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.

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 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.

Some embodiments relate to a filter material for coalescing a dispersed phase in a continuous phase. The filter material has binder fibers and irregular rayon fibers distributed among the binder fibers. The filter material lacks non-fibrous resin. Some embodiments relate to a filter assembly. The filter assembly has a particle filtration layer, a coalescing layer downstream of the particle filtration layer, and a growth media downstream of the coalescing layer. The coalescing layer is coupled to the particle filtration layer. The growth media has irregular rayon fibers and binder fibers distributed among the irregular rayon fibers. The growth media lacks non-fibrous resin.

Thermoplastic bicomponent binder fiber can be combined with other media, fibers and other filtration components to form a thermally bonded filtration media. The filtration media can be used in filter units, such as breather caps. Such filter units can be placed in the stream of a mobile fluid and can remove a particulate and/or fluid mist load from the mobile stream. The unique combination of media fiber, bicomponent binder fiber and other filtration additives and components provide a filtration media having unique properties in filtration applications.

A filter module for a water dispensing device according to the present disclosure includes a filter housing which has an inflow port and a discharge port, and a plurality of filters which includes a filtration member provided in the filter housing to purify water flowing therein through the inflow port and to supply purified water to the discharge port, and filtering raw water flowing therein from the outside into purified water, and the filter module includes a pre-filter through which raw water passes firstly and in which a first carbon block having a hollow shape is built-in, a hollow fiber membrane (UF membrane) filter through which water passes through the pre-filter passes secondly, an electrostatic adsorption member through which water passing through the hollow fiber membrane filter passes thirdly, and a second carbon block through which water passing through the electrostatic adsorption member passes fourthly.

A filtration media with improved filtration, strength, tear resistance and air permeability in the form of a relatively thin and lightweight wet-laid fibrous web that has a wet Mullen ratio of 60% to 80% to ensure that the media is flexible enough to be formed into a fluted structure, and strong enough to retain the fluted structure when wound into a roll and to permit further processing without the media becoming too brittle. The filtration media comprises a blend of cellulose and synthetic fibers having a weight percent of 81 wt % to 87 wt % of a weight of the media and a resin binder having a weight of 13 wt % to 19 wt % (preferably about 16 wt %) of the weight of the media.

Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.

A depth filter with excellent filtration accuracy and pressure resistance performance even for fluids containing high density and high viscosity powder fine particles. A depth filter having a base material layer, a filtration layer, and a skin layer, in that order, wherein: the substrate layer and the skin layer are layers made by a nonwoven fabric being wound and thermally fused; the filtration layer is a laminate in which at least a nonwoven fabric and a net are laminated, being wound twice or more; and the nonwoven fabric contained in the filtration layer contains a mixed-fiber nonwoven fabric containing two or more types of fibers with mutually different average fiber diameters.

A vent having a continuous, elongate mat having an upper face and a lower face, and having a first portion and a second portion. The mat includes a plurality of columns of patterned three-dimensional structures of a network of randomly convoluted polymeric filaments having a first density, at least one of the plurality of columns of patterned three-dimensional structures being provided in the first portion, and at least one other of the plurality of columns of patterned three-dimensional structures being provided in the second portion. The mat includes a throat portion between the first portion and the second portion, the throat portion having a network of randomly convoluted polymeric filaments of a second density different than the first density, a first cover layer covering an outer edge of the first portion, and a second cover layer covering an outer edge of the second portion.