Hydroentangled filter media and method

• US 20020187703A1
• Filed: 01/16/2002
• Published: 12/12/2002
• Est. Priority Date: 01/17/2001
• Status: Active Grant

• Current Assignee: Avintiv Specialty Materials Inc. (Berry Global Group Inc.)
• Original Assignee: Polymer Group Incorporated (Berry Global Group Inc.)
• Inventors: Hao, Ping, Carlson, Cheryl, Pearce, Charles Eric, Putnam, Michael, de Leon, Sergio
• Granted Patent: US 7,015,158 B2
• Time in Patent Office: Days
• US Class Current: 442/408
• CPC Class Codes: B01D 39/163 sintered or bonded
• CPC Class Codes: D04H 1/48 in combination with at least one other method of consolidation
• CPC Class Codes: D04H 1/49 entanglement by fluid jet in combination with another consolidation means
• CPC Class Codes: D04H 1/495 for formation of patterns, e.g. drilling or rearrangement
• CPC Class Codes: D04H 18/04 with water jets
• CPC Class Codes: Y10T 428/2904 Staple length fiber
• CPC Class Codes: Y10T 428/2915 including textile, cloth or fabric
• CPC Class Codes: Y10T 442/197 Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/608 Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/632 A single nonwoven layer comprising non-linear synthetic polymeric strand or fiber material and strand or fiber material not specified as non-linear
• CPC Class Codes: Y10T 442/633 Synthetic polymeric strand or fiber material is of staple length
• CPC Class Codes: Y10T 442/666 Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
• CPC Class Codes: Y10T 442/689 Hydroentangled nonwoven fabric
• CPC Class Codes: Y10T 442/69 Autogenously bonded nonwoven fabric

Abstract

A filter media formed in accordance with the present invention comprises hydroentangled, predominantly polyester staple length fibers having a basis weight of no more than about 12 oz/yd². The filter media exhibits a Mullen burst strength of at least about 395 psi, and machine-direction and cross-direction shrinkage of less than about 3%, preferably less than about 2%. The filter media exhibits a machine-direction tensile strength of at least about 105 lb/in, and a cross-direction tensile strength of at least about 110 lb/in.

Claims

1. A method of making a filter media comprising the steps of:

providing a precursor web comprising predominant staple length polyester fibers;

providing a foraminous surface, and positioning said precursor web and said foraminous surface; and

hydroentangling said precursor web to form said filter media, said filter media having a basis weight of no more than about 12 oz/yd², and exhibiting a Mullen burst strength of at least about 395 psi, and machine-direction and cross-direction shrinkage of less than about 3%.

2. A method of making a filter media in accordance with claim 1, wherein said foraminous surface is a three-dimensional image transfer device.

3. A method of making a filter media in accordance with claim 1, including:

heat-setting said filter media after said hydroentangling step.

4. A method of making a filter media in accordance with claim 2, wherein said precursor web comprises fusible fibers whereby said filter media is thermally bonded during said heat-setting step.

6. A filter media in accordance with claim 4, wherein said media exhibits machine-direction and cross-direction shrinkage of less than about 2%.

7. A filter media in accordance with claim 4, wherein said filter media exhibits a machine-direction tensile strength of at least about 105 lb/in and a cross-direction tensile strength of at least about 110 lb/in.

8. A filter media in accordance with claim 1, wherein said filter media is a gas filter.

9. A filter media in accordance with claim 1, wherein said filter media is an air filter.

10. A filter media in accordance with claim 1, wherein said filter media is a liquid filter.

5. A filter media comprising hydroentangled, predominant polyester staple length fibers having a basis weight of no more than about 12 oz/yd², a Mullen burst strength of at least about 395 psi, and machine-direction and cross-direction shrinkage of less than about 3%.