Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: Various embodiments disclose filtration apparatuses and processes for filtering particles from a particle-laden air stream. In one embodiment, a filter is provided with a front face layer, in which at least one impaction nozzle is formed, is to accelerate an air stream onto an interior substrate to capture large particle sizes with a calculated fractional efficiency. The interior substrate is formed within the filter. The filter further includes a rear face layer in which at least one opening is formed to exhaust the air stream. A filter media material may be placed between the front face layer and rear face layer. Other apparatuses and processes are disclosed as well.

Abstract: 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.