Filter media and elements

• US 10,357,730 B2
• Filed: 03/05/2014
• Issued: 07/23/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Donaldson Company Incorporated
• Original Assignee: Donaldson Company Incorporated
• Inventors: Gao, Qiong, Tronnes, Gregory S., Yadav, Rakesh Kumar, Madden, Michael A.
• Primary Examiner(s): Clemente, Robert
• Application Number:
  US14/776,447
• Publication Number:
  US 20160129381A1
• Time in Patent Office: 1,966 Days
• CPC Class Codes: B01D 2239/0233 Island-in-sea
• CPC Class Codes: B01D 2239/0428 Rendering the filter material hydrophobic
• CPC Class Codes: B01D 2239/0435 Electret apparatus incorporating such gas filtering material B01D46/0032
• CPC Class Codes: B01D 2239/0478 on a layer of the filter
• CPC Class Codes: B01D 2239/0622 Melt-blown
• CPC Class Codes: B01D 2239/0627 Spun-bonded
• CPC Class Codes: B01D 2239/065 More than one layer present in the filtering material apparatus incorporating such gas filtering material B01D2275/10
• CPC Class Codes: B01D 2239/0654 Support layers
• CPC Class Codes: B01D 2239/0681 The layers being joined by gluing
• CPC Class Codes: B01D 2239/086 Binders between particles or fibres
• CPC Class Codes: B01D 2239/1233 Fibre diameter
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: B01D 39/2017 the material being filamentary or fibrous
• CPC Class Codes: B01D 39/2024 otherwise bonded, e.g. by resins
• CPC Class Codes: B01D 46/521 using folded, pleated material

Abstract

Fibrous filter medium that includes a melt-blown filter layer comprising melt-blown fibers and a high-efficiency glass-containing filter layer comprising glass fibers.

Claims

1. An air filter medium comprising:

a melt-blown filter layer comprising melt-blown fibers; and

a high-efficiency glass-containing filter layer comprising glass fibers and multi-component binder fibers; and

an optional support layer;

wherein the layers are configured and arranged for placement in an air stream;

further wherein the glass-containing layer comprises a hydrophobic coating, wherein the glass-containing layer is coated with the hydrophobic coating.

2. The filter medium of claim 1, wherein the hydrophobic coating comprises a fluorochemical.

3. The filter medium of claim 1, wherein the melt-blown filter layer is the most upstream layer.

4. The filter medium of claim 1, wherein the glass-containing filter layer is positioned between the melt-blown filter layer and the support layer.

5. The filter medium of claim 1, wherein the multi-component binder fibers of the glass-containing filter layer comprise bicomponent fibers having a low melting point polyester sheath and a higher melting point polyester core.

6. The filter medium of claim 1, wherein the melt-blown filter layer is electrostatically charged.

7. The filter medium of claim 1 comprising a support layer, wherein the support layer is a spunbond layer.

8. The filter medium of claim 1, wherein the filter medium displays a hydrostatic head of at least 10 inches (25.4 cm) of water.

9. The filter medium of claim 1, wherein two or more layers are laminated together.

10. An air filter medium comprising:

a melt-blown filter layer comprising melt-blown fibers having an average diameter of greater than 1.5 microns; and

a high-efficiency glass-containing filter layer comprising glass fibers having an average diameter of less than 2 microns and multi-component binder fibers; and

a support layer;

wherein the melt-blown filter layer is the most upstream layer and the glass-containing layer is positioned between the melt-blown layer and the support layer.

11. The filter medium of claim 10, wherein the glass-containing layer comprises a hydrophobic coating, wherein the glass-containing layer is coated with the hydrophobic coating.

12. The filter medium of claim 11, wherein the hydrophobic coating comprises a fluorochemical.

13. The filter medium of claim 10, wherein two or more layers are laminated together.

14. The air filter medium of claim 10, wherein the multi-component binder fibers of the glass-containing filter layer comprise bicomponent fibers having a low melting point polyester sheath and a higher melting point polyester core.

15. The filter medium of claim 10, wherein the melt-blown filter layer is electrostatically charged.

16. The filter medium of claim 10, wherein the support layer is a spunbond layer.