Filtration media and method of manufacturing filtration media using nanofilm
The present application is direction to a system and method for preparing filter media from macro and nanofibers by ventilating a nanofiber media, combining the nanofiber media with macro fibers to form a hybrid media, inserting the hybrid media between a stitching plate and a stripper plate and alternatively inserting and withdrawing needles to combine the macro fibers with the nanofiber media and create a fiber web along at least one surface of the nanofiber media.
1. A method of preparing filter media comprising:
inserting one or more layers of a nanofiber media between an upper surface and a lower surface, wherein the upper surface and the lower surface are configured to receive a first plurality of needles;
piercing the nanofiber media with the first plurality of needles;
withdrawing the first plurality of needles;
aligning macro fibers along a first surface of the nanofiber media to create a hybrid media;
inserting the hybrid media between a stripper plate and a stitcher plate;
piercing the hybrid media with a second plurality of needles; and
withdrawing the second plurality of needles;
wherein at least a combination of the piercing of the hybrid media and the withdrawing from the hybrid media comprises:
catching, by the second plurality of needles, macro fibers; and
combining, by the second plurality of needles, the macro fibers with the nanofiber media.
2. The method of claim 1 , wherein the second plurality of needles comprise barbs, and wherein the catching of the macro fibers is performed by the barbs.
3. The method of claim 1 , wherein at least some of the second plurality of needles are also comprised with the first plurality of needles.
4. The method of claim 3 , wherein the second plurality of needles comprise barbs, and wherein the catching of the macro fibers is performed by the barbs.
5. The method of claim 1 , wherein additional macro fibers are placed along a second surface of the nanofiber media.
6. The method of claim 5 , wherein the additional macro fibers are of a different size than the macro fibers aligned along the first surface.
7. The method of claim 5 , wherein the nanofiber media, the macro fibers, and the additional macro fibers, form an air flow gradient through the filter media.
8. A method of preparing filter media comprising:
inserting one or more layers of a nanofiber media between an upper surface and a lower surface, wherein the upper surface and the lower surface are configured to receive a plurality of teeth;
piercing the nanofiber media with the plurality of teeth;
withdrawing the plurality of teeth;
aligning macro fibers along a first surface of the nanofiber media to create a hybrid media;
inserting the hybrid media between a stripper plate and a stitcher plate;
piercing the hybrid media with a plurality of needles; and
withdrawing the plurality of needles; wherein
at least a combination of the piercing of the hybrid media and the withdrawing from the hybrid media comprises:
catching, by the plurality of needles, macro fibers; and
combining, by the plurality of needles, the macro fibers with the nanofiber media.
9. The method of claim 8 , wherein the plurality of teeth are disposed along an outer surface of a licker drum.
10. The method of claim 9 , wherein the nanofiber media is advanced along the outer surface of the licker drum by a rotation of the licker drum.
11. The method of claim 10 , wherein additional macro fibers are placed along a second surface of the nanofiber media.
12. The method of claim 11 , wherein the additional macro fibers are of a different size than the macro fibers aligned along the first surface.
13. The method of claim 12 , wherein the nanofiber media, the macro fibers, and the additional macro fibers, form an air flow gradient through the filter media.