Mass Production of Hierarchically Designed Engine-Intake Air Filters by Multinozzle Electroblow Spinning

Particulate matter damages engines of vehicles when blown into the ventilation system. Conventional engine-intake filter is cellulose microfiber board with an average diameter larger than ten microns, which has low removal efficiency of ultrafine particular matter. In this work, we apply ultrafine polyurethane nanofibers (∼122.8 nm) onto pleated cellulose board using scalable multinozzle electroblow spinning technology, which improves filtration efficiency of particulate matter with a diameter of less than 0.3 μm PM_0.3 greatly. The thermoplastic polyurethane 85A nanofiber membranes are transparent, and display superior filtration performance which meets up with the 95% filtration efficiency standard in GB 19083-2010 technical requirements for protective face mask for medical use. The lightweight pleated thermoplastic polyurethane/cellulose composites intercept ∼90% ultrafine PM_0.3 under airflow velocity of 32 L min^-1 and possess great resistance to shock. These hierarchically designed filters follow a mechanical mechanism and can be used in on-road and off-road cars in the long run.