Ultralight Electrospun Composite Filters with Vertical Ternary Spatial Network for High‐Performance PM_0.3 Purification

Abstract

AbstractAir pollutants, particularly highly permeable particulate matter (PM), threaten public health and environmental sustainability due to extensive filter media consumption. Existing melt‐blown nonwoven filters struggle with PM0.3 removal, energy consumption, and disposal burdens. Here, an ultralight composite filter with a vertical ternary spatial network (TSN) structure that saves ≈98% of raw material usage and reduces fabrication time by 99.4%, while simultaneously achieving high‐efficiency PM0.3 removal (≥99.92%), eco‐friendly regeneration (near‐zero energy consumption), and enhanced wearing comfort (breathability >80 mm s⁻¹, infrared transmittance >85%), is reported. The TSN filter consists of a hybrid layer of microspheres (average diameter ≈1 µm)/superfine nanofibers (≈20 nm) sandwiched between two nanofiber scaffolds (diameter ≈400 nm and ≈100 nm). This arrangement offers high porosity (≈85%), ultralow areal density (<1 g m−2), alow airflow resistance (<90 Pa), guaranteeing superb thermal comfort. Notably, utilizing scalable one‐step free surface electrospinning technology, TSN mats can be mass‐produced at a rate of 60 meters per hour (width of 1.6 meters), which is critical and verified for various applications including window screens, individual respiratory protectors, and dust collectors. This work provides a viable strategy for designing high‐performance nanofiber filter media through structural regulation in a scalable, cost‐effective, and sustainable way.