Porous polyurethane foam was evaluated as a potential replacement substrate for the eight nylon meshes currently being used in the diffusion stage of the Nanoparticle Respiratory Deposition (NRD) Sampler. A semi-empirical particle deposition model and preliminary tests were used to select the dimensions of foam substrate needed to match the collection of the NRD sampler at recommended sampling conditions. The foam substrate consisted of a cylinder nominally 25-mm diameter by 40 mm in depth, housed in a conductive plastic cassette cowl (internal diameter of 23 mm) compatible with the existing NRD sampler. Pristine foam was evaluated for metals content via acid-assisted microwave digestion and inductively coupled plasma-optical emissions spectroscopy (ICP-OES) chemical analysis. Foam collection efficiency was evaluated using salt (NaCl) and metal fume test aerosols in independent tests. Foam collection efficiency was compared to the nanoparticulate matter (NPM) criterion (established to reflect the total deposition in the human respiratory system for particles smaller than 300 nm) and theoretical modeling.
The collection efficiency of NaCl particles was similar to the NPM criterion (R2 = 0.98) and the model underestimated the experimental efficiency (R2 = 0.38). Increased collection efficiency of metal fume was observed for particles larger than 70 nm presumably due to increased interception effects of fractal shaped particles. The pressure drop across the pristine foam was 1/12th that of the nylon meshes. Foam and nylon meshes were loaded with metal fume particles to evaluate performance under simulated field conditions. Changes in collection efficiency and pressure drop were used as measures of performance. Foam had substantially lower changes in collection efficiency and pressure drop with ~ 19 mg metal fume loaded compared to the nylon meshes with ~ 3 mg metal fume loaded.