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Recently, MnO 2 -coated polymeric filters have shown promising performance in room-temperature formaldehyde abatement. However, a commonly known concern of MnO 2 /polymer composites is either MnO 2 crystal encapsulation or weak adhesion. This work reports a low-cost high-throughput and green strategy to produce binder-free MnO 2 -nonwoven composite air filters. The production approach is energy saving and environmentally friendly, which combines MnO 2 crystal coating on bicomponent polyolefin spunbond nonwovens and subsequent heat immobilizing of crystals, followed by the removal of weakly bonded MnO 2 . The binder-free MnO 2 -nonwoven composites show firm catalyst-fiber adhesion, a gradient porous structure, and excellent formaldehyde removal capability (94.5% ± 0.4%) at room temperature, and the reaction rate constant is 0.040 min -1 . In contrast to the MnO 2 -nonwoven composites containing organic binders, the HCHO removal of binder-free filters increased by over 4%. This study proposes an alternative solution in producing catalyst/fabric composite filters for formaldehyde removal.

Gradient Porous Structured MnO2-Nonwoven Composite: A Binder-Free Polymeric Air Filter for Effective Room-Temperature Formaldehyde Removal