Multiscale Structured PS Nonwoven Materials via Solution Blow Spinning for Intelligent Robotic Air Filtration Systems

The advancement of intelligent filtration technologies for robotic and environmental control systems has created increasing demands for filter materials that simultaneously exhibit high filtration efficiency, low airflow resistance, and excellent durability. In this study, gradient-structured polystyrene (PS) nonwoven filtration materials were fabricated using electrostatic-assisted solution blow spinning (SBS) technology. The spinning conditions were precisely tuned to control the ratio of coarse and fine fibers, resulting in optimized filtration performance. When the coarse-to-fine fiber ratio was 1:1, the material achieved a pore size of 2.68 μm, filtration efficiency of 99.61%, a pressure drop of 140 Pa, and a high quality factor of 0.39 Pa⁻¹. Computational fluid dynamics (CFD) simulation and dynamic loading tests demonstrated significant synergistic interactions between fibers of different scales, enhancing the filter’s particle interception capability and operational lifespan. The developed multiscale PS nonwoven materials present strong potential as filtration interfaces in intelligent air purification systems, robotic respiratory modules, and protective environments.