Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D39/00—Filtering material for liquid or gaseous fluids
  • B01D39/10—Filter screens essentially made of metal
  • B01D39/12—Filter screens essentially made of metal of wire gauze; of knitted wire; of expanded metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D39/00—Filtering material for liquid or gaseous fluids
  • B01D39/14—Other self-supporting filtering material ; Other filtering material
  • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D39/00—Filtering material for liquid or gaseous fluids
  • B01D39/14—Other self-supporting filtering material ; Other filtering material
  • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
  • B01D39/1692—Other shaped material, e.g. perforated or porous sheets
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D39/00—Filtering material for liquid or gaseous fluids
  • B01D39/14—Other self-supporting filtering material ; Other filtering material
  • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
  • B01D39/18—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D39/00—Filtering material for liquid or gaseous fluids
  • B01D39/14—Other self-supporting filtering material ; Other filtering material
  • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
  • B01D39/2003—Glass or glassy material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
  • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y80/00—Products made by additive manufacturing
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/0007—Electro-spinning
  • D01D5/0061—Electro-spinning characterised by the electro-spinning apparatus
  • D01D5/0076—Electro-spinning characterised by the electro-spinning apparatus characterised by the collecting device, e.g. drum, wheel, endless belt, plate or grid
  • D01D5/0084—Coating by electro-spinning, i.e. the electro-spun fibres are not removed from the collecting device but remain integral with it, e.g. coating of prostheses
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
  • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
  • B01D2239/0258—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanoparticles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/04—Additives and treatments of the filtering material
  • B01D2239/0414—Surface modifiers, e.g. comprising ion exchange groups
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
  • B01D2239/0604—Arrangement of the fibres in the filtering material
  • B01D2239/0631—Electro-spun
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
  • B01D2239/065—More than one layer present in the filtering material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
  • B01D2239/069—Special geometry of layers
  • B01D2239/0695—Wound layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
  • B01D2239/10—Filtering material manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
  • B01D46/0001—Making filtering elements

Definitions

• Embodiments herein relate to the use of printed structures, made by additive manufacturing methods, as a support for, and in combination with electrospun fibers to create composite structures for a filtration media.
• Fine fibers are frequently used in filter media applications. These fibers are applied to substrates and used in liquid and air filtration applications.
• FIG. 1 is a cross-sectional view of a fin assembly, which is an example of a three-dimensional printed structure formed by additive manufacturing, for use in a media assembly, in accordance with various embodiments herein.
• FIG. 2 is a top view of the fin assembly of FIG. 1, in accordance with various embodiments herein.
• FIG. 3 is a cross-sectional view of a first three-dimensional printed structure including pillars on top of the fin assembly of FIG. 1, in accordance with various embodiments herein.
• FIG. 4 is a top view of first three-dimensional printed structure of FIG. 3, tn accordance with various embodiments herein.
• FIG. 5 is a cross-sectional view of a first three-dimensional printed structure including pillars on top of the fin assembly of FIG. 1 and also having a surface roughness feature on a top surface of at least one pillar, which is shown in a close-up view, in accordance with various embodiments herein.
• FIG. 6 is a cross-sectional view of a first media assembly, including the first three-dimensional structure of FIG. 3 and a first fine fiber layer lofted above the fin assembly, in accordance with various embodiments herein.
• FIG. 7 is a cross-sectional view of an alternate first media assembly, including the first three-dimensional structure of FIG. 3 and a first fine fiber layer that is in contact with the fin assembly, in accordance with various embodiments herein.
• FIG. 8 is a cross-sectional view' of a second media assembly, including a second pillar layer and a second fine fiber layer lofted above the first fine fiber layer, in accordance with various embodiments herein.
• FIG. 9 is a cross-sectional view of an alternate fin assembly having gradient spacing of the first fin layer, which is an example of three-dimensional printed structure formed by additive manufacturing, in accordance with various embodiments herein.
• FIG. 10 is a top view' of the gradient fin assembly of FIG. 9, in which it can be observed that both the first and the second fin layer have gradient spacing, in accordance with various embodiments herein.
• FIG. 11 is a cross-sectional view' of a still further alternate fin assembly having a first pillar layer with a gradient of heights of the pillars, in accordance with various embodiments herein.
• Additive manufacturing techniques also referred to as 3D printing, allow very precise manufacturing of objects using a digital model. Layers of material are deposited at precise locations to form the desired object. Compared to injection molding and other manufacturing techniques, 3D printing allows more flexibility with the sizes and shapes of the objects, as there is no limitation regarding shapes that can be removed from a mold. Another advantage of 3D printing is that highly permeable structures can be formed using 3D printing.
• Structures formed using 3D printing can be used in filtration media incorporating fine fibers to increase the available surface area of fine fibers, i.e., the surface area of the fine fibers not in direct contact with the underlying substrate, without increasing tire fine fiber basis weight.
• Fine fibers such as nanofibers, conform to typical substrates that are used in filtration media.
• Three-dimensional structures can be constructed using 3D printing and other manufacturing techniques and used in combination with a fine fiber layer to create a filtration media with an increase in the available surface area of fine fibers per underlying area unit, without increasing the fine fiber layer thickness. As a result, the face velocity across the fine fiber layer is decreased, thus reducing the pressure drop.
• the three-dimensional structures also provide additional surface area for dust loading and increased dust holding capacity.
• a three-dimensional structure can be covered with a fine fiber layer to form a first media assembly.
• a further, second three-dimensional structure can be printed on top of a first media assembly, and then a second fine fiber layer can be formed on top of that, to form a media assembly.
• Multiple additional layers are also possible, with further layers possibly including both a three-dimensional structure component and an additional fine fiber layer.
• a media assembly including a 3D printed structure and a fine fiber layer can be used as a filtration media without any other substrate.
• the media assembly including a 3D printed structure and a fine fiber layer can be formed upon or positioned upon a substrate.
• the media assembl ies described herein can be further assembled with other conventional filter structures to make a filter composite layer or filter unit.
• substrates can be a non-woven, woven, membrane, cellulosic medium, a glass medium, a synthetic medium, a scrim or an expanded metal support.
• the media assemblies describe herein can be used in conjunction with many other types of media, such as conventional media, to improve filter performance or lifetime.
• a perforate structure can be used to support the media assemblies under the influence of fluid under pressure passing through the media.
• the filter structures described herein can also be combined with additional layers of a perforate structure, a scrim, such as a high-permeability, mechanically-stable scrim, and additional filtration layers such as a separate loading layer.
• a multiregion media combination is housed in a filter cartridge commonly used in the filtration of non-aqueous liquids.
• a media assembly with or without a substrate, can be formed into a filtration element by being rolled, pleated, stacked in multiple layers, or assembled in other ways.
• the 3D structure can provide embossing features such as pleat spacing features.
• a filter element formed using the 3D structures described herein may have a variety of flow path configurations.
• dirty fluid passes through a filter media that has a pleated construction, stacked construction, or both.
• dirty fluid enters an open flute on the dirty air side of the filter pack. Because the flute is settled on the opposite end, air is forced to pass through the filter media into an adjacent flute. Filtered air exits the filter pack through a flute that is open on the clean air side of the filter element.
• the filter element is cylindrical and dirty fluid enters into the core of the element, passes through the filtration media, and exits as cleaner, filtered fluid at the exterior of tire filter element.
• a ‘‘flow by” flow path is used.
• Flow by filtration means that the fluid never goes through filtration media.
• the turbulence in the flow causes particles to come into contact with the filtration media and be captured.
• There are pressure drop advantages to this type of configuration typically at the expense of lower fractional efficiency.
• Filter elements having such a configuration can be used with the media assemblies described herein. Filter elements having a flow by configuration are described further in the following commonly -owned patent publication, which is hereby incorporated by reference in its entirety: WO2019032773, titled FLUID FILTRATION APPARATUSES, SYSTEMS, AND METHODS.
• a stacked construction of sheets of media assembly it is possible for the stacks of media assembly to vary in construction across one or more dimensions. ft is also possible tor the individual sheets in the stack to be different from each other. For example, a discrete 3D feature may be present on a first sheet and not present on the other sheets.
• Each substrate or sheet of substrate can include a grid of 3D structures.
• the 3D structures within the grid can have varying heights moving in a direction across the substrate.
• Filtration assemblies having fine fiber layers can have a significant pressure drop.
• the addition of 3D structures as described herein can reduce the pressure drop for filtration assemblies with fine fiber layers.
• Fine fiber layers can also dislodge from substrates in some prior art systems where the fine fiber layers do not have high adhesive strength.
• the addition of 3D structures can decrease the likelihood of dislodging.
• 3D structures and “three-dimensional structures” are used interchangeably herein .
• FIGS. 1-5 examples of three-dimensional printed structures will be discussed, which may be incorporated into filtration media along with fine fiber layers. These structures are merely examples, and many options exist for the 3D structures described herein.
• FIGS. 1 and 2 show a three-dimensional printed structure 100 formed of a first layer of fins 104 and a second layer of fins 106.
• the three- dimensional printed structure 100 can also be referred to as a fin assembly.
• the fin assembly can be formed by additive manufacturing, injection molding, or by other manufacturing techniques.
• 3D structure has dimensions, such as a height, width or length dimension that is greater than or equal to 1, 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 microns. In some embodiments, the dimension can be less than or equal to 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, or 1000 microns.
• the dimension can fall within a range of 1 to 2000 microns, or 100 to 1900 microns, or 200 to 1800 microns, or 300 to 1700 microns, or 400 to 1600 microns, or 500 to 1500 microns, or 600 to 1400 microns, or 700 to 1300 microns, or 800 io 1200 microns, or 900 to 1100 microns, or can be about 1000 microns.
• the first fin l ayer includes a plurality of first fins 104 oriented to be parallel to each other. In the view of FIG. 1 , the first fins are extending away from the viewer.
• the second fin layer includes a plurality of second fins oriented to be parallel to each other and perpendicular to the first fins. The second fins are stacked on the first fins.
• the fins in the examples of the FIGS are each generally cuboid.
• the fin assembly can be used as a 3D structure as describe herein and incorporated into a media assembly.
• further structures can be added to the fin assembly, such as pillars shown in FIG. 3-4.
• FIG. 3 is a cross-sectional view of another three-dimensional printed structure 100 including pillars 110 on top of the fin assembly of FIG. 1.
• FIG. 4 is a top view of first three-dimensional printed structure of FIG. 3.
• the pillars can be formed by 3D printing or by other manufacturing methods. At least some of the pillars are formed at intersection locations where the first fins and second fins intersect. In some embodiments, all of the pillars are formed at intersection locations where the first fins and second fins intersect.
• the dimensions for spacing between pillars, between fins, fin width, fin length, and fin height are dimensions that are greater than or equal to 1 , 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 microns. In some embodiments, the dimension can be less than or equal to 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, or 1000 microns.
• the dimension can fall within a range of 1 to 2000 microns, or 100 to 1900 microns, or 200 to 1800 microns, or 300 to 1700 microns, or 400 to 1600 microns, or 500 to 1500 microns, or 600 to 1400 microns, or 700 to 1300 microns, or 800 to 1200 microns, or 900 to 1 100 microns, or can be about 1000 microns.
• FIG. 5 is a cross-sectional view of a first three-dimensional printed structure 100 including pi llars 110 on top of the fin assembly of FIG. 1 .
• the 3D printed structure of FIG. 5 also has a surface roughness feature 500 on a top surface of at least one pillar, which is shown in a close-up view, in accordance with various embodiments herein.
• Surface roughness may be provided at all or just some of the top surfaces of the pillars.
• Surface roughness may be provided at other areas of the 3D structure, including, but not limited to, some or all of the side surfaces of the pillars, some or all of the top surfaces of the fins, some or all of the side surfaces of the fins, some or all of the bottom surfaces of the fins.
• Surface roughness can be created using a 3D printing technique to deposit additional structures on a top surface of the pillar.
• particles or fibers can be incorporated into the surface layers of the 3D printed materials to create the surface roughness features.
• a dimension of such a surface roughness feature can be greater than or equal to 10, 100, 200, 300, 400, or 500 nanometer.
• tire dimension can be less than or equal to 1000, 900, 800, 700, 600, or 500 nanometer.
• the dimension can fall within a range of 10 to 1000 nanometer, or 100 to 900 nanometer, or 200 to 800 nanometer, or 300 to 700 nanometer, or 400 to 600 nanometer, or can be about 500 nanometer.
• FIG. 6 is a cross-sectional view of a first media assembly 600, including the first three-dimensional structure 100 of FIG. 3 and a first fine fiber layer 604 lofted above the fin assembly, in accordance with various embodiments herein.
• the first fine fiber layer is deposited after the pillars 110 are formed on the first media assembly 600. At least some of the fine fibers of the first fine fiber layer are in contact with a top surface of the pillars 110, where the top surface of the pillars is the surface that is farthest away from the second fins 106.
• a gap 610 is present between the first fine fiber layer 604 and a first surface of the second fins 106.
• the height of the gap 610 in between the pillars which can also be described as the amount of sag of the lofted fine fiber layer, will depend on the spacing of the pillars.
• Deposition of the fine fiber layer 604 can occur after the 3D structure 100 has been constructed. Deposition of the fine fiber layer 604 can be one of the last steps to occur other than post-treatment steps.
• Close-up view 606 illustrates that the fine fiber layer is not a unitary structure. Instead, the fine fiber layer is made up of discrete fibers which intersect and define open spaces in the fine fiber layer.
• FIG. 7 is a cross-sectional view of an alternate first media assembly 700, including the first three-dimensional structure of FIG. 3 and a fine fiber layer 704.
• the fine fiber layer 704 has many fibers in contact with the fin assembly and is present in the spaces between the pillars 110.
• the pillars 110 minimize the potential dense packing of dust in the fine fiber layer 704, allowing for slower build-up of differential pressure, and therefore longer filter life.
• the fine fiber layer 704 is deposited after the pillars 110 are formed on the fin assembly.
• the fine fiber layer 704 may be referred to as a conforming fine fiber layer.
• a lofted fine fiber layer of FIG. 6 improves the ability to pulse clean the filtration media to remove dust, compared with the fine fiber layer 704 that is in contact with the fin assembly.
• FIG. 8 is a cross-sectional view of a second media assembly 800, including a second pillar layer and a second fine fiber layer lofted above the first fine fiber layer, in accordance with various embodiments herein.
• the second media assembly 800 includes all the components of the first media assembly 600 of FIG. 6, including a fin assembly, a first layer of pillars 1 10 and a lofted first fine fiber layer 604 defining a gap 610.
• the second media assembly 800 further includes a second pillar layer of pillars 808, which are formed on the top surface of the first pillars 110.
• the first fine fiber layer 604 is also on top of the first pillars.
• the intervening first fine fiber layer 604 it is still possible to form the second pillar layer 708 because of the precise control of 3D printing techniques and because the material forming the second pillar layer is a thermoplastic material that flows through the porosity of the fine fiber layer. The material flows around and past any individual, intervening fibers of the fine fiber layer and is deposited on the top surface of the first pillars.
• the second media assembly 800 also includes a lofted second fine fiber layer 814.
• the second fine fiber layer is deposited after the pillars 808 are formed on first pillars 110. At least some of the fine fibers of the second fine fiber layer are in contact with a top surface of the second pillars 808, where the top surface of the pillars is the surface that is farthest away from the second fins 106 and the remainder of the 3D structure.
• a gap 818 is present between the second fine fiber layer 814 and the first fine fiber layer 614. The height of the gap 818 in between the pillars, which can also be described as the amount of sag of the lofted fine fiber layer, will depend on the spacing of the pillars.
• the media assembly of FIG. 8 will have lower differential pressure.
• the first fine fiber layer differs from the second fine fiber layer.
• the first fine fiber layer can have a first pore size while the second fine fiber layer has a second, larger pore size.
• the second fine fiber layer which is upstream of the first fine fiber layer, is structured to better repel any wetting fluid and the first fine fiber layer is structured to optimize particulate filtration.
• FIG. 8 shows two fine fiber layers interspersed with two pillar layers, it is also possible to include third, fourth, and fifth fine fiber layers and pillar layers, interspersed with each other.
• first media assembly 600 including a 3D structure, as shown in different examples in the FIGS., is used on top of a filtration substrate
• the presence of the first media assembly 600 reduces the masking effect of a fine fiber layer on the underlying substrate.
• the media assembly provides a direct, non- tortuous, open path for fluid to be filtered to a particular point in the depth of the thickness of the media assembly.
• a path may extend from a first side to a second side of the 3D printed structure.
• Such a path is like a snorkel structure, providing a fluid passage to a specific desired location.
• Such a structure aids in fully utilizing the media assembly through its thickness.
• the structure creates a pathway for fluids to enter the interior of the filtration media in specified locations and at predetermined depths.
• Such structures can help to increase contaminant capacity and/or flux.
• the 3D structures described herein can also be used as a scaffold for cell growth, such as for the food and beverage industry, pharmaceutical industry, or biological industries.
• the media assemblies described herein can provide a lofty structure for a loading layer top layer for membranes, providing a low solidity, high volume structure for extended life.
• the precise control offered by additive manufacturing methods and ability to vary the material being added to the structure at each location enable the 3D structure to have gradients of size, such as gradients of height of repeating structures, gradients of width of repeating structures, gradients of thickness of repeating structures, gradients of spacing of repeating structures, and gradients of shape of repeating structures. Gradients in physical structure can in turn cause gradients in the fine fiber coverage of the fibers deposited on those structures. It is also possible to form gradients of material composition in any of the structure’s dimensions.
• variable spacing and gradient dimensions can be based on flow modeling to optimize pressure drop and loading.
• FIG. 9 is a cross-sectional view of an alternate fin assembly 900, which can also be referred to as a 3D structure 900, having gradient spacing of first fins 904 within the first fin layer. Moving from a left side of the fin assembly to a right side of the fin assembly in the view of FIG. 9, the fins 904 are positioned progressively farther apart.
• FIG. 10 is a top view of the gradient fin assembly of FIG. 9, in which it can be observed that both the first and the second fin layer have gradient spacing, in accordance with various embodiments herein. Moving from a first side of the fin assembly to a second side of the fin assembly in FIG. 10, which i s top to bottom in the view of FIG. 10, the fins 906 of the second fin layer are positioned progressively farther apart.
• FIG. 11 is a cross- sectional view of a still further alternate fin assembly 1 100 or 3D structure.
• a first pillar layer 1110 includes pillars with a gradient of heights of the pillars.
• a first pillar has a first height
• a second pillar has a second height less than the first height
• a third pillar has a third height less than the second height.
• An amount of variance between the first, second and third heights can be, in some embodiments, greater than or equal to 1 , 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1000 microns.
• the variance can be less than or equal to 2000, 1900, 1800, 1700, 1600, 1500, 1400, 1300, 1200, 1100, or 1000 microns. In some embodiments, the variance can fall within a range of 1 to 2000 microns, or 100 to 1900 microns, or 200 to 1800 microns, or 300 to 1700 microns, or 400 to 1600 microns, or 500 to 1500 microns, or 600 to 1400 microns, or 700 to 1300 microns, or 800 to 1200 microns, or 900 to 1100 microns, or can be about 1000 microns.
• a method for manufacturing a filtration media includes printing of a first three-dimensional structure using an additive manufacturing process and depositing a first fine fiber layer on the three-dimensional structure using an electrospinning process to form a first media assembly.
• the method can further include printing, on the first media assembly, a second three-dimensional structure using the additive manufacturing process to form a second media assembly.
• the method can further include depositing, on the first media assembly after printing of the second three-dimensional structure, a second fine fiber layer to form a second media assembly.
• the first three-dimensional structure is printed on a substrate.
• the substrate is rolled to form a filter unit.
• the method can further include forming a plurality of sheets of the first media-assembly and stacking the plurality of sheets to form a filter unit.
• each sheet comprises a plurality of the first media sub-assemblies.
• the first three-dimensional structure comprises a plurality of first fins oriented to be parallel to each other and a plurality of second fins oriented to be parallel to each other and petpendicular to the first fins, wherein the second fins are stacked on the first fins.
• the first three-dimensional structure further comprises a plurality of pillars formed on a first surface of the second fins.
• At least some of the pillars are formed at intersection locations where the first fins and second fins intersect.
• a media assembly including a lofted first fine fiber layer is formed when the first fine fiber layer is deposited after the pillars are formed on the first three-dimensional structure, at least some of the fine fibers of the first fine fiber layer are in contact with a top surface of the pillars that is farthest from the second fins, and a gap is present between the first fine fiber layer and the first surface of the second fins.
• the first fine fiber layer is deposited after the pillars are formed on the first three-dimensional structure, and the fine fiber layer is then located between the pillars and at least some of the fine fibers are in contact with the first surface of the second fins.
• a method for manufacturing a filtration media including the step of printing of a first three-dimensional structure using an additive manufacturing process. This step includes the sub-steps of printing a plurality of first fins oriented to be parallel to each other, printing a plurality of second fins oriented to be parallel to each other and perpendicular to the first fins, wherein the second fins are stacked on the first fins, and printing a first plurality of pillars forming a first pillar layer formed on a first surface of the second fins.
• the method further includes depositing a first fine fiber layer on the three-dimensional structure using an electrospinning process to form a first media assembly.
• the method can further include printing, on the first media assembly, a second three-dimensional structure using the additive manufacturing process to form a second media assembly, wherein the second three-dimensional structure comprises a second plurality of pillars forming a second pillar layer, wherein the pillars of the second plurality of pillars are each formed atop one of the pillars of the first plurality of pillars, forming a second media subassembly.
• the method can further include, after the printing of the second pillar layer, depositing a second fine fiber layer on the second media subassembly using the electrospinning process to form a first media assembly.
• the material of the 3D printed structure includes nanoparticles, fibers, nanofibers, additives, or a chemical treatment.
• the method includes changing a surface roughness, changing fine fiber adhesion, and reducing dust adhesion compared to the material without tlie chemical treatment or added particles.
• the first three-dimensional structure defines direct, non-tortuous open passages from a first side to a second side of the three- dimensional structure.
• thermoplastic polymers including, but not to be limited to polyamides, polypropylene, polyurethane, polyethylene, polylactic acid, acrylonitrile butadiene styrene, styrene, and co-polymers, mixtures, or derivatives thereof.
• the materials for 3D printing are selected to be compatible with the end application of the particular filtration element.
• the materials for 3D printing are selected to be chemically compatible and have suitable physical characteristics to interact with electrospun fibers and with the conditions of the electrospinning process.
• the 3D structures described herein can be formed using the process of additive manufacturing, referred to herein as three-dimensional (3D) printing.
• the 3D structures generated using 3D printing can include unique and fine structural detail, including those having a high aspect ratio.
• the fine features incorporated into the 3D structures described herein can include, but is not to be limited to, pillars, fins, intersecting fins, a honeycomb pore structure having a varying distribution of varying pore sizes, a honeycomb pore structure having a uniform distribution of uniform pores sizes, fine struts, fine mesh structures, a gradient pore structures throughout the material, threads, ridges, micro-surfaced to confer roughness and additional surface area, open cavities, central apertures, and the like.
• the 3D structures can be 3D printed to be or to include portions that are highly porous. In other embodiments, the 3D printing process can mix various materials to generate the 3D structures.
• the printed material of the structures described herein can be porous, such as to allow fluid to flow through the structure. This porosity can be accomplished during the printing process by defining many and frequent open spaces interspersed with solid material portions. Examples of structures defining many open areas include the fin assemblies illustrated herein. These open areas allow for fluid to flow through the structure. In some embodiments, the open area of an end cap or pleat guide structure can be greater than or equal to 50 %, 52 %, 55 %, 58 %, 60 %, 62 %, 65 %, 68 %, or 70 %.
• the open area can be less than or equal to 85 %, 83 %, 81 %, 79 %, 78 %, 76 %, 74 %, 72 %, or 70 %. In some embodiments, the open area can fall within a range of 50 % to 85 %, or 52 % to 83 %, or 55 % to 81 %, or 58 % to 79 %, or 60 % to 78 %, or 62 % to 76 %, or 65 % to 74 %, or 68 % to 72 %, or can be about 70 %.
• porosity can also be accomplished is by choosing material for the structure that is itself porous or can be modified after printing to be porous.
• Some 3D printing materials incorporate particles, such as spheres, of thermoplastic material of a different type than the remainder of the material. These particles can be partially cured and dissolved out of the structure after printing.
• Another option is to selectively bake or etch away particles that are included in the materials of the structure. These processes result in void spaces within the printed materials, increasing the porosity of the material.
• pore size refers to spaces formed by materials within a printed structure.
• the pore size of the media can be and estimated by reviewing electron photographs of the media.
• the average pore size of a media can also be calculated using a Capillary Flow Porometer having model no. APP 1200 AEXSC available from Porous Materials Inc. of Ithaca, NY.
• the average pore size for the printed material can be greater than or equal to 0.3 nanometers, 0.6 nanometers, 0.9 nanometers, 1.2 nanometers, or 1.5 nanometers. In some embodiments, the average pore size can be less than or equal to 3.0 nanometers, 2.6 nanometers, 2.2 nanometers, 1.9 nanometers, or 1.5 nanometers. In some embodiments, the average pore size can fall within a range of 0.3 nanometers to 3.0 nanometers, or 0.6 nanometers to 2.6 nanometers, or 0.9 nanometers to 2.2 nanometers, or 1.2 nanometers to 1.9 nanometers, or can be about 1.5 nanometers.
• the average pore size can be greater than or equal to 0.1 microns, 0.2 microns, 0.4 microns, 0.5 microns, 0.7 microns, 0.8 microns, 0.9 microns, 1.1 microns, 1.2 microns, 1.4 microns, or 1 .5 microns.
• the average pore size can be less than or equal to 3.0 microns, 2.8 microns, 2.7 microns, 2.6 microns, 2.4 microns, 2.2 microns, 2.1 microns, 2.0 microns, 1.8 microns, 1.6 microns, or 1.5 microns.
• the average pore size can fall within a range of 0.1 microns to 3.0 microns, or 0.2 microns to 2.8 microns, or 0.4 microns to 2.7 microns, or 0.5 microns to 2.6 microns, or 0.7 microns to 2.4 microns, or 0.8 microns to 2.2 microns, or 0.9 microns to 2.1 microns, or 1.1 microns to 2.0 microns, or 1.2 microns to 1.8 microns, or 1.4 microns to 1.6 microns, or can be about 1.5 microns.
• the average pore size can be greater than or equal to 0.01 micrometers, 0.02 micrometers, 0.03 micrometers, 0.04 micrometers, or 0.05 micrometers, or can be an amount falling within a range between any of the foregoing.
• the average pore size of the printed material can be greater than or equal to 15 microns, 17 microns, 18 microns, or 20 microns. In some embodiments, the average pore size can be less than or equal to 25 microns, 23 microns, 22 microns, or 20 microns. In some embodiments, the average pore size can fall within a range of 15 microns to 25 microns, or 17 microns to 23 microns, or 18 microns to 22 microns, or can be about 20 microns.
• the average pore size of the printed material in some embodiments, can be greater than or equal to 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, or 1.0 mm. In some embodiments, the average pore size can be less than or equal to 2.0 mm, 1.8 mm, 1.6 mm, 1.4 mm, 1.2 mm, or 1.0 mm.
• the average pore size can fall within a range of 0.5 mm to 2.0 mm, or 0.6 mm to 1.8 mm, or 0.7 mm to 1.6 mm, or 0.8 mm to 1.4 mm, or 0.9 mm to 1.2 mm, or can be about 1.0 mm.
• Particles or additives can be added to the 3D structure for many purposes, including to aid in directing the fine fibers to the desired location, to increase adhesion of the fibers to the 3D structure, to increase the adhesion of the 3D structure to a substrate.
• Chemical treatments can be added during or after the manufacturing process to provide additional benefits including changing the contact angle of the surface of the material, modifying surface roughness, increasing fme fiber adhesion, and reducing dust adhesion.
• additives that can be added to the 3D structure include oleophobic additives, hydrophobic additives, and additives to increase adhesion like a pressure sensitive adhesive.
• particles that can be added to the 3D structure include sorbents like activated carbon, silica gel, metal organic frameworks (MOFs), and molecular sieves.
• catalysts like MnO or Pt can be included in tlie 3D structure.
• Nanofibers are example of fine fibers that can be used with the assemblies described herein.
• Other examples of fine fibers can include meltblown fibers, spunbond fibers, solution-blown fibers, and melt-electrospun fibers.
• the phrase “configured” describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration.
• the phrase “configured” can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like.

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