Synthetic Multilayer Filter Media with Integrated Activated Carbon for PFAS Filtration

It is a self-supported, four-layer composite filter medium that combines multiple functional nonwoven layers and activated carbon in one pleatable sheet. Unlike traditional PFAS filters (like carbon block cartridges or ion exchange resin beds) which have limited shape flexibility and often require separate components, this integrated media can be built into pleated or wrapped filters while providing high PFAS removal performance. Each layer in the composite plays a specific role (from particle filtration to PFAS adsorption), allowing the media to simultaneously remove sediments and “forever chemicals” (PFAS) from water in one unit.

This approach bridges the gap between conventional high-PFAS-removal solutions and the design flexibility of pleated filters. By integrating activated carbon into synthetic support layers, the filter media achieves up to 70–99% PFAS removal efficiency while enabling use in modern pleated cartridge formats.

The media’s self-supporting structure provides mechanical stability in pleated or wrapped filter designs without requiring extra support layers, making it easier for OEMs to install in a variety of water filtration systems where PFAS reduction and particulate removal are needed.

The PFAS filter media integrates three complementary filtration mechanisms in one design:

1. Size exclusion – the fine fiber meltblown layers (Layer 1) physically strain out larger suspended particles and sediments, preventing them from reaching and clogging the carbon layers.

2. Adsorption - the activated carbon coating on Layer 3 has enormous surface area and strongly bonds PFAS molecules via chemical attractions (hydrophobic interactions and hydrogen bonding). This ensures targeted adsorption of even trace-level PFAS chemicals.

3. Absorption – the micro-porous structure of the meltblown fiber media (Layer 1, and in some designs an extra meltblown pre-filter stage) provides additional surface area to capture dissolved organic
contaminants (e.g. oils, natural organics) as they pass through, leaving more of the carbon’s surface free to focus on PFAS.

These three mechanisms work in tandem: the first stops particulates, the fibrous matrix traps co-contaminants, and the carbon layer adsorbs PFAS. This synergistic approach maximizes PFAS removal efficiency while protecting downstream treatment stages.

The PFAS filter media is engineered to achieve 70% up to ~99% PFAS removal efficiency, depending on the design and application needs.

The multi-layer architecture is modular and customizable – by adjusting each layer’s properties (e.g. fiber density or carbon loading) or adding upstream meltblown depth pre-filters, the media can be tailored to meet different PFAS concentration targets or system requirements.

For example, standard configurations may remove ~70–90% of PFAS in one pass, whereas higher carbon-loaded versions or multi-stage designs can reach removal levels close to 99% for more stringent regulations.

Because each layer is designed separately, the media can be customized to individual performance requirements (balancing PFAS efficiency, dirt-holding capacity, flow rate, and service life) for various water treatment applications

Pleatability and self-support mean the media can be formed into traditional pleated filter cartridges or used as a wrapped outer layer without needing extra support mesh. The integrated spunbond scrim layers (Layers 2 & 4) provide structural stiffness and prevent collapse or deformation, so the medium can hold a precise pleat shape on its own during operation.

For OEM filter manufacturers, this design flexibility allows drop-in integration into existing pleated filter formats such as cartridges, modules, or other high-surface-area designs.

The self-supported multilayer construction simplifies filter fabrication (no separate backing or cage required) and yields a robust, stable pleat pack that can withstand high flow rates and differential pressures
without damage.

Overall, this feature streamlines filter design and assembly while ensuring reliability in the field.

The four-layer PFAS media can be deployed upstream as a pre-treatment filter to reduce PFAS load and remove particulates before water reaches highgrade carbon or ion-exchange (IX) resin beds.

Acting as a PFAS “polishing” pre-filter, it captures sediment and some fraction of the PFAS (lowering the influent PFAS concentration), which prevents premature clogging or saturation
of the main downstream treatment media.

In practice, the meltblown layer stops particulate contaminants so that the downstream GAC (granular activated carbon) or resin is not blinded by solids, and most PFAS molecules are trapped in the integrated carbon layer (Layer 3) rather than traveling to the main bed.

By removing a significant portion of PFAS upstream, the service life of the primary carbon/resin filters can be extended by over 40% before replacement or regeneration is needed. This translates to fewer
change-outs, lower operational costs, and more reliable system performance.

As regulatory limits tighten, such a pre-filter strategy is increasingly valuable for protecting expensive downstream treatment stages and ensuring they operate more efficiently.