Hierarchical Fibrous Honeycomb Ceramics with High Load Capability and Low Light-Off Temperature for the Next-Generation Auto Emissions Standards.

Novel and stringent automotive exhaust gas emissions standards are urgently needed to counter the problems posed by the worsening global climate and environment. However, the traditional cordierite-based honeycomb ceramics substrates with ultimate pore density have seriously restricted the establishment of new emission standards. Herein, we introduce a novel robust substrate with tailored volume-specific surface area and low heat capacity. This substrate employs the synergy of high-strength ceramic fibers and ultrathin TiO2 nanosheets. The micro-sized fibers provide support to ensure structural strength during the catalytic reaction, while the nanosheets play the dual role of connecting the fibers and providing a high surface area for catalyst immobilization. The new three-dimensional (3D) microarchitecture exhibits a high volume-specific surface area of 3.59×104  cm2 /cm3 , a compressive strength of 2.01 MPa, and remarkable stability after high-speed air erosion at 800 °C. The honeycomb-like structure exhibit low resistance to gas flow. Furthermore, after loading with Pt and Pd nanoparticles, the composite 3D microarchitecture delivered an excellent catalytic performance and prominent structural stability, with a super low light-off temperature of 150 °C. The outstanding mechanical and thermal stability and the high surface area and light-off temperature of the new substrate indicate its potential for use as a highly efficient catalytic carrier to meet the next-generation auto emissions standards.

A Foldable All-Ceramic Air Filter Paper with High Efficiency and High-Temperature Resistance.

Advanced filter materials with high efficiency, low-pressure drop, and high-temperature resistance are urgently needed in the field of high-temperature gas filtration. Here, an Al2O3-stabilized ZrO2 (ASZ) submicron fiber air filter paper with excellent flexibility and thermal stability (up to 1100 °C) is developed using a cost-effective, scalable solution blow spinning method and subsequent calcination. The ASZ papers demonstrate excellent flexibility and foldability, which can be attributed to the tetragonal phase and small crystallite size of the ASZ fibers due to the presence of Al2O3. In addition, the ASZ papers with an areal density of 56 mg cm-2 show a high filtration efficiency (99.56%) and a low-pressure drop (108 Pa) for 15-615 nm NaCl particles at an airflow velocity of 5.4 cm s-1. We envision that the foldable all-ceramic air filter material will provide a solution for the removal of particulate matter from the high-temperature exhaust gases.

Polydopamine Nanocluster Embedded Nanofibrous Membrane via Blow Spinning for Separation of Oil/Water Emulsions.

Developing a porous separation membrane that can efficiently separate oil-water emulsions still represents a challenge. In this study, nanofiber membranes with polydopamine clusters polymerized and embedded on the surface were successfully constructed using a solution blow-spinning process. The hierarchical surface structure enhanced the selective wettability, superhydrophilicity in air (≈0°), and underwater oleophobicity (≈160.2°) of the membrane. This membrane can effectively separate oil-water emulsions, achieving an excellent permeation flux (1552 Lm-2 h-1) and high separation efficiency (~99.86%) while operating only under the force of gravity. When the external driving pressure was increased to 20 kPa, the separation efficiency hardly changed (99.81%). However, the permeation flux significantly increased to 5894 Lm-2 h-1. These results show that the as-prepared polydopamine nanocluster-embedded nanofiber membrane has an excellent potential for oily wastewater treatment applications.

A Flexible, Robust, and Gel-Free Electroencephalogram Electrode for Noninvasive Brain-Computer Interfaces.

Brain-computer interfaces (BCIs) enable direct and near-instant communication between the brain and electronic devices. One of the biggest remaining challenges is to develop an effective noninvasive BCI that allows the recording electrodes to avoid hair on human skin without the inconveniences and complications of using a conductive gel. In this study, we developed a cost-effective, easily manufacturable, flexible, robust, and gel-free silver nanowire/polyvinyl butyral (PVB)/melamine sponge (AgPMS) electroencephalogram (EEG) electrode that circumvents problems with hair. Because of surface metallization by the silver nanowires (AgNWs), the sponge has a high conductivity of 917 S/m while its weight remains the same. The flexible sponge framework and self-locking AgNWs combine to give the new electrode remarkable mechanical stability (the conductivity remains unchanged after 10 000 cycles at 10% compression) and the ability to bypass hair. A BCI application based on steady-state visual evoked potential (SSVEP) measurements on hairless skin shows that the BCI accuracy of the new electrode (86%) is approximately the same as that of conventional electrodes supported by a conductive gel (88%). Most importantly, the performance of the AgPMS on hairy skin is not significantly reduced, which indicates that the new electrode can replace conventional electrodes for both hairless and hairy skin BCIs and other EEG applications.

Mineral-Templated 3D Graphene Architectures for Energy-Efficient Electrodes.

3D graphene networks have shown extraordinary promise for high-performance electrochemical devices. Herein, the chemical vapor deposition synthesis of a highly porous 3D graphene foam (3D-GF) using naturally abundant calcined Iceland crystal as the template is reported. Intriguingly, the Iceland crystal transforms to CaO monolith with evenly distributed micro/meso/macropores through the releasing of CO2 at high temperature. Meanwhile, the hierarchical structure of the calcined template could be easily tuned under different calcination conditions. By precisely inheriting fine structure from the templates, the as-prepared 3D-GF possesses a tunable hierarchical porosity and low density. Thus, the hierarchical pores offer space for guest hybridization and provide an efficient pathway for ion/charge transport in typical energy conversion/storage systems. The 3D-GF skeleton electrode hybridized with Ni(OH)2 /Co(OH)2 through an optimal electrodeposition condition exhibits a high specific capacitance of 2922.2 F g-1 at a scan rate of 10 mV s-1 , and 2138.4 F g-1 at a discharge current density of 3.1 A g-1 . The hybrid 3D-GF symmetry supercapacitor shows a high energy density of 83.0 Wh kg-1 at a power density of 1011.3 W kg-1 and 31.4 Wh kg-1 at a high power density of 18 845.2 W kg-1 . The facile fabrication process enables the mass production of hierarchical porous 3D-GF for high-performance supercapacitors.

High-Temperature Particulate Matter Filtration with Resilient Yttria-Stabilized ZrO2 Nanofiber Sponge.

Particulate matter (PM) is a major air pollutant in many regions, jeopardizing ecosystems and public health. Filtration at pollutant source is one of the most important ways to protect the environment, however, considering the high-temperature exhaust gas emissions, effective removal of PM and related pollutants from their sources remains a major challenge. In this study, a resilient, heat-resisting, and high-efficiency PM filter based on yttria-stabilized ZrO2 (YSZ) nanofiber sponge produced with a scalable solution blow spinning process is reported. The porous 3D sponge composed of YSZ nanofibers is lightweight (density of 20 mg cm-3 ) and resilient at both room temperature and high temperatures. At room-temperature conditions, the YSZ nanofiber sponge exhibits 99.4% filtration efficiency for aerosol particles with size in the range of 20-600 nm, associated with a low pressure drop of only 57 Pa under an airflow velocity of 4.8 cm s-1 . At a high temperature of 750 °C, the ceramic sponge maintains a high filtration efficiency of 99.97% for PM0.3-2.5 under a high airflow velocity of 10 cm s-1 . A practical vehicle exhaust filter to capture particles with filtration efficiency of >98.3% is also assembled. Hence, the YSZ nanofiber sponge has enormous potential to be applied in industry.

Continuous Draw Spinning of Extra-Long Silver Submicron Fibers with Micrometer Patterning Capability.

Ultrathin metal fibers can serve as highly conducting and flexible current and heat transport channels, which are essential for numerous applications ranging from flexible electronics to energy conversion. Although industrial production of metal fibers with diameters of down to 2 µm is feasible, continuous production of high-quality and low-cost nanoscale metal wires is still challenging. Herein, we report the continuous draw spinning of highly conductive silver submicron fibers with the minimum diameter of ∼200 nm and length of more than kilometers. We obtained individual AgNO3/polymer fibers by continuous drawing from an aqueous solution at a speed of up to 8 m/s. With subsequent heat treatment, freestanding Ag submicron fibers with high mechanical flexibility and electric conductivity have been obtained. Woven mats of aligned Ag submicron fibers were used as transparent electrodes with high flexibility and high performance with sheet resistance of 7 Ω sq-1 at a transparency of 96%. Continuous draw spinning opened new avenues for scalable, flexible, and ultralow-cost fabrication of extra-long conductive ultrathin metal fibers.

Continuous production and properties of mutil-level nanofiber air filters by blow spinning.

Nanofibers are gradually being widely used in air filtration due to their unique characteristics. However, the mass production of nanofiber filter material faces several problems. Blow spinning is an emerging technology, which have great potential for mass production of nanofibers. In this work, we have successfully realized the continuous production of 500 mm wide nanofiber membranes by blow spinning, which enables continuous preparation of multi-level nanofiber filter materials: PAN60 (filtration efficiency is 63.2%, pressure drop is 18 Pa), PAN80 (filtration efficiency is 80.7%, pressure drop is 38 Pa), PAN90 (filtration efficiency is 92.9%, pressure drop is 58 Pa) and PAN99 (filtration efficiency is 99.5%, pressure drop is 123 Pa). In order to improve the stability performance of melt-blown filters, we provide a strategy that combines nanofibers with a melt-blown filter. PAN nanofibers were sprayed directly on the melt-blown filter by blow spinning. The composite filters have more stable filtration performance and higher efficiency when intercepting particles with a diameter below 100 nm than melt-blown filters.

Metal-Based Nanocatalysts via a Universal Design on Cellular Structure.

Metal-based nanocatalysts supported on carbon have significant prospect for industry. However, a straightforward method for efficient and stable nanocatalysts still remains extremely challenging. Inspired by the structure and comptosition of cell walls and membranes, an ion chemical bond anchoring, an in situ carbonization coreduction process, is designed to obtain composite catalysts on N-doped 2D carbon (C-N) loaded with various noble and non-noble metals (for example, Pt, Ru, Rh, Pd, Ag, Ir, Au, Co, and Ni) nanocatalysts. These 2 nm particles uniformly and stably bond with the C-N support since the agglomeration and growth are suppressed by anchoring the metal ions on the cell wall and membrane during the carbonization and reduction reactions. The Pt@C-N exhibits excellent catalytic activity and long-term stability for the hydrogen evolution reaction, and the relative overpotential at 100 mA cm-2 is only 77 mV, which is much lower than that of commercial Pt/C and Pt single-atom catalysts reported recently.

Ultralight, scalable, and high-temperature-resilient ceramic nanofiber sponges.

Ultralight and resilient porous nanostructures have been fabricated in various material forms, including carbon, polymers, and metals. However, the development of ultralight and high-temperature resilient structures still remains extremely challenging. Ceramics exhibit good mechanical and chemical stability at high temperatures, but their brittleness and sensitivity to flaws significantly complicate the fabrication of resilient porous ceramic nanostructures. We report the manufacturing of large-scale, lightweight, high-temperature resilient, three-dimensional sponges based on a variety of oxide ceramic (for example, TiO2, ZrO2, yttria-stabilized ZrO2, and BaTiO3) nanofibers through an efficient solution blow-spinning process. The ceramic sponges consist of numerous tangled ceramic nanofibers, with densities varying from 8 to 40 mg/cm3. In situ uniaxial compression in a scanning electron microscope showed that the TiO2 nanofiber sponge exhibits high energy absorption (for example, dissipation of up to 29.6 mJ/cm3 in energy density at 50% strain) and recovers rapidly after compression in excess of 20% strain at both room temperature and 400°C. The sponge exhibits excellent resilience with residual strains of only ~1% at 800°C after 10 cycles of 10% compression strain and maintains good recoverability after compression at ~1300°C. We show that ceramic nanofiber sponges can serve multiple functions, such as elasticity-dependent electrical resistance, photocatalytic activity, and thermal insulation.

Highly Flexible Indium Tin Oxide Nanofiber Transparent Electrodes by Blow Spinning.

Transparent conductive film (TCF) has found wide applications. Indium tin oxide (ITO) is currently the most widely used transparent electrode. However, major problem of ITO is the lacking of flexibility, which totally limits its applications. Here, we report a highly flexible transparent electrode consisting of freestanding ITO nanofiber network fabricated by blow spinning, the advantage of which is its high-efficiency, low cost and safety. When the bending radius decreased to 0.5 mm, the resistance of the transparent electrodes only increased by 18.4%. Furthermore, the resistance was almost unchanged after thousands of bending cycles at 3.5 mm bending radius.