Apertured polymeric layers, sheets, mesh or films are provided for a variety of different applications. A polymeric sheet comprises at least one polymer layer having one or more apertures for flow of gas or liquid therethrough, and a plurality of nanoparticles disposed within the polymer sheet such that the nanoparticles are disposed between a first surface of the polymer sheet and a second surface opposite the first surface. The nanoparticles filter contaminants passing through the polymeric sheet. The apertured sheets may comprise filter media and/or support membranes for filter media in gas or liquid filters. The nanoparticles reduce the overall pressure drop across the support membranes to improve the efficiency of such filters.
C08J 9/00 - Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
B29C 48/08 - Flat, e.g. panels flexible, e.g. films
F01N 3/022 - Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
2.
FILTERS WITH MECHANICAL AND ELETROSTATIC FILTERING CAPABILITIES
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that capture submicron particles with both electrostatic forces and the utilization of nanoparticles within the filter media. A filtration media includes a substrate comprising fibers and nanoparticles disposed within the substrate. At least one of the fibers or the nanoparticles are electrostatically charged. The electrostatic charge effectively captures submicron particles during at least the initial use of the filter. The nanoparticles ensure that the efficiency of the filter remains high even after the electrostatic charge starts to decay over time. In addition, the bond between the fibers and the nanoparticles may be enhanced by the electrostatic charge, which allows the nanoparticles to be dispersed in depth throughout the filter media.
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include nanoparticles dispersed throughout at least a portion of the filter media. A filter media comprises a fiber substrate with a first surface and an opposing second surface. The filter media includes nanoparticles disposed within the fiber substrate at least between the first and second surfaces such that an area density of the nanoparticles decreases from the first surface towards the second surface. This density gradient formed by the nanoparticles through at least a portion of the substrate improves the performance characteristics of the filter. The nanoparticles increase the overall surface area within the fiber substrate, which may increase its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop or air flow through the filter.
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include high linear density fibers and nanoparticles dispersed throughout at least a portion of the filter media. A filter includes a filter media comprising a substrate of fibers having a linear density of greater than about 3 denier, and nanoparticles disposed within the substrate. The larger linear density fibers provide more open space or pores within the filter media, allowing for a greater density of nanoparticles to be dispersed therein. This improves the overall efficiency of the filter. The three-dimensional distribution of nanoparticles within the filter also provides resistance against complete blockage of a particular portion of the filter, thereby reducing the overall pressure drop across the filter.
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
D04H 1/413 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing granules other than absorbent substances
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D04H 1/56 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
D04H 1/587 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
D04H 1/4382 - Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
D04H 1/4374 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
Systems, devices and methods are provided for producing a product comprising fibrous material, such as a filter. A system for manufacturing a fibrous material comprises a feeder for advancing a substrate of fibers from an upstream end to a downstream end and a first dispersion device for dispersing a binding agent onto the substrate to coat at least a portion of the fibers with the binding agent. The system further includes a second dispersion device for dispersing nanoparticles through the first surface of the substrate such that the nanoparticles are disposed within the substrate between the first and second surfaces. The binding agent facilitates the bond between the fibers and the nanoparticles to retain the nanoparticles within the internal structure of the substrate. In addition, facilitating this bond provides a more uniform distribution of the nanoparticles throughout the substrate, which improves the performance characteristics of the material.
Systems, devices and methods are provided for producing a product comprising fibrous material, such as a filter. A system for manufacturing a product comprises a first device for isolating individual nanoparticles within a gaseous medium and a second device for combining the individual nanoparticles with fibers to form a product containing the fibers and the nanoparticles. This distributes the nanoparticles more uniformly throughout the product and in depth into the internal structure of the product. The nanoparticles increase the overall surface area within the filter media, which increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop through the filter. In addition, the filters produced with the systems and methods described herein are capable of withstanding rigorous conditioning, which allows a filter to achieve the same level of filtration performance throughout the lifetime of the filter.
Systems, devices and methods are provided for producing fibrous materials and products, such as filters. A system comprises a first device for generating one or more fiber stream(s), and a second device for isolating nanoparticles within a gaseous medium. The second device forms the nanoparticles into a stream and feeds this stream into the fiber streams to form the fibrous material. This distributes the nanoparticles more uniformly throughout the fibrous material. In addition, the nanoparticles increase the overall surface area within the material, which, in certain applications, increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop through the filter. Filters produced with these systems and methods are capable of withstanding rigorous conditioning, which allows the filter to achieve substantially the same level of filtration performance throughout the lifetime of the filter.
D04H 1/413 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing granules other than absorbent substances
D04H 1/4226 - Glass fibres characterised by the apparatus for manufacturing the glass fleece
D04H 1/587 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
D04H 1/64 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
D04H 1/72 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
D04H 1/4382 - Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include nanoparticles dispersed throughout at least a portion of the filter media. A filter media comprises a fiber substrate with a first surface and an opposing second surface. The filter media includes nanoparticles disposed within the fiber substrate at least between the first and second surfaces such that an area density of the nanoparticles decreases from the first surface towards the second surface. This density gradient formed by the nanoparticles through at least a portion of the substrate improves the performance characteristics of the filter. the nanoparticles increase the overall surface area within the fiber substrate, which may increase its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop or air flow through the filter.
D01F 8/04 - Conjugated, i.e. bi- or multicomponent, man-made filaments or the like; Manufacture thereof from synthetic polymers
D01F 8/06 - Conjugated, i.e. bi- or multicomponent, man-made filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
A41D 13/11 - Protective face masks, e.g. for surgical use, or for use in foul atmospheres
B29C 48/25 - Component parts, details or accessories; Auxiliary operations
B01D 39/00 - Filtering material for liquid or gaseous fluids
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include nanoparticles dispersed throughout at least a portion of the filter media. A filter media comprises a substrate comprising fibers and nanoparticles disposed within the substrate. The nanoparticles have at least one dimension less than 1 micron, and the filter media has a MERV rating greater than about 10 and a pressure drop less than about 0.5 inches of water. The nanoparticles increase the overall surface area within the fiber substrate, which increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop (i.e., air flow) through the filter.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
10.
SYSTEMS AND METHODS FOR CONTINUOUS PRODUCTION OF FIBROUS MATERIALS AND NANOPARTICLES
Systems and methods are provided for continuously manufacturing fibrous materials and products, such as filters. A system comprises a conveyor for advancing a substrate comprising fibrous materials from an upstream end to a downstream end, and a feeder for feeding groups of nanofibers into a fluid medium. A fiberization device is coupled to the feeder and configured to convert the groups of nanofibers into individual nanoparticles. A dispersion device coupled to the fiberization device disperses the nanoparticles into the substrate to form a fibrous material. This distributes the nanoparticles more uniformly throughout the fibrous material. In addition, the system continuously manufactures the material to form a product with improved quality, yield and reduced cost and time.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
11.
SYSTEMS AND METHODS FOR SEPARATING AND/OR ISOLATING NANOPARTICLES WITHIN A GASEOUS MEDIUM
Systems, devices and methods are provided for separating and/or isolating individual nanoparticles from groups or clusters of nanofibers within a gaseous medium. The system comprises a housing configured to contain the groups of nanofibers, and a pump coupled to the housing. The system further includes one or more passages coupled to the pump and a gaseous medium within the passages. The pump is configured to propel the nanofibers through, or with, the gaseous medium against one or more surface(s) within the passages at a sufficient velocity and/or momentum to open up or separate, the groups of nanofibers into individual nanoparticles. Isolating individual nanoparticles in a gaseous medium and then dispersing them into a substrate or a fluid stream to form a product allows the nanoparticles to be distributed more uniformly and "in depth" throughout the product.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
12.
SYSTEMS AND METHODS FOR MAKING PRODUCTS CONTAINING FIBROUS MATERIAL
Systems, devices and methods are provided for producing a product comprising fibrous material, such as a filter. A system for manufacturing a product comprises a first device for isolating individual nanoparticles within a gaseous medium and a second device for combining the individual nanoparticles with fibers to form a product containing the fibers and the nanoparticles. This distributes the nanoparticles more uniformly throughout the product and in depth into the internal structure of the product. The nanoparticles increase the overall surface area within the filter media, which increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop through the filter. In addition, the filters produced with the systems and methods described herein are capable of withstanding rigorous conditioning, which allows a filter to achieve the same level of filtration performance throughout the lifetime of the filter.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
Systems, devices and methods are provided for producing fibrous materials and products, such as filters. A system comprises a first device for generating one or more fiber stream(s), and a second device for isolating nanoparticles within a gaseous medium. The second device forms the nanoparticles into a stream and feeds this stream into the fiber streams to form the fibrous material. This distributes the nanoparticles more uniformly throughout the fibrous material. In addition, the nanoparticles increase the overall surface area within the material, which, in certain applications, increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop through the filter. Filters produced with these systems and methods are capable of withstanding rigorous conditioning, which allows the filter to achieve substantially the same level of filtration performance throughout the lifetime of the filter.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
14.
NONWOVEN MATERIALS AND PRODUCTS CONTAINING NONWOVEN MATERIALS
Nonwoven materials and products comprising nonwoven materials are provided that include a substrate comprising fibers and nanoparticles incorporated into at least a portion of the substrate. A nonwoven material comprises a substrate comprising fibers and having a first surface and an opposing second surface, and nanoparticles disposed within the substrate at least between the first and second surfaces. The density of the nanoparticles decreases from the first surface towards the second surface, or a higher density of nanoparticles is disposed on the two surfaces as compared to the middle section of the substrate. This density gradient formed by the nanoparticles improves the performance characteristics of the material for a number of different applications. For example, the nanoparticles increase the overall surface area within the substrate, which may increase its filtration efficiency and allow for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop across the filter.
D04H 1/413 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing granules other than absorbent substances
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include nanoparticles dispersed throughout at least a portion of the filter media. A filter media comprises a substrate comprising fibers and nanoparticles disposed within the substrate. The nanoparticles have at least one dimension less than 1 micron, and the filter media has a MERV rating greater than about 10 and a pressure drop less than about 0.5 inches of water. The nanoparticles increase the overall surface area within the fiber substrate, which increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop (i.e., air flow) through the filter.
Systems and methods are provided for continuously manufacturing fibrous materials and products, such as filters. A system comprises a conveyor for advancing a substrate comprising fibrous materials from an upstream end to a downstream end, and a feeder for feeding groups of nanofibers into a fluid medium. A fiberization device is coupled to the feeder and configured to convert the groups of nanofibers into individual nanoparticles. A dispersion device coupled to the fiberization device disperses the nanoparticles into the substrate to form a fibrous material. This distributes the nanoparticles more uniformly throughout the fibrous material. In addition, the system continuously manufactures the material to form a product with improved quality, yield and reduced cost and time.
Filter media and filters are provided that include at least two layers and a plurality of nanoparticles dispersed in depth within at least one of the layers. A gas filter comprises a first layer of fibers, a second layer of fibers bonded to the first layer and a plurality of nanoparticles incorporated into the first layer. The nanoparticles increase the overall surface area within the filter, which increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop (i.e., air flow) through the filter. In addition, the filters disclosed herein are capable of withstanding rigorous conditioning, which allows the filter to achieve the same level of filtration performance throughout the lifetime of the filter. Systems, devices and methods are also provided for manufacturing such filters.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 37/24 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
18.
SYSTEMS AND METHODS FOR SEPARATING AND/OR ISOLATING NANOPARTICLES WITHIN A GASEOUS MEDIUM
Systems, devices and methods are provided for separating and/or isolating individual nanoparticles from groups or clusters of nanofibers within a gaseous medium. The system comprises a housing configured to contain the groups of nanofibers, and a pump coupled to the housing. The system further includes one or more passages coupled to the pump and a gaseous medium within the passages. The pump is configured to propel the nanofibers through, or with, the gaseous medium against one or more surface(s) within the passages at a sufficient velocity and/or momentum to open up or separate, the groups of nanofibers into individual nanoparticles. Isolating individual nanoparticles in a gaseous medium and then dispersing them into a substrate or a fluid stream to form a product allows the nanoparticles to be distributed more uniformly and “in depth” throughout the product.
Apertured polymeric layers, sheets, mesh or films are provided for a variety of different applications. A polymeric sheet comprises at least one polymer layer having one or more apertures for flow of gas or liquid therethrough, and a plurality of nanoparticles disposed within the polymer layer such that the nanoparticles are disposed between a first surface of the polymer layer and a second surface opposite the first surface. The nanoparticles filter contaminants passing through the polymeric sheet. In certain embodiments, the apertured sheets comprise support membranes in gas or liquid filters. The nanoparticles reduce the overall pressure drop across the support membranes to improve the efficiency of such filters.
B01D 69/02 - Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B29C 48/16 - Articles comprising two or more components, e.g. co-extruded layers
B01D 53/04 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
B01J 20/28 - Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that capture submicron particles with both electrostatic forces and the utilization of nanoparticles within the filter media. A filtration media includes a substrate comprising fibers and nanoparticles disposed within the substrate. At least one of the fibers or the nanoparticles are electrostatically charged. The electrostatic charge effectively captures submicron particles during at least the initial use of the filter. The nanoparticles ensure that the efficiency of the filter remains high even after the electrostatic charge starts to decay over time. In addition, the bond between the fibers and the nanoparticles may be enhanced by the electrostatic charge, which allows the nanoparticles to be dispersed in depth throughout the filter media.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
21.
NONWOVEN MATERIALS AND PRODUCTS CONTAINING NONWOVEN MATERIALS
Nonwoven materials and products comprising nonwoven materials are provided including a substrate comprising fibers and nanoparticles incorporated into at least a portion of the substrate. A nonwoven material comprises a substrate comprising fibers and having a first surface and an opposing second surface, and nanoparticles disposed within the substrate at least between the first and second surfaces. The density of the nanoparticles decreases from the first surface towards the second surface, or a higher density of nanoparticles is disposed on the two surfaces as compared to the middle section of the substrate. This density gradient formed by the nanoparticles improves the performance characteristics of the material for a number of different applications. For example, the nanoparticles increase the overall surface area within the substrate, which may increase its filtration efficiency and allow for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop across the filter.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
22.
FILTRATION MEDIA INCORPORATING NANOPARTICLES AND LARGE LINEAR DENSITY FIBERS
Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include high linear density fibers and nanoparticles dispersed throughout at least a portion of the filter media. A filter includes a filter media comprising a substrate of fibers having a linear density of greater than about 3 denier, and nanoparticles disposed within the substrate. The larger linear density fibers provide more open space or pores within the filter media, allowing for a greater density of nanoparticles to be dispersed therein. This improves the overall efficiency of the filter. The three-dimensional distribution of nanoparticles within the filter also provides resistance against complete blockage of a particular portion of the filter, thereby reducing the overall pressure drop across the filter.
B01D 39/14 - Other self-supporting filtering material
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
23.
DUAL-LAYER GAS FILTERS AND SYSTEMS AND METHODS FOR MAKING THE SAME
Filter media and filters are provided that include at least two layers and a plurality of nanoparticles dispersed in depth within at least one of the layers. A gas filter comprises a first layer of fibers, a second layer of fibers bonded to the first layer and a plurality of nanoparticles incorporated into the first layer. The nanoparticles increase the overall surface area within the filter, which increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop (i.e., air flow) through the filter. In addition, the filters disclosed herein are capable of withstanding rigorous conditioning, which allows the filter to achieve the same level of filtration performance throughout the lifetime of the filter. Systems, devices and methods are also provided for manufacturing such filters.
B01D 39/08 - Filter cloth, i.e. woven, knitted or interlaced material
B01D 39/14 - Other self-supporting filtering material
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B82Y 30/00 - Nanotechnology for materials or surface science, e.g. nanocomposites
24.
SYSTEMS AND METHODS FOR RETAINING NANOPARTICLES WITHIN FIBROUS MATERIAL
Systems, devices and methods are provided for producing a product comprising fibrous material, such as a filter. A system for manufacturing a fibrous material comprises a feeder for advancing a substrate of fibers from an upstream end to a downstream end and a first dispersion device for dispersing a binding agent onto the substrate to coat at least a portion of the fibers with the binding agent. The system further includes a second dispersion device for dispersing nanoparticles through the first surface of the substrate such that the nanoparticles are disposed within the substrate between the first and second surfaces. The binding agent facilitates the bond between the fibers and the nanoparticles to retain the nanoparticles within the internal structure of the substrate. In addition, facilitating this bond provides a more uniform distribution of the nanoparticles throughout the substrate, which improves the performance characteristics of the material.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B01D 39/14 - Other self-supporting filtering material
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
25.
FILTRATION MEDIA FIBER STRUCTURE AND METHOD OF MAKING SAME
Fiber structures and methods are described that incorporate a body of a micron fiber modified by the attachment of discrete length nano-fibers. Numerous of these modified fiber structures can be assembled into air filter media. Further augmentations of the modified fibers and media can be implemented to improve filtration characteristics.
Fiber structures and methods are described that incorporate a body of a micron fiber modified by the attachment of discrete length, crimped nano-fibers. Numerous of these modified fiber structures can be assembled into air filter media. Further augmentations of the modified fibers and media can be implemented to improve filtration characteristics.
Various embodiments comprise apparatuses and methods for capturing particles from a particle-laden airstream. An embodiment of a device includes an inlet air passage to direct a particle-laden airstream, an outlet air passage, an impaction nozzle in fluid communication with and downstream of the inlet air passage, and a channel in fluid communication with and downstream of the impaction nozzle and upstream of the outlet air passage. An open portion of the channel is oriented substantially toward the inlet air passage and has a cavity at least partially covered with a substrate material. A base of the substrate material is substantially normal to an incoming direction of the particle-laden airstream. Other embodiments of the device and a method of using the device are also provided.
patents
