Filtration media fiber structure and method of making same
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.
1. A fiber structure, having an upstream side and a downstream side, comprising:
a plurality of micron-sized fibers, each micron-sized fiber comprising a body having a diameter of at least one micron; and
a plurality of discrete length nano-fibers having at least a first portion and a second portion, the first portion of the plurality of discrete length nano-fibers attached to respective ones of the bodies of the plurality of micron-sized fibers, wherein the first portion of the plurality of discrete length nano-fibers further entangle upon themselves to form a plurality of micro-volumes, and wherein the second portion of the plurality of discrete length nano-fibers entangle with the first portion of the plurality of discrete length nano-fibers and upon themselves.
2. The fiber structure of claim 1 , wherein the diameter of the micron-sized fibers is from about 2 microns to about 1000 microns.
3. The fiber structure of claim 1 , wherein the plurality of discrete length nano-fibers have a diameter of from about 0.001 microns to about 2 microns.
4. The fiber structure of claim 1 , wherein at least a portion of the plurality of discrete length nano-fibers extends into at least one micro-pore formed by the plurality of micron-sized fibers.
5. The fiber structure of claim 4 , wherein at least a portion of the plurality of discrete length nano-fibers extend outwardly from the plurality of micron-sized fibers into the at least one micro-pore forming at least one localized micro-volume.
6. The fiber structure of claim 1 , wherein a distribution of the plurality of discrete length nano-fibers increases from the upstream side to the downstream side of the fiber structure.
7. The fiber structure of claim 1 , wherein a diameter of the plurality of discrete length nano-fibers decreases from the upstream side to the downstream side of the fiber structure.
8. The fiber structure of claim 1 , further comprising an adhesive on one or more of the plurality of micron-sized fibers and the plurality of discrete length nano-fibers.
9. The fiber structure of claim 1 , further comprising one or more functional nano-particles attached to one or more of the plurality of micron-sized fibers and the plurality of discrete length nano-fibers.
10. The fiber structure of claim 9 , wherein the one or more functional nano-particles include one or more of activated carbon and an antimicrobial material.
11. The fiber structure of claim 1 , wherein one or more of the plurality of micron-sized fibers and the plurality of discrete length nano-fibers comprises electrostatic material.
12. The fiber structure of claim 1 , wherein one or more of the plurality of micron-sized fibers and the plurality of discrete length nano-fibers includes a hydrophobic material.
13. The fiber structure of claim 1 , wherein one or more of the plurality of micron-sized fibers or and the plurality of discrete length nano-fibers includes a hydrophilic material.
14. A filter media structure, comprising:
a plurality of filter layers, at least one layer of the plurality of filter layers including:
a plurality of micron-sized fibers, each micron-size fiber comprising a body having a diameter of at least one micron, respective ones of the plurality of micron-sized fibers defining at least one pore between the micron-sized fibers; and
a plurality of discrete length nano-fibers attached to respective ones of the bodies of the micron-sized fibers and extending outwardly from the micron-sized fibers into the at least one pore formed between the micron-size fibers, wherein each layer of the plurality of layers includes a differing size of discrete length nano-fibers than respective ones of the plurality of layers.
15. The filter media structure of claim 14 , wherein the plurality of layers are arranged as a high loft filtration media.
16. The filter media structure of claim 14 , wherein each layer of the plurality of layers includes a differing amount of discrete length nano-fibers than respective ones of the plurality of layers.
17. The filter media structure of claim 14 , wherein each layer of the plurality of layers includes at least one of a differing pore size or a differing thickness than respective ones of the plurality of layers.
18. The filter media structure of claim 14 , wherein at least a portion of the plurality of discrete length nano-fibers extend outwardly from the micron-sized fibers into the at least one pore forming at least one localized micro-volume.