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: 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 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.

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.