NANO membrane filter

Abstract

The application relates generally to a filter system for removing contaminating molecules from a fluid flow. The filer system includes a nano membrane filter applicable to physically only allow the passage of material having a size less than or equal to 0.4 nanometers.

Description

[0001] NANO MEMBRANE FILTER

[0002] CROSS REFERENCE TO RELATED APPLICATIONS

[0003] The present application claims the benefit of United States Provisional Patent Application No. 63 / 666,076 filed on June 28, 2024 and incorporated herein by reference.

[0004] TECHNICAL FIELD

[0005] The present application relates generally to the removal of impurities from liquids. More specifically the present application relates to the separation of per and polyfluoroalkyl substances (PFAS) from water.

[0006] BACKGROUND

[0007] A major concern for the modem world is the availability of safe clean water. The continued industrialization of the world creates added strain on an already overtaxed and contaminated water supply. Per and polyfluoralkyl materials (PFAS) are manmade compounds that have been widely used in the manufacturing of goods and industrial chemicals. Examples include: firefighting foam; surface treatment in carpeting, upholstery, cookware; and, chemicals used for lubricants, industrial processes and the like.

[0008] PFAS materials include molecules that are contaminants in water and remain in groundwater and the bodies of humans, plants and animals for a very long period of time. The PFAS materials are very stable and include carbon-fluorine bonds which are one of the strongest bonds known and difficult to break. Many approaches are being utilized to combat the PFAS contamination of water. The prior approaches have many short - comings and nano membrane technology is considered an important path forward for addressing the PFAS contamination.

[0009] The present application provides significant contributions to nano membrane filtration for the removal of PF As from water.

[0010] SUMMARY

[0011] In accordance with one form of the application there is disclosed nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a cast body having a three dimensional passage adapted to receive the flow of water, the three dimensional passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a plurality of passageways in the body that are disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of chemically inert water insoluble first ceramic particles when unfired having a substantially spherical shape with a particle size distribution and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner; the plurality of pores includes a first plurality of pores in the inner surface with a first pore size of about forty nanometers and separated by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, and the average pore size of the plurality of pores is about eighty nanometers, the body has a volume porosity within a range of twenty-five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of chemically inert water insoluble second ceramic particles when unfired having a substantially spherical shape with an average particle size within a range of one to five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores with an average fourth pore size less than one and one half nanometers, the fourth plurality of pores allows only the passage of the flow of molecules having a size less than or equal to 0.4 nanometers to enter into fluid communication with the plurality of passageways in the body; and wherein the membrane is interconnected with the body at the inner surface and extends into the intermix portion and is defined by a sintered structure connection that is fired distinct from the body.

[0012] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a sintered cast ceramic body having a cylindrical opening formed therein, the cylindrical opening has an inner surface and an outer surface spaced from the inner surface, the body formed of chemically inert water insoluble first ceramic particles when unfired having a near spherical shape with an average particle size of about three hundred nanometers and a particle size gradient increasing from the inner surface to the outer surface, the body has a poly-crystalline microstructure with a plurality of pores with a size less than forty nanometers formed in the inner surface and separated by portions of the inner surface having a surface roughness of less than seventy nanometers, the cast ceramic body has a volume porosity within a range of twenty -five to forty five percent; and a ceramic membrane with a cubic structure disposed on and connected with the inner surface by an in-situ secondary firing, the ceramic membrane formed of a plurality of chemically inert water soluble second ceramic particles when unfired having a near spherical shape with an average particle size less than five nanometers and a second inner surface having a random distribution of second plurality of pores with a pore size less than or equal to one and one half nanometers for receiving water separated from the PFAS contaminated water, the ceramic membrane having a volume porosity within a range of ten to fifty percent; and wherein the second plurality of pores allows only the passage of molecules having a size less than or equal to 0.4 nanometer to pass into the body.

[0013] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant in a volume of water, comprising: ceramic substrate means for supporting a cast ceramic membrane including a surface in fluid flow communication with the PFAS contaminant in the volume of water, the ceramic substrate means being a fired structure; the membrane allows only the flow of molecules with a particle size less than or equal to 0.4 nanometers into the ceramic substrate means; wherein the membrane is a formed of a plurality of substantially spherical shaped ceramic particles when un-thermally processed and having an average size within the range of one to five nanometers; wherein the membrane is connected into the ceramic substrate means by thermal processing independently of the ceramic substrate means; and wherein the ceramic substrate means has a volume porosity within the rang of twenty - five to forty-five percent.

[0014] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a ceramic body having a three dimensional passage adapted to receive the PFAS-contaminated flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the cleaned water separated from the PFAS-contaminated water into a plurality of passageways in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of pure alumina particles having in an unfired state a near spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of gadolinia doped cerium oxides particles have an unfired near spherical shape with an average particle size of about five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than three nanometers, the fourth plurality of pores disposed in fluid flow communication with the flow of water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and into fluid communication with the plurality of pores and passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a fired connection distinct from the firing of the body.

[0015] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant in a flow of water, comprising: a cast ceramic body having a cylindrical passage adapted to receive the flow of water, the cylindrical passage has an inner cylindrical surface and an outer surface spaced from the inner cylindrical surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a plurality of passageways in the body disposed in fluid communication with the inner cylindrical surface and the outer surface;the body formed of a plurality of pure alumina particles having an unfired substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner cylindrical surface to the outer surface, the body includes an intermix portion proximate the inner cylindrical surface; the plurality of pores includes a first plurality of pores in the inner cylindrical surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second average pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner cylindrical surface of the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty-five to forty -five percent; a cast membrane abutting the inner cylindrical surface and formed of a plurality of cubic yttria stabilized zirconia ceramic particles having an unfired near spherical shape with an average particle size within a range of one to one and one half nanometers, the membrane is a sintered structure with a second cylindrical surface with a random distribution of fourth pores therein with an average fourth pore size less than one nanometer, the fourth plurality of pores in fluid flow communication with the water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a thermally processed connection distinct from the fired body.

[0016] Another form of the present application discloses a nano membrane filter for separating a PFAS-contaminated volume of water, comprising: a fluid tight mechanical housing including an inlet for receiving the PFAS-contaminated volume of water; a sintered cast ceramic body disposed within the mechanical housing and having an internal fluid flow passage formed therein, the body spaced from the mechanical housing to define a fluid flow path therebetween, one of the internal fluid flow passage and the fluid flow path in fluid communication with the inlet for receiving the PFAS- contaminated water and the other configured to receive the cleaned water with PFAS contaminant removed; the body formed of a plurality of chemically inert water insoluble first ceramic particles having a substantially spherical shape when unfired and an average particle size of about three hundred nanometers, the body having a plurality of pores for the passage of the water with the PFAS contaminant removed, the plurality of pores including a first plurality of pores on a first surface of the body for receiving the water with the PFAS contaminant removed and a second plurality of pores on a second surface of the body for allowing the passage of the water with the PFAS contaminant removed from the body, the body including an intermix portion proximate the first surface, the body further has a bulk porosity within a range of twenty-five to forty-five percent; the first surface configured for receiving a ceramic membrane thereon, the first surface having an as cast surface roughness of less than seventy nanometers to which the ceramic membrane is connected to and includes an intermix portion consistent with thermal processing independently of the sintering of the body, the ceramic membrane formed of a plurality of chemically inert water insoluble second ceramic particles having a substantially spherical shape when unfired and an average particle size within a range of one to five nanometers, the membrane physically allows only the passage of molecules having a size less than or equal to 0.4 nanometer.

[0017] Another form of the present application discloses a nano membrane filter for separating a PFAS-contaminated volume of water, comprising: a fluid tight mechanical housing including an inlet for receiving the PFAS-contaminated volume of water; a sintered cast ceramic body disposed within the mechanical housing and having an internal fluid flow passage formed therein, the body spaced from the mechanical housing to define a fluid flow path therebetween, one of the internal fluid flow passage and the fluid flow path in fluid communication with the inlet for receiving the PFAS- contaminated water and the other configured to receive the cleaned water with PFAS contaminant removed; the body having a first body portion and a second body portion that are sintered together, the first body portion formed of a plurality of chemically inert water insoluble first ceramic particles having a substantially spherical shape when unfired and an average particle size of about three hundred nanometers, the second body portion formed of a plurality of chemically inert water insoluble third ceramic particles having a substantially spherical shape when unfired and an average particle size of about three microns, the body having a plurality of pores for the passage of the water with the PFAS contaminant, the plurality of pores including a first plurality of pores on an outer surface of the second body portion for receiving the water with the PFAS contaminant removed and a second plurality of pores for allowing the passage of the water with the PFAS contaminant removed from the body, the body including an intermix portion proximate the outer surface, the body further has a bulk porosity of about twenty-five to forty -five percent; the outer surface configured for receiving a ceramic membrane thereon, the outer surface having an as cast surface roughness of less than seventy nanometers to which the ceramic membrane is abutting and connected to and into the intermix portion by thermal processing independent of the sintering of the body, the ceramic membrane formed of a plurality of chemically inert water insoluble second ceramic particles having a substantially spherical shape when unfired and an average particle size within a range of one to five nanometers, the fired membrane physically allows only the passage of the molecules having a size less than or equal to 0.4 nanometers.

[0018] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: cast ceramic body having a three dimensional passage adapted to receive the PFAS-contaminated flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the cleaned water separated from the PFAS-contaminated water into a plurality of passageways in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of ceramic particles having in an unfired state a substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with an average second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty -five percent; a cast membrane abutting the inner surface and formed of a plurality of cerium oxide particles have an unfired substantially spherical shape with an average particle size of about five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one and one half nanometers, the fourth plurality of pores disposed in fluid flow communication with the flow of water and allows only the passage of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a diffusion bond formed distinct from the firing of the body.

[0019] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant entrained in a flow of water, comprising: a cast ceramic body having a three dimensional passage adapted to receive the flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a plurality of interconnected pores in the body and disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of ceramic particles having in an unfired state a substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore diameter of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty-five to forty-five percent; a cast membrane abutting the inner cylindrical surface and formed of a plurality of cubic centered yttria stabilized zirconia ceramic particles have an unfired substantially spherical shape with an average particle size within a range of one to three nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one nanometer, the fourth plurality of pores in fluid flow communication with the flow of water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores defining passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a thermally processed connection distinct from the sintered body.

[0020] Another form of the present application discloses a filter for separating a PFAS contaminant from a flow of water, comprising: a cast body having a passage adapted to receive the flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a passageway in the body that is disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of chemically inert water insoluble first ceramic particles when unfired having a substantially spherical shape with a particle size distribution of about seventy nanometers and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with a first pore size of about forty nanometers and separated from one another by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, and the average pore size of the plurality of pores is about eighty nanometers, the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of chemically inert water insoluble second ceramic particles when unfired having a substantially spherical shape with an average particle size within a range of one to five nanometers, the membrane is a sintered structure with a second surface and an abutment surface, the second surface includes a random distribution of fourth pores with an average fourth pore size within a range of one and five nanometers, the fourth plurality of pores allows only the passage of molecules having a size less than or equal to 0.4 nanometers to enter into fluid communication with the plurality of pores and passageway in the body; and wherein the abutment surface of the membrane is interconnected with the body at the inner surface and extends into the intermix portion and is defined by a diffusion bond connection that is formed distinct from the firing of the body.

[0021] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant in a volume of water, comprising: a fired cast ceramic substrate including a three dimensional surface for supporting a cast ceramic membrane; the membrane abutting the three dimensional surface and has a surface in fluid communication with the PFAS contaminant in the volume of water, the membrane only allows the passage of the material having a particle size less than or equal to 0.4 nanometers into the ceramic substrate; wherein the membrane is a formed of a plurality of substantially spherical shaped ceramic particles when un-thermally processed and having an average size within the range of one to five nanometers; wherein the membrane is connected into the ceramic substrate by a diffusion bond formed independent of the fired ceramic substrate; and wherein the ceramic substrate has a volume porosity within the range of twenty -five to forty-five percent.

[0022] Another form of the present application discloses a nano membrane filter for separating a PFAS contaminant in a volume of water, comprising: ceramic substrate means for supporting a cast ceramic membrane including a surface in fluid flow communication with the PFAS contaminant in the volume of water, the ceramic substrate means being a fired three dimensional structure; the membrane has a surface in fluid communication with the PFAS contaminant in the volume of water, the membrane allows only the passage of material with a particle size less than or equal to 0.4 nanometers into the ceramic substrate; wherein the membrane is a formed of a plurality of substantially spherical shaped ceramic particles when un-thermally processed and having an average size within a range of one to five nanometers; wherein the membrane is connected into the ceramic substrate means by thermal processing independent of the ceramic substrate means; and wherein the ceramic substrate means has a volume porosity within the range of twenty -five to forty-five percent.

[0023] Another form of the present application contemplates a filter for separating a PFAS contaminant from a flow of water, comprising: a cast ceramic body having a three dimensional passage formed therein for receipt of the water flow, the body has an inner surface and an outer surface and a plurality of pores for the passage of the water separated from the PFAS-contaminated water into a passageway in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of pure alumina particles having in an unfired state a substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has a particle size gradient increasing from the inner surface to the outer surface, the body includes an intermix portion extending proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with an average second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty -five percent; a cast membrane abutting the inner surface and formed of a plurality of cerium oxides ceramic particles have an unfired substantially spherical shape with an average particle size of about five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one and one half nanometers, the fourth plurality of pores disposed in fluid flow communication with the flow of water and only permits a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageway in the body; and wherein the membrane is interconnected with the body at the inner surface, the connection extends into the intermix portion and is a diffusion bond connection distinct from the firing of the body.

[0024] Another form of the present application discloses an apparatus for separating a PF AS contaminant in a flow of water, comprising: a cast ceramic body having a passage adapted to receive the flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a passageway in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of pure alumina particles having an unfired near spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has a particle size gradient increasing from the inner surface to the outer surface, the body includes an intermix portion proximate the inner cylindrical surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second average pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner cylindrical surface of the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the the body has a volume porosity within a range of twenty-five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of cubic yttria stabilized zirconia ceramic particles having an unfired near spherical shape with an average particle size within a range of one to two nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one nanometer, the fourth plurality of pores in fluid flow communication with the flow of water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageway in the body; and wherein the membrane is interconnected with the body at the inner surface, the connection extends into the intermix portion and is defined by a thermal bond sintering the body.

[0025] Another form of the present application discloses a nano membrane filter for separating a PFAS-contaminated volume of water, comprising: a fluid tight mechanical housing including an inlet for receiving the PFAS-contaminated volume of water; a sintered cast ceramic body disposed within the mechanical housing and having an internal fluid flow passage formed therein, the body spaced from the mechanical housing to define a fluid flow path therebetween, one of the internal fluid flow passage and the fluid flow path in fluid communication with the inlet for receiving the PFAS- contaminated water and the other configured to receive the cleaned water with PFAS contaminant removed; the body having a first body portion and a second body portion that are sintered together, the first body portion formed of a plurality of chemically inert water insoluble first ceramic particles having a substantially spherical shape when unfired and an average particle size of about three hundred nanometers, the second body portion formed of a plurality of chemically inert water insoluble third ceramic particles having a substantially spherical shape when unfired and an average particle size of about three microns, the body having a plurality of pores for the passage of the water with the PFAS contaminant, the plurality of pores including a first plurality of pores on an outer surface of the second body portion for receiving the water with the PFAS contaminant removed and a second plurality of pores for allowing the passage of the water with the PFAS contaminant removed from the body, the body including an intermix portion proximate the outer surface, the body further has a bulk porosity of about twenty-five to forty -five percent; the outer surface configured for receiving a ceramic membrane thereon, the outer surface having an as cast surface roughness of less than seventy nanometers to which the ceramic membrane is connected and to the intermix portion by a diffusion bond formed independent of the sintering of the body, the ceramic membrane formed of a plurality of chemically inert water insoluble second ceramic particles having a substantially spherical shape when unfired and an average particle size within a range of one to five nanometers, the fired membrane physically allows only the passage of the of material having a size less than or equal to 0.4 nanometers.

[0026] BRIEF DESCRIPTION OF THE FIGURES

[0027] FIG. 1 schematically depicts one embodiment of a system for removing PFAS from water.

[0028] FIG. 2 illustratively depicts a perspective view of one embodiment of a nano membrane comprising a portion of the system of FIG. 1.

[0029] FIG. 3 depicts an illustrative cross-sectional view of the nano membrane of FIG. 2 taken along line 3-3.

[0030] FIG 3A depicts an illustrative view of water and material flow relative to nano membrane fdter.

[0031] FIG. 4 depicts an illustrative view of a portion of one embodiment of the nano membrane including a layered material distribution of the support portion.

[0032] FIG. 5 depicts an illustrative view of one embodiment of the nano membrane including a portion exposed to fluids containing contaminants.

[0033] FIG. 6 depicts an illustrative view of one embodiment of the nano membrane in cross section.

[0034] FIG. 7 is an illustrative view of one embodiment of the nano membrane in cross section depicting flow paths therethrough.

[0035] FIG. 8 depicts an illustrative view of a ceramic particle arrangement of the nano membrane of one embodiment of the present application.

[0036] FIG. 9 is an illustrative view of another embodiment of the nano membrane in cross section depicting flow paths therethrough. DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

[0037] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.

[0038] With reference to FIG. 1 there is schematically illustrated a water system 10 receiving a supply of water 12 from conventional places such as wells or a municipality. The system will be described herein for a residential dwelling, however systems contemplated herein are equally applicable to all types of dwellings and non-dwellings that require substantially clean and safe water. In one embodiment the water 12 passes into a holding tank 13 that then passes through a pump 14 to the nano membrane fdter system 11. Cleaned water with the contaminating molecules substantially removed exits at 15 the nano membrane filter system 11 for use at the dwelling. The remainder of the water including some contaminating molecules exits the nano membrane filter system at 16 and is returned to the tank 13. In one embodiment the process continues on with the water including some contaminating molecules passing through the nano membrane filter system 11 and substantially clean water exiting at 15 and recycled water including some contaminating molecules exiting at 16 returning to tank 13 for continued processing through the nano membrane filter system 11. In a preferred form of the present application the contaminating molecules include

[0039] PF AS molecules. The present application contemplates that materials is a term that includes one or more molecules and is used interchangeably within this specification unless specifically stated to the contrary. The application will discuss the present inventions in terms of removal of PFAS molecules but in some embodiments contemplates other contaminating molecules,

[0040] The present application contemplates the ability to remove PFAS molecules having a unwetted smallest characteristic down to about 0.4 nanometers from the water. In one embodiment the PFAS molecules will be accumulated in the tank 13 for subsequent removal. In one form the water system 10 is applicable for utilization in a residential dwelling with a water feed pressure of about 60 pounds per square inch (PSI) and a daily volume of substantially clean water of about three hundred (300) gallons. In another form the water system is applicable to point use, for example attached to the outlet of a faucet. In another form the water system is applicable for utility use filtering millions of gallons. The present application is applicable to a variety of flow rates, pressures and volume requirements.

[0041] The present application has been described in terms of a continuous flow system however, the present application also contemplates a dead end system where the separated substantially clean water is discharged and the initially rejected PFAS- contaminated water remains in the filter for subsequent removal with filter replacement or by removing the water with the elevated concentration of PFAS molecules. In describing aspects and embodiments of the present application reference is made to ceramic particle sizes and these sizes are provided for material in an un-sintered / non thermally processed form.

[0042] With reference to FIG. 2 there is illustratively depicted a portion of a nano membrane filter 20 forming at least a portion of the nano membrane filter system 11. The nano membrane filter 20 is enclosed within a fluid tight housing 21 and the PFAS- contaminated water 12 enters the nano membrane filter under pressure and passes through the nano membrane filter 20 to separate the PF AS-contaminated water into cleaned water exiting the interior volume 27 of the nano membrane filter 20 through a plurality of pores 22 and the substantially clean water passes out through the structure of the nano membrane filter 22 to exit 15 into the dwelling for use. The plurality of pores 22 are spaced along the length and the interior volume of the nano membrane filter 20. The remainder of the PF AS-contaminated water after passing through the length of the nano membrane filter 20 exits the nano membrane filter 20 at 23 a and out of the nano membrane filter system to the tank 13. The process continues and water from the supply and the PFAS contaminated water from tank 13 continues through the process described previously to separate the substantially cleaned water for delivery to the dwelling and the remaining PFAS-contaminated water is continued to be processed in the system.

[0043] The embodiment in FIG. 2, illustrates a single nano membrane filter 20 however the present application contemplates a plurality of nano membrane filters being within the nano membrane filter system. A preferred form of the present application contemplates a plurality of nano membrane filters 20 within a fluid tight housing 21. The present application further contemplates that the PFAS-contaminated water passes along the outside of the nano membrane filter within the mechanical housing and the substantially clean water passes through the membrane portion into an internal passage for delivery to the desired need for clean water.

[0044] PF AS is a broadly interpreted term containing many different compounds, and in general the smallest PFAS compound is PFBS having a smallest characteristic of about 0.4 nanometers. Generally PFAS molecules subject to environmental regulations are less than ten (10) nanometers in size and a very large PFAS molecule can be greater than one hundred (100) nanometers.

[0045] With reference to the figures, one embodiment of the nano membrane filter 20 will be described. The nano membrane filter 20 has the interior flow path volume extending along a centerline X. In one form the interior flow path volume has a cylindrical shape and configuration, however other three dimensional shapes and configurations are contemplated herein including but not limited to substantially cylindrical, conical frustum, polygonal prisms, polygonal frustum and multiple channel geometries including honeycomb configurations which geometrically maximize surface area for membrane function while minimizing material required for support. The present application will generally describe the flow path 23 through the nano membrane filter 20 in terms of a cylindrical volume. The membrane surface 28 defining a cylinder shape that having a deviation that is less than 0.004 inches over a length of sixteen (16) inches. However, the present application is not limited to the specific deviation unless specifically stated.

[0046] With reference to FIG. 3, there is an illustrative cross sectional view of one embodiment of nano membrane filter 20. The nano membrane filter 20 includes a support portion 25, a membrane portion 26, a membrane portion 27, a membrane surface 28, and an outer surface 29. The membrane portion includes the membrane surface 28, which defines the outermost radial fluid flow boundary for the interior flow path volume. In one embodiment the membrane surface 28 extends completely around the interior flow path volume and along the entire longitudinal length of the nano membrane filter 20. However other embodiments contemplate the membrane portion 27 and associated membrane surface 28 only extending partially around and / or along the interior flow path volume. For further clarity, in alternate forms of the present application the area(s) where the membrane does not extend may also be sealed so that no molecules will penetrate and / or pass through these areas.

[0047] In one form of the present application the outer surface 29 is cylindrical shaped and is aligned co-axially with the membrane surface 28 about centerline X. In one form the outer surface 29 includes sealing surfaces 30 proximate each end of the outer surface 29 for creating a fluid tight seal within and / or with the fluid tight housing 21. In a preferred form of the present application a sealing surface 60 is formed circumferentially around the membrane surface 28 proximate each end for providing a fluid tight seal within and / or with the fluid tight housing 21. The shape of the outer surface 29 is not limited to a cylindrical shape in the present application and a variety of three dimensional shapes are contemplated herein.

[0048] The membrane portion 26 has a radially located outer surface 26a that abuts the support portion 25 at an inner surface 33 of the support portion 25 and is connected into the support portion 25 in an intermix region 35 defined in the support portion. In one form of the present application the membrane portion 26 is a single cast layer having a thickness within the range of two (2) nanometers to one thousand (1,000) nanometers. The present application in alternative embodiments contemplate the membrane being formed as a plurality of layers that are bonded together. One preferred form of the membrane portion 26 has a thickness within a range of thirty (30) nanometers to fifty (50) nanometers. The membrane portion 26 thickness values do not include the infiltration portion of the membrane material in the intermix region 35 of the support portion 25. The surface roughness of the support surface 33 in contact with the membrane portion is preferably but not limited to being equal to, or smaller than, the desired membrane layer thickness.

[0049] With reference to FIG. 7, there is schematically illustrated in sectional view the intermix region 35 formed in the support portion 25. The intermix region 35 is defined by where the ceramic membrane material would normally pass, through the pores and associated passages defined by the interconnection of the plurality of pores, into support portion 25. The ceramic membrane material passes through the plurality of pores 22 into the support portion 25 to define a continuous structure after being thermally processed independently of the prior fired support portion 25. The present application contemplates a diffusion bond connecting the ceramic membrane material with the support portion 25 in the intermix region 35. The present application contemplates penetration into the intermix region 35 a distance ‘Z’ of at least forty (40) nanometers. With reference to one form of the present application there is contemplated a continuous intermix region 35 that is about one hundred and twenty (120) nanometers. In another form of the present application there is contemplated a continuous intermix region 35 that is about eighty (80) nanometers. However, the present application contemplates other penetration depths. The membrane portion 26 is formed of water insoluble ceramic particles that in one embodiment are cast as a single layer followed by heat treatment to form the applicable structure. In one form the membrane portion is defined by a polycrystalline layer with a porosity within the membrane layer of ten (10) percent to thirty-five (35) or in another embodiment to ten (10) percent to fifty (50) percent with the ceramic material making up the remainder of the layer volume. The porosity of one form of the present application has at least eighty (80) percent open pores and in a preferred form of the present application is greater than ninety (90) percent open pores. The present application contemplates a cast multi-layer membrane portion that is formed of water insoluble ceramic particles followed by a heat treatment to form the applicable structure. In one form of the present application the multi layer membrane portion has porosity levels as previously described for single layer membrane. The present application contemplates other porosity levels for the membrane portion.

[0050] With reference to the figures there is illustratively depicted the plurality of pores 22 in the membrane surface 28 and a plurality of flow paths 50 defined by the interconnection of the pores throughout the membrane portion 26 and the support portion 25. The flow path through the nano membrane 20 having a tortuosity in one embodiment of 1 to 4 and in a more preferred embodiment of 2 to 3, however other flow paths with different tortuosity are contemplated by the application. Particle size distribution in one form of the present application for the membrane portion 26 is that seventy-five (75) percent of the ceramic particles are within + / - twenty (20) percent of the mean particle size. The support and nano membrane can in general be made of any composition that is non-reactive with water and compounds found in water. Ceramics are preferable over polymers due to not swelling in the presence of water and being mechanically stronger.

[0051] Ceramics are preferable to metals, as most metals will react either with water, or compounds in the water like salts, acids, etc. In one form the materials to make up the support and nano membranes can be ceramic compositions including but not limited to the common examples of silica (amorphous and crystalline), alumina, TiO2, ZrO2, CuO, , alumino-silicates, CeO2, and combinations thereof. Ceria, doped ceria, zirconia, doped zirconia with a wide range of dopants and concentrations are non-limiting examples of preferred forms of ceramic membrane portions 26 contemplated by the present application. Ceria (CeCh) precursors include but are not limited to: cerium ammonium nitrate x-hydrate up to ten (10) weight percent, cerium chloride up to ten (10) weight percent, cerium nitrate up to ten (10) weight percent. In a reaction to form nano-particles of cerium oxides, a ph adjuster is needed. In one form this can be tetramethylammonium hydroxide up to twelve (12) weight percent or ammonia up to twelve and one half (12.5) weight percent can be used. A surfactant to stabilize particles is needed. In one form, bicine up to two (2) weight percent. Only one cerium source is required, others are options. One preferred form is cerium ammonium nitrate hexahydrate.

[0052] Characteristics of the ceria (doped and undoped) based membrane portions include: particle size distribution of two (2) to ten (10) nanometers, with a preferred range of two (2) to three and one half (3.5) nanometers; particle sphericity (the measure of how close a shape is to being a theoretical perfect sphere) sphere S=1 is a sphere minimum diameter to a sphere maximum diameter on a single particle, 0.5<S<1.5, with a preferred range of 0.9<S<l.l; and particle roundness (2D closeness to circle R) in a range of 0.7<R<l, with a preferred range of 0.95<R<l. Sphericity is for the pre-sintered particles and affecting packing of these individual and mobile particles, once thermal processing and sintering begins sphericity is no longer applicable to individual particles. FIG. 8 provides a diagrammatic illustration of the relationship between ceramic particles to define the space therebetween. The present application when discussing geometric shapes contemplates that the item may be of the theoretically shape and / or be of a substantially near geometric shape.

[0053] In the doped ceria (Sm, Y, Ca, Gd, etc — doped CeCCh ) the precursors are the same as for ceria, but depending on the dopant and dopant concentration of “X” (where X is up to twenty (20) percent atomic substitutions) the concentration of ceria precursor is reduced by X and X amount of dopant salts (nitrates, chlorides, etc) is added. Ceria (CeCh) precursors include but are not limited to: cerium ammonium nitrate x-hydrate up to ten (10) weight percent, cerium chloride up to ten (10) weight percent, cerium nitrate up to ten (10) weight percent. In a reaction to form nano-particles of cerium oxides, a ph adjuster is needed. In one form this can be tetramethylammonium hydroxide up to twelve (12) weight percent or ammonia up to twelve and one half (12.5) weight percent can be used. A surfactant to stabilize particles is needed. In one form, bicine up to two (2) weight percent. Only one cerium source is required, others are options. One preferred form is cerium ammonium nitrate hexahydrate.

[0054] In the membrane portion 26 embodiments are contemplated as being formed of ceria or doped ceria. In one form the membrane portion 26 is formed of the ceramic particles that are cast as a single layer. As previously discussed the membrane portion 26 is also contemplated as being a multi layer structure. In one form the fired membrane portion is defined by a polycrystalline layer having a thickness of about forty (40) nanometers and intermixing with the support portion up to one hundred and twenty (120) nanometers with a porosity within the membrane layer in one form of ten (10) percent to twenty -five (25) percent or in another form of ten (10) percent to fifty (50) percent with the ceria or doped ceria ceramic material making up the remainder of the layer volume. The porosity in this one form has at least eighty (80) percent open pores and in a preferred form greater than ninety (90) percent open pores. The fired grain size is less than thirty (30) nanometers and in one preferred form is within the range of eight to ten (8-10) nanometers. The plurality of pores 22 in the membrane surface 28 are less than ten (10) nanometers and in one preferred form is within a range of three to five (3-5) nanometers.

[0055] In the membrane portion 26 formed of yttra stabilized zirconia, YSZ, the present application contemplates other stabilizers including Sc, Sm, Ca, Gd instead of just yttra. Some forms of the present application contemplate mixtures of the dopants. Precursors contemplated: yttrium chloride, yttrium nitrate x-hydrate, scandium nitrate, scandium chloride gadolinium nitrate, samarium nitrate, yttrium oxinitrate, zirconium nitrate x- hydrate, zirconal chloride, zirconal nitrate x-hydrate up to ten (10) weight percent. One preferred precursor is yttrium nitrate hexahydrate having sixteen (16) mole percent and zirconal nitrate 2.1 - hydrate having eighty-four mole percent. Depending on dopant and doping concentration of “X” (where X is between ten (10) and twenty (20) percent atomic substitutions) the concentration of zirconium precursor is reduced by X amount, and X amount of dopant salts (nitrates, chlorides, etc,) is added. Tetramethylammonium hydroxide up to twelve and one half (12.5) weight percent, bicine up to two (2) weight percent, ammonia up to twelve and one half (12.5) weight percent.

[0056] In the membrane portion 26 there are embodiments contemplated as formed of yttria stabilized zirconia. In one form the membrane portion 26 is formed of the ceramic particles that are cast as a single layer. As discussed previously the present application contemplates forms of the membrane portion being formed as a multi layer structure. In one form the fired membrane portion is defined by a polycrystalline layer having a thickness of about thirty (30) nanometers and intermixing with the support portion 25 up to eighty (80) nanometers with a porosity within the membrane layer of ten (10) percent to fifty (50) percent, preferably formed with a porosity of ten (10) percent to thirty -five (35) percent with the yttria stabilized zirconia ceramic material making up the remainder of the layer volume. The porosity in this one form has at least eighty (80) percent open pores and in a preferred form has greater than ninety (90) percent open pores. The fired grain size is less than ten (10) nanometers and in one preferred form is within the range of three to five (3-5) nanometers. The pores 22 in the membrane surface 28 are less than seven (7) nanometers in size and in one preferred form are within a range of 0.7 to 1.5 nanometers.

[0057] Characteristics of the yttra stabilized zirconia based membrane portions 26 include: particle size distribution of one half (0.5) nanometers to five (5) nanometers, with a preferred range of one half nanometers (0.5) to two (2) ) nanometers, with a more preferred range of one half nanometer (1 / 2) to one and one half (1.5) nanometer; particle sphericity (the measure of how close a shape is to a theoretical perfect sphere) S=1 is a sphere minimum diameter to a sphere maximum diameter on a single particle, 0.5<S<1.5, with a preferred range of 0.95<S<1.05; and particle roundness (2D closeness to theoretical circle R) in a range of 0.7<R<l, with a preferred range of 0.98<R< 1.

[0058] In the membrane portion 26 there are embodiments contemplated as formed of silica, where it can be any of the five low temperature phases or amorphous, however to obtain the tight particle size and morphology control the vast majority of the silica in the membrane layer should be amorphous, if not completely phase pure amorphous. The present application contemplates that commercially pure material may contain slight contaminations / impurities. The membrane portion 26 is formed of the silica particles that are cast as a single layer. As set forth previously the present application contemplates the membrane portion can also be a multi layer structure. In one form the fired membrane portion is defined by a layer made of many particles having a thickness of about thirty (30) nanometers and intermixing with the support portion 25 up to eighty (80) nanometers with a porosity within the membrane layer of ten (10) percent to fifty (50) percent, preferably formed with a porosity of ten (10) percent to thirty -five (35) percent with the amorphous silica material making up the remainder of the layer volume. The porosity in this one form has at least eighty (80) percent open pores and in a preferred form has greater than ninety (90) percent open pores. The fired grain size is less than ten (10) nanometers and in one preferred form is within the range of three to five (3- 5) nanometers. The pores 22 in the membrane surface 28 are less than seven (7) nanometers in size and in one preferred form are within a range of 0.7 to 1.5 nanometers.

[0059] Characteristics of the amorphous silica based membrane portions 26 include: particle size distribution of one half (0.5) nanometers to five (5) nanometers, with a preferred range of one half nanometers (0.5) to two (2) nanometers, with a more preferred range of one half (1 / 2) nanometer to one and one half (1.5) nanometers; particle sphericity (the measure of how close a shape is to a theoretical perfect sphere) sphere S=1 is a sphere minimum diameter to a sphere maximum diameter on a single particle, 0.5<S< 1.5, with a preferred range of 0.95<S<1.05; and particle roundness (2D closeness to theoretical circle R) in a range of 0.7<R<l, with a preferred range of 0.98<R< 1.

[0060] With reference to FIG. 4, there is depicted an illustrative view of one form of the support portion 25 having a material size gradient from inner surface 33 to outer surface 29. The drawing is purely illustrative to show that in one form the material particle size at inner surface 33 is smaller than the material particle size at outer surface 29; however the drawing does not show actual particle sizes but is depictive of the understanding of the relative size. The present application contemplates a support portion 25 that has a substantially homogenous distribution of particle size and pore size locally within the support portion; both of which radially increase in size . A further embodiment contemplates a two zone support portion with each having a substantially homogenous distribution of particle size through their respective zones and each zone having a different average particle size.

[0061] With reference to FIG. 5, there is depicted an illustrative view of one embodiment of a portion of the membrane surface 28 disposed in flow communication with the PFAS contaminated water flowing through the nano membrane fdter 20. The membrane surface 28 has a plurality of passages in fluid flow communication with pores 28 that are spread across the cylindrical surface to allow the passage of substantially cleaned water through the membrane portion 26 into the support portion 25. The membrane portion physically allows only the passage of molecules having a size less than or equal to than 0.4 nanometers to pass therethrough, thereby filtering PFAS molecule(s) and / or material from the water being passed to the dwelling. The pore 22 size distribution on the membrane surface in one embodiment is within a range of 0.5 nanometers to 3 nanometers, with another embodiment having a pore 22 size distribution of 0.5 nanometers to 1.7 nanometers and a preferred form having a pore 22 size distribution of 0.5 nanometers to 1.2 nanometers. In one form the pore 22 density in the membrane surface area 28 is randomly distributed and has a value greater than three (3) pores per one hundred (100) nanometers2. The total surface area of the membrane surface area 28 has a uniform pore distribution with a pore 22 density greater than three (3) pores per one hundred (100) nanometers2. The present application contemplates other pore sizes and pore densities in the membrane portion.

[0062] Referring to the figures, the support portion 25 will be further described. One embodiment of the present application contemplates a single cast support portion 25 having a thickness of at least 0.5 millimeters. As discussed below the present application contemplates a multi layer structure that is bonded together A preferred wall thickness of the support portion 25 is about 1.5 millimeters for one application where the nanometer membrane portion is about one hundred and twenty (120) nanometers. However, other physical sizes are contemplated and will be adjusted to address the pressures and stress related to the water pressure of the water flowing in the system. The present application contemplates a dual cast support portion 25 with a first region 25a and a second region 25b. The two regions are formed in the same process as microstructurally distinct layers one on top of the other and sintered together. In one embodiment layer 25b being in the range of about one (1) to one hundred (100) microns thick and formed of a substantially similar material as used in the single cast support port 25 described above. In another form the layer 25b is about one hundred (100) microns thick. In one form the region 25a having a wall thickness of about 1.4 millimeters of water insoluble ceramic particles with an average particle size of about three (3) microns and pores and passages through the region 25a of about one (1) to one and one half (1.5) microns and a surface roughness of about three hundred (300) nanometers at the inner face 80 with the region 25b.

[0063] In one form of the present application the ceramic material for the single cast support portion 25 and the region 25a of the dual cast support portion 25 is formed of alumina particles, however the application contemplates other support portions formed of silica, zirconia and multi-cation compounds Precursors: nano-particle alpha alumina particles (monodispersed size having an average particle size of three hundred (300) nanometers), ammonium hydroxide (a ph adjustor), Darvan 821 (dispersing agent / dispersant), polyvinyl alcohol (PVA) is the binder. A preferred mixture of the precursors is: AI2O3 about 50 wt. %; Darvan 821 about 3 wt. %; PVA about 3 wt. %; ammonium hydroxide < 1 wt. %; and the remainder water. The prior example is just one description of the utilization of a three hundred (300) nanometer particles and utilizing appropriate adjustments relative to ph, binder and dispersant. The present application will describe the support structure generally in terms of 25 and is equally applicable to region 25a of the dual cast support portion.

[0064] As discussed previously the support portion 25 is formed of water insoluble ceramic particles that in one form is formed as a single cast structure. The fired support portion 25 is defined as a polycrystalline alpha phase alumina structure. With reference to FIG. 4, there is illustrated the support portion 25 with a gradient structure with smaller particles proximate the inner surface 33 and pores 100 formed in the inner surface 33. Larger particles are located proximate the outer surface and larger pores 101 formed in the outer surface 29. In one form particles proximate the inner surface 33 have an average size of two hundred (280) nanometers and a plurality of pores 33 having a size of about forty (40) nanometers. In one form the outside surface 29 has a plurality of pores 101 formed therein with an pore size of about one hundred (100) nanometers and the average particle size adjacent the outside surface 29 is three hundred and thirty (330) nanometers. The support portion 25 including 25a has bulk average particles size of about three hundred (300) nanometers and the bulk average pore size is about eighty (80) nanometers. The present application considers that particle size distribution and particle size ratios are important considerations for the control of pore size. In one form of the present application at least seventy-five (75) percent of the ceramic particles are + / - twenty (20) percent of the average ceramic particle size. A preferred form of the support portion 25 and region 25a will have great than ninety-five (95) percent of the ceramic particles within + / - 17percent of the average particle size.

[0065] In one form the support portion 25 including region 25a have a porosity in the range of twenty-five (25) volume percent to forty-five (45) volume percent with open porosity being at least seventy -five (75) percent; in a preferred form the open porosity being greater than ninety -nine (99) percent. A preferred embodiment having a porosity of thirty-eight (38) to thirty-nine (39) volume percent with the remaining volume being the ceramic material. The pore 100 size at the inner surface 33 is in one form being less than forty (40) nanometers and in a preferred form has a size less than forty (40) nanometers and a distribution of + / - 5 nanometers. The localized pore 100 distribution is random, with an average pore 100 distribution of about five (5) pores per micron2.

[0066] Across the outer surface 33 this pore distribution is substantially uniform. The tortuosity through the nanomembrane being in a range of 2 to 3, with one form being in the range of 2.4- 2.6. The alumina particles in one embodiment having a particle size distribution of two hundred thirty (230) nanometers to three hundred and seventy (370) nanometers with an average size of about three hundred (300) nanometers. The particle sphericity, ( the measure how close a shape is to a theoretical sphere) (S=l) is a sphere minimum diameter to maximum diameter on a single particle, 0.2<S<3. A preferred form of the present application has a sphere ratio of 0.90<S<l .1. The particle roundness (2D closeness to circle R) is within a range of 0.3<R<l, and more preferably the particle roundness R>0.9.

[0067] The inner surface 33 of the support portion 25 having a surface roughness less than seventy (70) nanometers, and in one form of the present application is less than fifty (50) nanometers and in a another form is within a range of twenty -five (25) to twenty-six (26) nanometers; and in a more preferred form is less that twenty-six nanometers. In the embodiment where the nanometer membrane 20 having a tubular inner volume the characteristics include: circularity ( R) of the diameter of the structure defining the tubular inner volume is defined where R>0.95 and preferably R>0.995; parallelness of the structure defining the walls of the tubular inner volume in one form is a deviation of less than 0.004 inches over a sixteen (16) inch length.

[0068] One specific embodiment contemplated herein relate to tubular porous support formed of alumina particles having an average particle size of three hundred (300) nanometers sintered to yield a microstructure with a pore size at the membrane interface surface of about forty (4) nanometers. The support having a bulk pore size of about eighty (80) nanometers that gradiently increases from the membrane interface surface to an outer surface of the structure. A primary membrane layer of about three (3) nanometers cerium oxide spherical particles with a one and one-half nanometer pore size. The primary membrane layer is about one hundred (100) nanometers thick is deposited on the membrane interface surface which has a surface roughness of about twenty-five (25) nanometers. Another membrane layer comprised of yttria stabilized zirconia particles of about three-fourths (.75) nanometers to one and one half (1.5) nanometers with pores of about three tenths (0.3) nanometers and having a thickness of fifty (50) nanometers to one hundred nanometers. The another membrane layer is deposited on top of the primary membrane layer. The support and membrane layers having a porosities of about thirty-eight (38) volume percent, with the vast majority of the pores being open pores as opposed to closed pores.

[0069] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and / or “a portion” is used the item can include a portion and / or the entire item unless specifically stated to the contrary.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a cast body having a three dimensional passage adapted to receive the flow of water, the three dimensional passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a plurality of passageways in the body that are disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of chemically inert water insoluble first ceramic particles when unfired having a substantially spherical shape with a particle size distribution and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner; the plurality of pores includes a first plurality of pores in the inner surface with a first pore size of about forty nanometers and separated by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, and the average pore size of the plurality of pores is about eighty nanometers, the body has a volume porosity within a range of twenty -five to forty -five percent; a cast membrane abutting the inner surface and formed of a plurality of chemically inert water insoluble second ceramic particles when unfired having a substantially spherical shape with an average particle size within a range of one to five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores with an average fourth pore size less than one and one half nanometers, the fourth plurality of pores allows only the passage of the flow ofmolecules having a size less than or equal to 0.4 nanometers to enter into fluid communication with the plurality of passageways in the body; and wherein the membrane is interconnected with the body at the inner surface and extends into the intermix portion and is defined by a sintered structure connection that is fired distinct from the body.

2. A nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a sintered cast ceramic body having a cylindrical opening formed therein, the cylindrical opening has an inner surface and an outer surface spaced from the inner surface, the body formed of chemically inert water insoluble first ceramic particles when unfired having a near spherical shape with an average particle size of about three hundred nanometers and a particle size gradient increasing from the inner surface to the outer surface, the body has a poly-crystalline microstructure with a plurality of pores with a size less than forty nanometers formed in the inner surface and separated by portions of the inner surface having a surface roughness of less than seventy nanometers, the cast ceramic body has a volume porosity within a range of twenty-five to forty five percent; and a ceramic membrane with a cubic structure disposed on and connected with the inner surface by an in-situ secondary firing, the ceramic membrane formed of a plurality of chemically inert water soluble second ceramic particles when unfired having a near spherical shape with an average particle size less than five nanometers and a second inner surface having a random distribution of second plurality of pores with a pore size less than or equal to one and one half nanometers for receiving water separated from the PFAS contaminated water, the ceramic membrane having a volume porosity within a range of ten to fifty percent; and wherein the second plurality of pores allows only the passage of molecules having a size less than or equal to 0.4 nanometer to pass into the body.

3. A nano membrane filter for separating a PFAS contaminant in a volume of water, comprising: ceramic substrate means for supporting a cast ceramic membrane including a surface in fluid flow communication with the PFAS contaminant in the volume of water, the ceramic substrate means being a fired structure; the membrane allows only the flow of molecules with a particle size less than or equal to 0.4 nanometers into the ceramic substrate means; wherein the membrane is a formed of a plurality of substantially spherical shaped ceramic particles when un-thermally processed and having an average size within the range of one to five nanometers; wherein the membrane is connected into the ceramic substrate means by thermal processing independently of the ceramic substrate means; and wherein the ceramic substrate means has a volume porosity within the rang of twenty -five to forty-five percent.

4. A nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a ceramic body having a three dimensional passage adapted to receive the PFAS- contaminated flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the cleaned water separated from the PFAS-contaminated water into a plurality of passageways in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of pure alumina particles having in an unfired state a near spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness of less than seventynanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of gadolinia doped cerium oxides particles have an unfired near spherical shape with an average particle size of about five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than three nanometers, the fourth plurality of pores disposed in fluid flow communication with the flow of water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and into fluid communication with the plurality of pores and passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a fired connection distinct from the firing of the body.

5. A nano membrane filter for separating a PFAS contaminant in a flow of water, comprising: a cast ceramic body having a cylindrical passage adapted to receive the flow of water, the cylindrical passage has an inner cylindrical surface and an outer surface spaced from the inner cylindrical surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a plurality of passageways in the body disposed in fluid communication with the inner cylindrical surface and the outer surface; the body formed of a plurality of pure alumina particles having an unfired substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and hasan increasing particle size gradient from the inner cylindrical surface to the outer surface, the body includes an intermix portion proximate the inner cylindrical surface; the plurality of pores includes a first plurality of pores in the inner cylindrical surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second average pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner cylindrical surface of the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner cylindrical surface and formed of a plurality of cubic yttria stabilized zirconia ceramic particles having an unfired near spherical shape with an average particle size within a range of one to one and one half nanometers, the membrane is a sintered structure with a second cylindrical surface with a random distribution of fourth pores therein with an average fourth pore size less than one nanometer, the fourth plurality of pores in fluid flow communication with the water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a thermally processed connection distinct from the fired body.

6. A nano membrane filter for separating a PFAS-contaminated volume of water, comprising: a fluid tight mechanical housing including an inlet for receiving the PFAS- contaminated volume of water; a sintered cast ceramic body disposed within the mechanical housing and having an internal fluid flow passage formed therein, the body spaced from the mechanicalhousing to define a fluid flow path therebetween, one of the internal fluid flow passage and the fluid flow path in fluid communication with the inlet for receiving the PFAS- contaminated water and the other configured to receive the cleaned water with PFAS contaminant removed; the body formed of a plurality of chemically inert water insoluble first ceramic particles having a substantially spherical shape when unfired and an average particle size of about three hundred nanometers, the body having a plurality of pores for the passage of the water with the PFAS contaminant removed, the plurality of pores including a first plurality of pores on a first surface of the body for receiving the water with the PFAS contaminant removed and a second plurality of pores on a second surface of the body for allowing the passage of the water with the PFAS contaminant removed from the body, the body including an intermix portion proximate the first surface, the body further has a bulk porosity within a range of twenty-five to forty -five percent; the first surface configured for receiving a ceramic membrane thereon, the first surface having an as cast surface roughness of less than seventy nanometers to which the ceramic membrane is connected to and includes an intermix portion consistent with thermal processing independently of the sintering of the body, the ceramic membrane formed of a plurality of chemically inert water insoluble second ceramic particles having a substantially spherical shape when unfired and an average particle size within a range of one to five nanometers, the membrane physically allows only the passage of molecules having a size less than or equal to 0.4 nanometer.

7. A nano membrane filter for separating a PFAS-contaminated volume of water, comprising: a fluid tight mechanical housing including an inlet for receiving the PFAS- contaminated volume of water; a sintered cast ceramic body disposed within the mechanical housing and having an internal fluid flow passage formed therein, the body spaced from the mechanical housing to define a fluid flow path therebetween, one of the internal fluid flow passage and the fluid flow path in fluid communication with the inlet for receiving the PFAS-contaminated water and the other configured to receive the cleaned water with PFAS contaminant removed; the body having a first body portion and a second body portion that are sintered together, the first body portion formed of a plurality of chemically inert water insoluble first ceramic particles having a substantially spherical shape when unfired and an average particle size of about three hundred nanometers, the second body portion formed of a plurality of chemically inert water insoluble third ceramic particles having a substantially spherical shape when unfired and an average particle size of about three microns, the body having a plurality of pores for the passage of the water with the PFAS contaminant, the plurality of pores including a first plurality of pores on an outer surface of the second body portion for receiving the water with the PFAS contaminant removed and a second plurality of pores for allowing the passage of the water with the PFAS contaminant removed from the body, the body including an intermix portion proximate the outer surface, the body further has a bulk porosity of about twenty-five to forty -five percent; the outer surface configured for receiving a ceramic membrane thereon, the outer surface having an as cast surface roughness of less than seventy nanometers to which the ceramic membrane is abutting and connected to and into the intermix portion by thermal processing independent of the sintering of the body, the ceramic membrane formed of a plurality of chemically inert water insoluble second ceramic particles having a substantially spherical shape when unfired and an average particle size within a range of one to five nanometers, the fired membrane physically allows only the passage of the molecules having a size less than or equal to 0.4 nanometers.

8. A nano membrane filter for separating a PFAS contaminant from a flow of water, comprising: a cast ceramic body having a three dimensional passage adapted to receive the PF AS-contaminated flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the cleaned water separated from the PFAS-contaminated water into a plurality of passageways in the body disposed in fluid communication with the inner surface and the outer surface;the body formed of a plurality of ceramic particles having in an unfired state a substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with an average second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of cerium oxide particles have an unfired substantially spherical shape with an average particle size of about five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one and one half nanometers, the fourth plurality of pores disposed in fluid flow communication with the flow of water and allows only the passage of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a diffusion bond formed distinct from the firing of the body.

9. A nano membrane filter for separating a PFAS contaminant entrained in a flow of water, comprising: a cast ceramic body having a three dimensional passage adapted to receive the flow of water, the passage has an inner surface and an outer surface spaced from the innersurface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a plurality of interconnected pores in the body and disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of ceramic particles having in an unfired state a substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore diameter of less than or equal to forty nanometers and separated by a portion of the inner cylindrical surface having an average surface roughness less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner cylindrical surface and formed of a plurality of cubic centered yttria stabilized zirconia ceramic particles have an unfired substantially spherical shape with an average particle size within a range of one to three nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one nanometer, the fourth plurality of pores in fluid flow communication with the flow of water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores defining passageways in the body; and wherein the membrane is interconnected with the body at the inner cylindrical surface, the connection extends into the intermix portion and is defined by a thermally processed connection distinct from the sintered body.

10. A filter for separating a PFAS contaminant from a flow of water, comprising: a cast body having a passage adapted to receive the flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a passageway in the body that is disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of chemically inert water insoluble first ceramic particles when unfired having a substantially spherical shape with a particle size distribution of about seventy nanometers and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has an increasing particle size gradient from the inner surface to the outer surface, the body includes an intermix portion proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with a first pore size of about forty nanometers and separated from one another by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, and the average pore size of the plurality of pores is about eighty nanometers, the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of chemically inert water insoluble second ceramic particles when unfired having a substantially spherical shape with an average particle size within a range of one to five nanometers, the membrane is a sintered structure with a second surface and an abutment surface, the second surface includes a random distribution of fourth pores with an average fourth pore size within a range of one and five nanometers, the fourth plurality of pores allows only the passage of molecules having a size less than or equal to 0.4 nanometers to enter into fluid communication with the plurality of pores and passageway in the body; andwherein the abutment surface of the membrane is interconnected with the body at the inner surface and extends into the intermix portion and is defined by a diffusion bond connection that is formed distinct from the firing of the body.

11. A nano membrane filter for separating a PFAS contaminant in a volume of water, comprising: a fired cast ceramic substrate including a three dimensional surface for supporting a cast ceramic membrane; the membrane abutting the three dimensional surface and has a surface in fluid communication with the PFAS contaminant in the volume of water, the membrane only allows the passage of the material having a particle size less than or equal to 0.4 nanometers into the ceramic substrate; wherein the membrane is a formed of a plurality of substantially spherical shaped ceramic particles when un-thermally processed and having an average size within the range of one to five nanometers; wherein the membrane is connected into the ceramic substrate by a diffusion bond formed independent of the fired ceramic substrate; and wherein the ceramic substrate has a volume porosity within the range of twenty - five to forty-five percent.

12. A nano membrane filter for separating a PFAS contaminant in a volume of water, comprising: ceramic substrate means for supporting a cast ceramic membrane including a surface in fluid flow communication with the PFAS contaminant in the volume of water, the ceramic substrate means being a fired three dimensional structure; the membrane has a surface in fluid communication with the PFAS contaminant in the volume of water, the membrane allows only the passage of material with a particle size less than or equal to 0.4 nanometers into the ceramic substrate; wherein the membrane is a formed of a plurality of substantially spherical shaped ceramic particles when un-thermally processed and having an average size within a range of one to five nanometers;wherein the membrane is connected into the ceramic substrate means by thermal processing independent of the ceramic substrate means; and wherein the ceramic substrate means has a volume porosity within the range of twenty -five to forty-five percent.

13. A filter for separating a PFAS contaminant from a flow of water, comprising: a cast ceramic body having a three dimensional passage formed therein for receipt of the water flow, the body has an inner surface and an outer surface and a plurality of pores for the passage of the water separated from the PFAS-contaminated water into a passageway in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of pure alumina particles having in an unfired state a substantially spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has a particle size gradient increasing from the inner surface to the outer surface, the body includes an intermix portion extending proximate the inner surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with an average second pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner surface and the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of cerium oxides ceramic particles have an unfired substantially spherical shape with an average particle size of about five nanometers, the membrane is a sintered structure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one and one half nanometers, the fourth plurality of pores disposed in fluidflow communication with the flow of water and only permits a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageway in the body; and wherein the membrane is interconnected with the body at the inner surface, the connection extends into the intermix portion and is a diffusion bond connection distinct from the firing of the body.

14. An apparatus for separating a PFAS contaminant in a flow of water, comprising: a cast ceramic body having a passage adapted to receive the flow of water, the passage has an inner surface and an outer surface spaced from the inner surface, the body includes a plurality of pores for the passage of the water separated from the PFAS contaminant into a passageway in the body disposed in fluid communication with the inner surface and the outer surface; the body formed of a plurality of pure alumina particles having an unfired near spherical shape and an average particle size of about three hundred nanometers, the body is a sintered structure with a poly-crystalline microstructure and has a particle size gradient increasing from the inner surface to the outer surface, the body includes an intermix portion proximate the inner cylindrical surface; the plurality of pores includes a first plurality of pores in the inner surface with an average first pore size of less than or equal to forty nanometers and separated by a portion of the inner surface having an average surface roughness of less than seventy nanometers, the plurality of pores includes a second plurality of pores in the outer surface with a second average pore size of about one hundred nanometers, the plurality of pores includes a third plurality of pores located within the body and spaced from the inner cylindrical surface of the outer surface, further the plurality of pores has an average pore size of about eighty nanometers; the body has a volume porosity within a range of twenty -five to forty-five percent; a cast membrane abutting the inner surface and formed of a plurality of cubic yttria stabilized zirconia ceramic particles having an unfired near spherical shape with an average particle size within a range of one to two nanometers, the membrane is a sinteredstructure with a second surface with a random distribution of fourth pores therein with an average fourth pore size less than one nanometer, the fourth plurality of pores in fluid flow communication with the flow of water and allows only a flow of molecules having a size less than or equal to 0.4 nanometers to pass through the membrane and enter into fluid communication with the plurality of pores and passageway in the body; and wherein the membrane is interconnected with the body at the inner surface, the connection extends into the intermix portion and is defined by a thermal bond sintering the body.

15. A nano membrane filter for separating a PF AS -contaminated volume of water, comprising: a fluid tight mechanical housing including an inlet for receiving the PFAS- contaminated volume of water; a sintered cast ceramic body disposed within the mechanical housing and having an internal fluid flow passage formed therein, the body spaced from the mechanical housing to define a fluid flow path therebetween, one of the internal fluid flow passage and the fluid flow path in fluid communication with the inlet for receiving the PFAS- contaminated water and the other configured to receive the cleaned water with PFAS contaminant removed; the body having a first body portion and a second body portion that are sintered together, the first body portion formed of a plurality of chemically inert water insoluble first ceramic particles having a substantially spherical shape when unfired and an average particle size of about three hundred nanometers, the second body portion formed of a plurality of chemically inert water insoluble third ceramic particles having a substantially spherical shape when unfired and an average particle size of about three microns, the body having a plurality of pores for the passage of the water with the PFAS contaminant, the plurality of pores including a first plurality of pores on an outer surface of the second body portion for receiving the water with the PFAS contaminant removed and a second plurality of pores for allowing the passage of the water with the PFAS contaminant removed from the body, the body including an intermix portion proximate the outer surface, the body further has a bulk porosity of about twenty-five to forty -five percent;the outer surface configured for receiving a ceramic membrane thereon, the outer surface having an as cast surface roughness of less than seventy nanometers to which the ceramic membrane is connected and to the intermix portion by a diffusion bond formed independent of the sintering of the body, the ceramic membrane formed of a plurality of chemically inert water insoluble second ceramic particles having a substantially spherical shape when unfired and an average particle size within a range of one to five nanometers, the fired membrane physically allows only the passage of the of material having a size less than or equal to 0.4 nanometers.

16. The nano membrane filter of claims 1-1 , wherein the average surface roughness is about 25.

17. The nano membrane filter of claims 1-15, wherein the average surface roughness is within range of 25 to 26 nanometers.

18. The nano membrane filter of claims 1-15, wherein the volume porosity is within a range of 38 to 39 %19. The nano membrane filter of claims 17- 18, wherein the volume porosity being at least seventy-five percent open.

20. The nano membrane filter of claims 17-18, wherein the volume porosity being at least ninety-nine percent open pores opposed to closed pores which lack uninterrupted pathways to at least two surfaces.

21. The nano membrane filter of claims 1-5, 8 and 9-13, wherein the nanomembrane filter is disposed within a fluid tight mechanical housing.

22. The nano membrane filter of claims 1-15, wherein the plurality of pores are substantially uniformly distributed across the surface.

23. The nano membrane filter of claims 1-15, wherein the membrane is connected to the body by a connection consistent with Rapid Thermal Processing.

24. The nano membrane filter of claims 1, 3, 4, 6, 9-15, wherein the passage is one of substantially cylindrical, conical frustum, polygonal prisims and polygonal frustum.

25. The nano membrane filter of any prior claim, wherein the membrane only allowing flow through a portion of the membrane surface area.

26. The nano membrane filter of any prior claim, wherein the membrane has portions that are sealed so that no molecules will penetrate through these areas.

27. The nano membrane filter of any prior claim, wherein the membrane having a thickness within a range of two to one thousand nanometers.

28. The nano membrane filter of claims 1-27, wherein the membrane has a thickness of thirty to fifty nano meters.

29. The nano membrane filter of claims 1-15, wherein the membrane has a thickness less than or equal to the surface roughness.

30. The nano membrane filter of any prior claim, wherein the intermix region is defined by ceramic passing into the plurality of interconnected pores in the body.31 . The nano membrane filter of any prior claims, wherein the intermix region extends into the body about one hundred and twenty nano meters.

32. The nano membrane filter of claims 1-30, wherein the intermix region extends into the body about at least forty nano meters.

33. The nano membrane filter of any prior claim, wherein the membrane having a porosity of ten to thirty -five volume percent.

34. The nano membrane filter of claims 1-32, wherein the membrane having a porosity of ten to fifty volume percent.

35. The nano membrane filter of any prior claim, wherein the flow paths through the nano membrane filter having a tortuosity of one to four.

36. The nano membrane filter of claims 1-34, wherein the flow paths through the nanomembrane filter having a tortuosity of two to three.

37. The nano membrane filter of claims 1, 2, 3, 6, and 7-13, wherein the support portion and membrane can be formed of ceramics including silica, alumina, TiCh, ZrCh, CuO, , alumino-silicates, CeCh doped versions thereof and combinations thereof.

38. The nano membrane filter of any prior claim, wherein the fired grain size of the membrane is less than thirty nanometers.

39. The nano membrane filter of claims 1-37, wherein the fired grain size is within the range of eight to ten nano meters.

40. The nano membrane filter of claims 1-1 , wherein the pore size distribution of the membrane within a range of 0.5 nanometers to 3.0 nanometers.

41. The nano membrane filter of any prior claims, wherein the plurality of pores on the membrane surface area is randomly distributed and has a density equal to or greater than three pores per one hundred nanometers242. The nano membrane filter of claims 1-40, wherein the plurality of pores on the membrane surface area is uniformly distributed and has a density value greater than three pores per one hundred nanometers243. The nano membrane filter of claims 1-15, wherein seventy five percent of the ceramic particles are within + / - twenty percent of the ceramic particle average size for the body.

44. The nano membrane filter of claims 1-15, wherein ninety -five percent of the ceramic particles are within + / - seventeen percent of the ceramic particle average size for the body.

45. The nano membrane filter of claim 4, wherein the particle size distribution of the ceramic particles within a range of 230 to 370 nanometers.

46. The filter of any previous claim, wherein the particles are spherical.

47. The filter of any previous claim, wherein the body is formed as a single case structure.

48. The filter of any of claims 1-46, wherein the membrane is formed as a multi layer structure.

49. The membrane filter of claims 1, wherein the sintered structure connection is formed as a diffusion bond.

50. The membrane filter of claim 2, wherein the in-situ secondary firing is defined by a diffusion bond.

51. The membrane filter of claims 3 and 6, 7 12, wherein the thermal processing independently of the ceramic substrate means is a diffusion bond.

52. The membrane filter of claim 4, wherein the fired connection distinct from the firing of the body is a diffusion bond.

53. The membrane filter of claims 5 and 9, wherein the thermally processed connection distinct from the fired body is a diffusion bond.

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