FILTER MEDIA WITH A MULTI-LAYER STRUCTURE

• US 20110259813A1
• Filed: 04/27/2010
• Published: 10/27/2011
• Est. Priority Date: 04/27/2010
• Status: Active Grant

• Current Assignee: Hollingsworth & Vose Company
• Original Assignee: Hollingsworth & Vose Company
• Inventors: Guimond, Douglas M., Wertz, John A.
• Granted Patent: US 8,679,218 B2
• Time in Patent Office: Days
• US Class Current: 210/491
• CPC Class Codes: B01D 2239/025 comprising nanofibres apparatus incorporating such gas filtering material see B01D46/546
• CPC Class Codes: B01D 2239/0622 Melt-blown
• CPC Class Codes: B01D 2239/0672 The layers being joined by welding
• CPC Class Codes: B01D 39/1615 of natural origin
• CPC Class Codes: B01D 39/163 sintered or bonded
• CPC Class Codes: B01D 46/546 using nano- or microfibres
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/664 Including a wood fiber containing layer
• CPC Class Codes: Y10T 442/695 Including a wood containing layer

Abstract

Filter media are described. The filter media may include multiple layers. In some embodiments, the filter media include a nanofiber layer adhered to another layer. In some embodiments, the layer to which the nanofiber layer is adhered is formed of multiple fiber types (e.g., fibers that give rise to structures having different air permeabilities and/or pressure drops). In some embodiments, the nanofiber layer is adhered to a single-phase or a multi-phase layer. In some embodiments, the nanofiber layer is manufactured from a meltblown process. The filter media may be designed to have advantageous properties including, in some cases, a high dust particle capture efficiency and/or a high dust holding capacity.

Claims

1. A filter media comprising:

a first layer comprising;

a first phase including a first plurality of fibers and a second plurality of fibers different from the first plurality of fibers; and

a second phase including a third plurality of fibers and a fourth plurality of fibers different from the third plurality of fibers, the third plurality of fibers being the same as or different from the first or second plurality of fibers and the fourth plurality of fibers being the same as or different from the first or second plurality of fibers, wherein the air permeability of the first plurality of fibers is greater than the air permeability of the second plurality of fibers and the air permeability of the third plurality of fibers is greater than the air permeability of the fourth plurality of fibers; and

a second layer attached to the first layer, wherein the second layer is a nanofiber layer.

2. The filter media of claim 1, wherein a ratio of basis weight between the first phase and the second phase ranges between about 10:

90 and about 90;

10.

3. The filter media of claim 1, wherein the first layer and the second layer are attached by an adhesive material.

4. The filter media of claim 1, wherein the first layer includes a polyester having a denier of at least 3.0.

5. The filter media of claim 1, wherein the first layer comprises at least 50% by weight softwood and at least 10% by weight polyester.

6. The filter media of claim 5, wherein the first layer comprises about 80% by weight softwood and about 20% by weight polyester.

7. The filter media of claim 1, wherein the second layer comprises a meltblown material.

8. The filter media of claim 7, wherein the meltblown material includes at least one of polybutylene terephthalate fibers, polypropylene fibers, nylon, or thermoplastic polyurethane.

9. The filter media of claim 1, further comprising a resin content ranging between about 10% and about 50% by weight of the filter media.

10. The filter media of claim 9, wherein the resin content ranges between about 15% and about 30% by weight of the filter media.

11. The filter media of claim 1, wherein the filter media has a dust holding capacity of at least 200 g/m² and an initial efficiency of at least 80%.

12. The filter media of claim 1, wherein the filter media has a permeability of at least 75 CFM.

13. The filter media of claim 1, wherein the filter media has an initial pressure drop of at least 30 Pa.

14. The filter media of claim 1, wherein, in a flat sheet test of the filter media, a period of at least 80 minutes elapses for the filter media to reach a pressure drop of 1,800 Pa.

15. The filter media of claim 1, wherein the filter media has a mullen burst strength that ranges between about 10 kPa and about 100 kPa.

16. The filter media of claim 1, wherein at least one of the first, second, third, and fourth pluralities of fibers are made from an organic polymeric material.

17. The filter media of claim 1, wherein the third plurality of fibers are the same as the first or second plurality of fibers and the fourth plurality of fibers are the same as the first or second plurality of fibers.

18. The filter media of claim 1, wherein the third plurality of fibers are different from the first or second plurality of fibers and the fourth plurality of fibers are different from the first or second plurality of fibers.

19. A filter element comprising the filter media of claim 1.

20. A filter media comprising:

a first layer including a plurality of cellulose fibers; and

a second layer attached to the first layer, wherein the second layer is a nanofiber layer, and

wherein the filter media has a dust holding capacity of at least 200 g/m² and an initial efficiency of at least 80%.

21. The filter media of claim 20, wherein the first layer comprises a first phase including a first plurality of fibers and a second plurality of fibers different from the first plurality of fibers;

and a second phase including a third plurality of fibers and a fourth plurality of fibers different from the third plurality of fibers, the third plurality of fibers being the same as or different from the first or second plurality of fibers and the fourth plurality of fibers being the same as or different from the first or second plurality of fibers, wherein the air permeability of the first plurality of fibers is greater than the air permeability of the second plurality of fibers and the air permeability of the third plurality of fibers is greater than the air permeability of the fourth plurality of fibers.

22. The filter media of claim 21, wherein the first layer includes synthetic fibers having a denier of at least 3.0.

23. The filter media of claim 21, wherein the second layer comprises a meltblown material.

24. A filter element comprising the filter media of claim 21.

25. A method of manufacturing a filter media comprising:

forming a first layer comprising;

forming a first phase including a first plurality of fibers and a second plurality of fibers different from the first plurality of fibers; and

forming a second phase including a third plurality of fibers and a fourth plurality of fibers different from the third plurality of fibers, the third plurality of fibers being the same as or different from the first or second plurality of fibers and the fourth plurality of fibers being the same as or different from the first or second plurality of fibers, wherein the air permeability of the first plurality of fibers is greater than the air permeability of the second plurality of fibers and the air permeability of the third plurality of fibers is greater than the air permeability of the fourth plurality of fibers;

forming a nanofiber layer; and

adhering the first layer and the nanofiber layer together to form a fiber composite.

26. The method of claim 25, wherein the nanofiber layer is formed using a meltblown process.