Abstract: Use of physical vapor deposition methodologies to deposit nanoscale gold on activating support media makes the use of catalytically active gold dramatically easier and opens the door to significant improvements associated with developing, making, and using gold-based, catalytic systems. The present invention, therefore, relates to novel features, ingredients, and formulations of gold-based, heterogeneous catalyst systems generally comprising nanoscale gold deposited onto a nanoporous support.

Abstract: Articles comprise: a nonwoven fiber web and one or more strips bonded to the nonwoven fiber web. The strips comprise a shape-memory polymer that has a strained temporary shape and an intrinsic shape. If heated at or above a transition temperature, the strip at least partially converts from the strained temporary shape to the intrinsic shape, thereby causing at least one of folding, cupping, or puckering of the non-woven fiber web. Methods of heating the articles to provide folded, cupped, and/or puckered articles are also disclosed.

Abstract: Reinforced filter media are prepared by adhering discrete, non-intersecting strands of thermoplastic or thermoset materials to the filter media web. The filter media may be a fabric, a nonwoven web or a filtering foam. The reinforced filter media can be used to prepare respirators, including flat-fold respirators or molded respirators.

Abstract: Methods of preparing polymeric webs include hot melt blending of thermoplastic resins and processing aids. The process aids include hindered amine N-substituted succinimide oligomers. The webs prepared from the blends may be in the form of films or non-woven fibrous webs. Non-woven microfiber webs are useful as filtration media. Among the polymeric webs produced are electret webs. The processing aids also function as charge-enhancing additives for the electret webs.

Abstract: The present invention provides technology for controlling, or tuning, the catalytic activity of gold provided upon nanoporous supports such as those derived from nanoparticulate titania. It has been discovered that the nature of the surfaces of the nanoparticles used to support a nano-metal catalyst, such as catalytically active gold, has a profound effect upon the catalytic properties of the supported catalyst. The support surface may be altered as desired to control the activity of the gold. The present invention teaches how thermal treatment of nanoparticulate media incorporated into a nanoporous support prior to deposition of catalytically active gold dramatically suppresses the ability of a resultant catalyst system to oxidize hydrogen. Yet, the system still readily oxidizes CO.

Abstract: Electret webs are presented which include a blend of a thermoplastic resin and a charge-enhancing additive. The charge-enhancing additives include a heterocyclic imide material which is free of fluorinated groups. The webs prepared from the blends may be in the form of films or non-woven fibrous webs. Non-woven microfiber webs are useful as filtration media.

Abstract: Heterogeneous catalyst systems, methods of making these systems, and methods of using these systems, wherein catalytically active gold is deposited onto composite support media. The composite support media is formed by providing nanoporous material on at least a portion of the surfaces of carbonaceous host material. In representative embodiments, relatively fine, nanoporous guest particles are coated or otherwise provided on surfaces of relatively coarser activated carbon particles. Catalytically active gold may be deposited onto one or both of the guest or host materials either before or after the guest and host materials are combined to from the composite host material. PVD is the preferred catalyst system of depositing gold.

Abstract: Use of physical vapor deposition methodologies to deposit nanoscale gold on activating support media makes the use of catalytically active gold dramatically easier and opens the door to significant improvements associated with developing, making, and using gold-based, catalytic systems. The present invention, therefore, relates to novel features, ingredients, and formulations of gold-based, heterogeneous catalyst systems generally comprising nanoscale gold deposited onto a nanoporous support.

Abstract: Heterogeneous catalyst systems, methods of making these systems, and methods of using these systems, wherein catalytically active gold is deposited onto composite support media. The composite support media is formed by providing nanoporous material on at least a portion of the surfaces of carbonaceous host material. In representative embodiments, relatively fine, nanoporous guest particles are coated or otherwise provided on surfaces of relatively coarser activated carbon particles. Catalytically active gold may be deposited onto one or both of the guest or host materials either before or after the guest and host materials are combined to from the composite host material. PVD is the preferred catalyst system of depositing gold.

Abstract: A flat-fold respirator is made from a stiff filtration panel joined to the remainder of the respirator through at least one line of demarcation. The panel contains a porous monocomponent monolayer nonwoven web that contains charged intermingled continuous monocomponent polymeric fibers of the same polymeric composition and that has sufficient basis weight or inter-fiber bonding so that the web exhibits a Gurley Stiffness greater than 200 mg and the respirator exhibits less than 20 mm H2O pressure drop. The respirator may be formed without requiring additional stiffening layers, bicomponent fibers, or other reinforcement and can be flat-folded for storage. Scrap from the manufacturing process may be recycled to make additional stiff filtration panel web.

Abstract: A filter element utilizes a porous shape-retaining self-supporting non-woven web. The web includes thermoplastic elastomeric polymer fibers and active particles disposed in the fibers. The web also possesses a three-dimensional deformation.

Abstract: A filter element includes a porous non-woven web. The porous non-woven web includes a first layer with first thermoplastic elastomeric polymer fibers and first active particles disposed therein and a second layer including second thermoplastic elastomeric polymer fibers and second active particles disposed therein. The web possesses a three-dimensional deformation and the first layer is contiguous with the second layer across the deformation.

Abstract: Shaped filtration articles are made from a monocomponent nonwoven web formed by flowing first and second fiber-forming materials of the same polymeric composition through first and second die cavities in respective fluid communication with first and second sets of orifices in a meltblowing die tip. The first fiber-forming material flows at a lesser flow rate or viscosity through the first die cavity and first set of orifices to form a set of smaller size filaments and the second fiber-forming material flows at a greater flow rate or viscosity through the second die cavity and second set of orifices to form a set of larger size filaments. The collected nonwoven web contains a meltblown bimodal mass fraction/fiber size mixture of intermingled continuous microfibers and larger size fibers of the same polymeric composition.

Abstract: Use of physical vapor deposition methodologies to deposit nanoscale gold on activating support media makes the use of catalytically active gold dramatically easier and opens the door to significant improvements associated with developing, making, and using gold-based, catalytic systems. The present invention, therefore, relates to novel features, ingredients, and formulations of gold-based, heterogeneous catalyst systems generally comprising nanoscale gold deposited onto a nanoporous support.

Abstract: A method of making a fluorinated fibrous web, which method includes providing a nonwoven web 22 that contains polymeric fibers, creating a plasma that contains fluorine atoms at a first location 14, and contacting the nonwoven web with products from the plasma at a second location 26 remote from the first location 14. The method avoids exposure of the web to the plasma and hence expands the manufacturing processing window. Webs so fluorinated have a different C3F4H+ to C2F5+ ratio when compared to locally fluorinated webs having similar levels of surface fluorination. The remote fluorinated webs can be subsequently charged electrically to provide a good performing electret filter 40 suitable for use in an air purifying respirator 30. Webs fluorinated in accordance with this invention also may exhibit good performance even after being “aged” at high temperatures.

Abstract: Electret webs are presented which include a blend of a thermoplastic resin and a charge-enhancing additive. The charge-enhancing additives include N-substituted amino carbocyclic aromatic materials. The webs prepared from the blends may be in the form of films or non-woven fibrous webs. Non-woven microfiber webs are useful as filtration media.

Abstract: Materials are disclosed which can enhance the electrostatic charge of electret materials. The materials comprise N-substituted amino carbocyclic aromatic compounds of the formula R1R2N—Ar(G)n where Ar is an aryl group, the group R1 is hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroalkyl or substituted alkyl, alkenyl, alkynyl, the group R2 is alkyl, alkenyl, alkynyl, aryl, heteroalkyl or substituted alkyl, and each G is independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroalkyl, substituted alkyl, or —NR3R4 where each R3 is independently hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroalkyl or substituted alkyl, and each R4 is independently alkyl, alkenyl, alkynyl, aryl, heteroalkyl or substituted alkyl, and Ar is a phenyl group when n is 5, a naphthalene group when n is 7, and an anthracene group when n is 9.

Abstract: Highly active, low pressure drop catalyst systems. Catalytically active material is provided on at least a portion of the channel sidewalls of a body comprising one or more flow-through channels. The channel sidewalls preferably bear a charge, e.g., an electrostatic or electret charge, to help adhere the catalytically active material to the sidewall. The catalytically active material preferably includes gold provided on a particulate support, and PVD techniques are used to deposit catalytically active gold onto the support. Optionally, the gold-bearing particulates may be charged as well in a manner to facilitate attraction between the particulates and the sidewalls.

Abstract: Electret webs are presented which include a blend of a thermoplastic resin and a charge additive. The charge additives include ester-substituted and amide-substituted trianilino triazine materials. The webs prepared from the blends may be in the form of films or non-woven fibrous webs. Non-woven microfiber webs are useful as filtration media.

Abstract: The present invention provides technology for controlling, or tuning, the catalytic activity of gold provided upon nanoporous supports such as those derived from nanoparticulate titania. It has been discovered that the nature of the surfaces of the nanoparticles used to support a nano-metal catalyst, such as catalytically active gold, has a profound effect upon the catalytic properties of the supported catalyst. The support surface may be altered as desired to control the activity of the gold. The present invention teaches how thermal treatment of nanoparticulate media incorporated into a nanoporous support prior to deposition of catalytically active gold dramatically suppresses the ability of a resultant catalyst system to oxidize hydrogen. Yet, the system still readily oxidizes CO.