization, release, and detachment of functional fillers should still be evaluated in the context of the intended application site. For membranes containing silver or other inorganic components, functional performance and component stability must be treated as related but independent issues.^2,4,6

The material research described in this text helps answer “how filtration or antibacterial functions can be formed” but does not yet address how much infection risk finished products can reduce in healthcare settings. Clearly distinguishing research stages facilitates establishing a pathway from material screening to complete product validation, avoiding the attribution to a single test conclusions that it cannot support.

07Toward Reproducible Functional Layers by Studying Fiber Orientation

First Determine Whether to Use a Stand-Alone Membrane or a Composite Substrate

Electrospinning can produce stand-alone fibrous membranes or deposit fibers directly onto a support substrate. Effective width, surface density, substrate solvent resistance, interlayer bonding, and post-treatment must first be determined before discussing liquid supply, nozzle design, needleless formats, and continuous collection. After lamination, air permeability and liquid transport should be retested, because the performance of the complete structure is not simply the sum of its individual layers.

Incorporate Moisture Resistance, Loading, and Storage Conditions into Comparisons

Filtration materials can be compared based on their initial state and changes after exposure to moisture or particle loading, according to their intended environment. Liquid-transport materials can be compared in terms of directional transport and structural integrity after repeated liquid exposure. Antibacterial layers require specification of the test organism, contact method, and state of the active component. These comparisons should be designed for the planned application rather than merely reproducing the best samples from published papers.^{1,2,3,4,5,6,7}

Check Uniformity Across Width and Time Directions

During scale-up, raw material batches, solution preparation, liquid supply, temperature and humidity, collection speed, and lamination steps can be correlated with sample results. In addition to fiber morphology, attention should be paid to variations in surface density, porosity, and functional components across different locations to confirm that continuous production does not introduce localized weak areas.

If particles or coatings are to be used, structural changes after substrate attachment, bending, and friction can be included in initial sample observations. If reusable materials are desired, validation must be repeated according to the specific cleaning process. A single filtration or antibacterial result cannot automatically support a conclusion of reusability.

08Common Issues in the Development of Medical and Hygienic Fibrous Materials

Does High Particle Filtration Efficiency Equate to Antiviral Activity?

No. Particle capture, viral particle filtration, and changes in viral activity each have their own evaluation methods. Actual protection also depends on the complete product and its mode of use; evidence should be described separately for each aspect.^2,4,7

Do Natural Polymers or Biodegradable Polymers Not Require Cytocompatibility Verification?

Verification is still required. Formulation, impurities, additives, post-treatment, and contact site all affect the final material; the name of the raw material cannot substitute for finished-product validation.^1,3,5,6

If a Nonwoven Product Already Exists, Can a Thin Electrospun Layer Simply Be Added?

This can be discussed as a fabrication approach. First, specify whether the added layer is intended for filtration, liquid transport, or antibacterial function. Then determine the position of the electrospun layer and reevaluate the structure and target function of the composite.

References

The following are the original studies selected for this article. The literature interpretation does not imply that the paper authors or research institutions have equipment procurement or cooperative relationships with TONGLI; the reported results apply only to the materials, models, and experimental conditions in the original texts.

Bibliographic records retain the original publication language for accurate lookup.

1. Wang L, et al. Biodegradable and high-performance multiscale structured nanofiber membrane as mask filter media via poly(lactic acid) electrospinning. Journal of Colloid and Interface Science. 2022;606:961–970.

   DOI：10.1016/j.jcis.2021.08.079 ↗

   Scope of review: review of the full text of the original local paper, including relevant methods and results, and verification of the published bibliography

2. Park K, et al. Fabrication of silver nanowire coated fibrous air filter medium via a two-step process of electrospinning and electrospray for anti-bioaerosol treatment. Journal of Hazardous Materials. 2021;411:125043.

   DOI：10.1016/j.jhazmat.2021.125043 ↗

   Scope of review: review of the full text of the original local paper, including relevant methods and results, and verification of the published bibliography

3. Yan G, et al. Antibacterial biodegradable nanofibrous membranes by hybrid needleless electrospinning for high-efficiency particulate matter removal. Chemical Engineering Journal. 2023;461:142137.

   DOI：10.1016/j.cej.2023.142137 ↗

   Scope of review: review of the full text of the original local paper, including relevant methods and results, and verification of the published bibliography

4. Chen P, et al. Electrospun nanofibrous membrane with antibacterial and antiviral properties decorated with Myoporum bontioides extract and silver-doped carbon nitride nanoparticles for medical masks application. Separation and Purification Technology. 2022;298:121565.

   DOI：10.1016/j.seppur.2022.121565 ↗

   Scope of review: review of the full text of the original local paper, including relevant methods and results, and verification of the published bibliography

5. Li L, et al. Stretchable unidirectional liquid-transporting membrane with antibacterial and biocompatible features based on chitosan derivative and composite nanofibers. Carbohydrate Polymers. 2022;276:118703.

   DOI：10.1016/j.carbpol.2021.118703 ↗

   Scope of review: review of the full text of the original local paper, including relevant methods and results, and verification of the published bibliography

6. Deng Q, et al. Improving the particulate matter filtration, antibacterial, and degradation properties of electrospinning poly(lactic acid) membranes with ZIF-8@chitosan. Carbohydrate Polymers. 2024;342:122427.

   DOI：10.1016/j.carbpol.2024.122427 ↗

   Scope of review: review of the full text of the original local paper, including relevant methods and results, and verification of the published bibliography

7. Saikaew R, Intasanta V. Versatile nanofibrous filters against fine particulates and bioaerosols containing tuberculosis and virus: Multifunctions and scalable processing. Separation and Purification Technology. 2021;275:119171.

   DOI：10.1016/j.seppur.2021.119171 ↗

   Scope of Review: Original Abstracts and Bibliography from the Publisher; Full Methods Not Read or Verified