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 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.

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.

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.

Fibrous filter medium that includes a surface-loading filter layer comprising fine fibers having an average diameter of less than 1 micron; a depth loading filter layer; and a support layer; wherein the layers are configured and arranged for placement in a gas stream with the surface loading filter layer being the most upstream layer.

The present application relates generally to filter media useful for manufacturing air filters for residential and commercial office's Heating, Ventilation, and Air Conditioning (HVAC), particularly to filters and filter media comprising soybean-based materials. The present invention provides an inexpensive, effective, environmentally friendly, and sustainable media for manufacturing HVAC air filters for residential and commercial buildings.

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.

Articles and methods relating to filter media are generally provided. In some embodiments, a filter media has an irregular surface structure. For instance, the filter media may comprise a plurality of peaks that are irregular in one or more ways. A ratio of a peak height standard deviation to an average peak height may be greater than or equal to 0.05, and/or a ratio of a peak spacing standard deviation to an average peak spacing may be greater than or equal to 0.08. In some embodiments, a filter media comprises a non-woven fiber web having a layer thickness of greater than 0.3 mm and/or a stiffness of less than or equal to 100 mg.

A shaped cross-section composite fiber for an intake filter is manufactured from a single material of polypropylene, without separate binder processing by using the single material of polypropylene as a filter material. The shaped cross-section composite fiber includes: a sheath comprising a reformed polypropylene resin; and a core comprising a polypropylene resin, where the sheath and the core are combined to provide a sheath-core structure.