SYSTEMS AND METHODS FOR CONTINUOUS PRODUCTION OF FIBROUS MATERIALS AND NANOPARTICLES
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.
1 . A method for the continuous production of a fibrous material, the method comprising:
advancing a substrate comprising fibrous materials from an upstream end to a downstream end;
feeding groups of nanofibers into a fluid medium;
converting the groups of nanofibers into nanoparticles within the fluid medium, wherein the nanoparticles have at least one dimension less than 1 micron; and
dispersing the individual nanoparticles into the substrate between the upstream and downstream ends to form a product.
2 . The method of claim 1 , further comprising propelling the clusters of nanofibers within the fluid medium at a velocity of about 500 to about 10,000 feet per minute (fpm).
3 . The method of claim 1 , wherein the nanoparticles are dispersed into the substrate at a rate of about 0.1 grams/m 2 to about 10 grams/m 2 .
4 . The method of claim 3 , wherein the rate is at least about 2.0 grams/m 2 .
5 . The method of claim 1 , wherein the substrate is advanced at a rate of about 0.05 to 1.0 meters/second.
6 . The method of claim 1 , wherein the substrate has a thickness from the first surface to a second surface opposite the first surface, further comprising dispersing the nanoparticles within the substrate in at least 25% of the thickness from the first surface to the second surface.
7 . The method of claim 1 , wherein the individual nanoparticles are incorporated substantially throughout the substrate to form a composite material.
8 . The method of claim 1 , further comprising propelling the groups of nanofibers against a surface to break up at least a portion of the groups of nanofibers into the individual nanofibers.
9 . The method of claim 8 , further comprising separating the individual nanofibers from the groups of nanofibers.
10 . The method of claim 9 , further comprising propelling the groups of nanofibers and the individual nanoparticles into a chamber to create a vortex within the chamber and applying negative pressure to the chamber to draw the groups of nanofibers away from the individual nanoparticles.
11 . A filter media formed from the method of claim 1 .
12 . A system for the continuous production of a fibrous material, the system comprising:
a conveyor for advancing a substrate comprising fibrous materials from an upstream end to a downstream end;
a feeder for feeding groups of nanofibers into a fluid medium;
a fiberization device coupled to the feeder and configured to convert the groups of nanofibers into nanoparticles, wherein the nanoparticles have at least one dimension less than 1 micron; and
a dispersion device coupled to the fiberization device for dispersing the nanoparticles into the substrate to form a product.
13 . The system of claim 12 , wherein the fiberization device is configured to propel the groups of nanofibers within the fluid medium at a velocity of about 500 feet per minute (fpm) to about 10,000 fpm.
14 . The system of claim 13 , wherein the nanoparticles are dispersed into the substrate at a rate of about 0.1 grams/m 2 to about 10 grams/m 2 .
15 . The system of claim 14 , wherein the rate is at least about 2.0 grams/m 2 .
16 . The system of claim 12 , wherein the conveyor is configured to advance the substrate at a rate of about 0.05 to 1 meters/second.
17 . The system of claim 12 , wherein the dispersion device comprises a nozzle configured to disperse the nanoparticles onto a first surface of the substrate such that the nanoparticles penetrate through at least the first surface of the substrate.
18 . The system of claim 17 , wherein the substrate has a thickness from the first surface to a second surface opposing the first surface, wherein the nozzle disperses the nanoparticles within the substrate in at least 25% of the width from the first surface to the second surface.
19 . The system of claim 18 , further comprising a separator coupled to the feeder and configured to mechanically separate the macro clusters of nanofibers into the groups of nanofibers.
20 . The system of claim 19 , wherein the fiberization device comprises
a source of compressed air; and
a pump, wherein the pump is configured to propel the groups of nanofibers and the compressed air against a surface with a velocity sufficient to break apart at least a portion of the groups of nanofibers into individual nanoparticles,