High-Throughput Integration of Functional Powder Materials into Industrial Fiber Sheets via Roll-to-Roll...

Functional powder materials, including emerging photocatalysts and porous materials, can be incorporated into high-surface-area fiber sheets for industrial applications such as hydrogen production and water treatment. Although this can be achieved using electrostatic layer-by-layer assembly, time-consuming repeated dip-rinse cycles have hindered commercial-scale production. In this study, a high-throughput integration strategy based on electrostatic assembly is developed to avoid such repetitive cycling. This approach requires a single dip-dry step, enabling an impressive throughput of >1,000 m² per day using a commercial-scale impregnation coater, wherein the powder particles are electrostatically pre-complexed with silica or alumina nanoparticles. These nanoparticles ultimately form the backbone of the porous binder, ensuring the adhesion and activity of the functional thin films. Although demonstrated using powdered titanium dioxide and activated carbon, this strategy establishes a broadly applicable framework for designing and integrating surface-charged functional powder materials.