APERTURED POLYMER SHEETS INCORPORATING NANOPARTICLES
Apertured polymeric layers, sheets, mesh or films are provided for a variety of different applications. A polymeric sheet comprises at least one polymer layer having one or more apertures for flow of gas or liquid therethrough, and a plurality of nanoparticles disposed within the polymer sheet such that the nanoparticles are disposed between a first surface of the polymer sheet and a second surface opposite the first surface. The nanoparticles filter contaminants passing through the polymeric sheet. The apertured sheets may comprise filter media and/or support membranes for filter media in gas or liquid filters. The nanoparticles reduce the overall pressure drop across the support membranes to improve the efficiency of such filters.
1 . A polymeric sheet comprising:
at least one polymer layer having one or more apertures for flow of gas or liquid therethrough, wherein the apertures are circular, hexagonal, square, oblong, triangular, rectangular or diamond shaped; and
a plurality of nanoparticles disposed within the polymer layer, wherein the nanoparticles have at least one dimension less than 1 micron.
2 . The polymeric sheet of claim 1 , wherein the nanoparticles comprise nanofibers having a length between about 100 microns to about 10000 microns.
3 . The polymeric sheet of claim 1 , wherein the polymer layer has a first surface and a second surface opposite the first surface, wherein at least a portion of the nanoparticles are disposed between the first surface and the second surface.
4 . The polymeric sheet of claim 1 , wherein the polymer layer comprises at least one crease to form a pleat within the sheet.
5 . The polymeric sheet of claim 1 , wherein the polymer layer is an extruded film.
6 . The sheet of claim 1 , wherein the polymer layer is selected from a group consisting of a polypropylene film, a high density polyethylene film, a polylactic acid film and combinations thereof.
7 . The polymeric sheet of claim 1 , wherein the polymer layer is a substantially rigid support layer for use with a gas filter.
8 . The polymeric sheet of claim 1 , wherein the polymer layer is a flexible surface layer for use with a face mask.
9 . The polymeric sheet of claim 1 , wherein the polymer layer is a flexible surface layer for use with a finger bandage pad.
10 . The polymeric sheet of claim 1 , wherein the nanoparticles form a gradient within the polymer layer such that a density of the nanoparticles decreases from the first surface to the second surface.
11 . The sheet of claim 1 , wherein the nanoparticles are substantially uniformly dispersed throughout the polymer layer.
12 . The polymeric sheet of claim 1 , wherein the polymer layer comprises fibers having an electrostatic charge.
13 . The polymeric sheet of claim 1 , further comprising a binding agent within the polymer layer bonding the nanoparticles to the polymer layer, wherein the binding agent comprises a material selected from the group consisting of starch, dextrin, guar gum, PVOH and synthetic resins.
14 . The polymeric sheet of claim 1 , wherein the nanoparticles have at least one dimension less than 1 micrometer.
15 . A composite material comprising:
a substrate having pores within an internal structure, wherein the pores are circular, hexagonal, square, oblong, triangular, rectangular or diamond shaped;
a plurality of nanoparticles within the internal structure of the substrate, the nanoparticles having at least one dimension less than 1 micrometer; and
wherein the nanoparticles form a gradient within the substrate such that a density of the nanoparticles decreases from a first surface to an opposing second surface of the substrate.
16 . The composite material of claim 15 , wherein the nanoparticles comprise nanofibers having a length between about 100 microns to about 10000 microns.
17 . The composite material of claim 15 , wherein the substrate comprises a fibrous material comprising a plurality of microfibers, the microfibers having a dimension of 1 micrometer or greater.
18 . The composite material of claim 15 , wherein the nanoparticles extend below the first surface by a distance of between about 1 millimeter and about 3 millimeters.
19 . The composite material of claim 15 , wherein the substrate comprises fibers having an electrostatic charge.
20 . The composite material of claim 15 , further comprising a binding agent within the substrate bonding the nanoparticles to the polymer layer, wherein the binding agent comprises a material selected from the group consisting of starch, dextrin, guar gum, PVOH and synthetic resins.
21 . The composite material of claim 15 , wherein the substrate comprises an extruded film.
22 . A filtration device comprising the composite material of claim 15 .