Prior art production of nanofiber required large processing equipment and agitators that wasted time, energy, and labor. Subsequent solids-liquid separation of these wet nanofibers was both costly and difficult to scale up.
KT Corporation's nanofiber production process reduces energy consumption by nearly 80% while increasing production capacity and productivity nearly ten-fold. This permits production of metric ton quantities of this critical raw material.
Our new process eliminates the need to separate water from the fibers, which emerge only slightly moist and fully sterilized. These fibers can now be economically shipped long distances and stored safely for extended periods.
Early electrokinetic filters consisted of positively charged fibers or membranes, where negatively charged pathogens could be captured efficiently even when the filter medium’s pores were too large to carry out direct interception.
This process becomes much more efficient as the volume and surface area of the filter increases and this can be accomplished using nanofibers, but nanofibers were, in the past, very expensive.
To make the most efficient electrokinetic materials, KT Corporation first manufactures nanofibers with an extremely negative charge. Next, these negatively charged fibers are coated with a positively-charged polymer. This positive charge is stable throughout a pH range of pH = 3 to 12. These nanofibers provide foolproof interception of microbiological threats – down to the smallest virus.
In addition, our nanofibers serve as the binder that retains the extremely small particulate adsorbents that efficiently intercept organic and inorganic contaminants. The scanning electron micrograph included shows how nanofibers hold these 5-10 micron particles.
Overcoming earlier deficiencies, heat-stable and high-activity catalytic activated carbons have become available. Unfortunately these carbons are 5-10 times more expensive than conventional activated carbons.
The challenge has been to retain powerful catalytic properties without the enormous economic burden. Our super-catalytic carbon is heat stable and of low cost. Fusion Filters achieve superior efficiency by eliminating the need for thermoplastic binders that foul catalytic carbons. A single FF-1 or FF-2 gravity-flow filter reduces chloramines and sulfide meeting NSF STD 42 for 700 liters (laboratory result) using only 4-grams of this carbon – a teaspoonful!
Today, the term CTO (Chlorine, Taste and Odor) is used by nearly every company in the world to describe the aesthetic capabilities of common carbon block filters. But CTO filters are insufficient when many municipalities have switched to using chloramine disinfectants, when well water is contaminated with sulfide, or surface waters are contaminated with musty smelling/tasting organics. To meet these challenges, we have moved to a new standard – STOCC.
A STOCC filter intercepts Sulfide; chemicals that contribute to Taste; rust sediment, dirt and Turbidity at NSF STD 42 Class 1 levels (0.5 micron); Odors; Chlorine; and Chloramine. What emerges is pristine, super-purified water. No off-tastes, no off-smells, and crystal clear... no exceptions.
KT Corporation produces many of the critical raw materials used in Fusion Filters, including nanofibers and metals adsorbents. We also convert these materials into finished filter media and then into complete filter modules. Our proprietary technology allows for effective and efficient scalability of these processes, permitting tremendous rates of production.
Our early products, the FF-1 and FF-2 gravity-flow filter elements can be produced at volumes of 100-million devices per year and we can expand such production even further, if required. Our pressurized water filter capacity is limited only by final filter assembly and can be increased to tens-of-millions of filters using the automation we have previously developed.