Facile fabrication of reinforced sub-micron fibrous media with hierarchical structure compounded thermally for effective air purification in application

Air pollution has steadily worsened in recent years, and the coronavirus disease 2019 has been spreading since 2020. The electrospun fibrous filters present superior filtration performance, while the low mechanical property and yield of them limit their applications, which must be addressed urgently. Herein, polyacrylonitrile (PAN) sub-micron fibrous membrane with hierarchical structure was easily manufactured using free surface electrospinning in mass production for air purification. The “sandwich” structured fibrous filter was thermally bonded with bi-component nonwoven through traditional bonding procedures, due to melting and bonding of the cortex of bi-component fibers, in which the electrospun fibrous web as the mid layer with tortuous channels showed superior filtration performance for aerosol particles with diameter of 260 nm, which could effectively intercept different-sized particles suspended in the air. In addition, the impact of the processing parameters on the characteristics and filtration mechanisms of thermally bonded composite materials was thoroughly investigated. The results showed that composite material with “dendrites” and “axon” morphologies presented the best formability, outstanding peeling strength and breaking strength, and steady filtration performance, following an easy through-air bonding procedure, making it useful for post-processing in air purification. The reinforced composite filter, which is thermally bonded with sub-micron fibers with high yield and nonwoven, is save-energy and has a low operation cost, indicating its promising commercial possibilities.