Cleanable HEPA filter media

• US 6,409,785 B1
• Filed: 08/07/2000
• Issued: 06/25/2002
• Est. Priority Date: 08/07/2000
• Status: Expired due to Term

• Current Assignee: BHA Altair LLC (Parker-Hannifin Corporation)
• Original Assignee: BHA Technologies, Inc.
• Inventors: Doehla, James Roy, Thill, Anthony Joseph, Smithies, Alan
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): PHAM, MINH CHAU THI
• Application Number:
  US09/633,435
• Time in Patent Office: 687 Days
• Field of Search: 554/85, 554/86, 554/87, 554/97, 555/00, 555/02, 555/11, 555/21, 555/22, 55D/IG.2, 55D/IG.39, 555/24, 555/27, 428/36.1
• US Class Current: 55/486
• CPC Class Codes: B01D 2275/10 Multiple layers
• CPC Class Codes: B01D 2279/55 for cleaning appliances, e.g. suction cleaners suction cleaners comprising filters A47L9/10
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: B01D 39/1692 Other shaped material, e.g. perforated or porous sheets
• CPC Class Codes: B01D 46/2414 End caps including additional functions or special forms
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: Y10S 55/02 Vacuum cleaner bags
• CPC Class Codes: Y10S 55/39 Electrets separator
• CPC Class Codes: Y10T 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]

Abstract

A pleatable and cleanable filter media (22) that has a HEPA filtration rating. The filter media (22) includes a porous primary filtration layer (22). The primary filtration layer tending to be less than HEPA rated upon being damaged. A first substrate layer (64) attached to said primary filtration layer (62) for maintaining the shape of the filter media (22). The first substrate layer (64) includes a non-woven filtration media and being less than HEPA rated. A second substrate layer (82) attached to the first substrate layer (64) functioning as a secondary filter in the event of damage to the primary filtration layer (62). The second substrate layer (82) includes a non-woven filtration media and being less than HEPA rated.

Claims

1. A cleanable filter media laminate, said cleanable filter media laminate comprising:

a porous primary filtration layer, said primary filtration layer tending to have less than a HEPA filtration rating upon being damaged, said porous primary filtration layer comprising a microporous expanded polytetrafluoroethyene membrane;

a first substrate layer attached to said primary filtration layer for maintaining shape of said filter media, said first substrate layer comprising a non-woven filtration media and being less than HEPA rated; and

a second substrate layer attached to said first substrate layer to function as a secondary filter in the event of damage to said primary filtration layer, said second substrate layer comprising a non-woven filtration media and being less than HEPA rated; and

said cleanable filter media laminate being pleated and having a HEPA filtration rating.

2. The filter media of claim 1 wherein said porous primary filtration layer is bonded to said first substrate layer.

3. The filter media of claim 1 wherein said porous primary filtration layer is thermally laminated to said first substrate layer.

4. The filter media of claim 1 wherein said first substrate layer is adhesively bonded to said second substrate layer.

5. The filter media of claim 1 wherein said first substrate layer is thermally laminated to said second substrate layer.

6. The filter media of claim 1 wherein said first substrate layer is made from fiber material of a weight in the range of 0.5 oz./sq. yd. to 12 oz./sq. yd. and selected from the group including spun bond polyethylene terephthalate (PET) polyester, polyphenylene sulfide (PPS), or polypropylene (PP), a bicomponent fiber with a polybutylene terephthalate (PBT) sheath and a polyethylene terephthalate (PET) core and a bicomponent fiber with a polyethylene terephthalate (PET) core and a polyethylene (PE) sheath.

7. The filter media of claim 1 wherein said second substrate layer is made from fiber material of a weight in the range 0.25 oz./sq. yd. to 5.0 oz./sq. yd. and selected from the group including glass, melt blown polypropylene (PP), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), ethylene-chlorotrifluorethylene (ECTFE) polyethylene terephthalate (PET) polyester and polyethylene (PE).

8. The filter media of claim 1 wherein said filter media has an air flow regeneration of at least 99% immediately subsequent to being cleaned by loosening accumulated particulates from a filtering surface of said primary filtration layer.

10. The filter media of claim 9 wherein said first substrate layer is made from the filter media of claim 1 wherein said first substrate layer is made from fiber material of a weight in the range of 0.5 oz./sq. yd. to 12 oz./sq. yd. and selected from the group including spun bond polyethylene terephthalate (PET) polyester, polyphenylene sulfide (PPS), or polypropylene (PP), a bicomponent fiber with a polybutylene terephthalate (PBT) sheath and a polyethylene terephthalate (PET) core and a bicomponent fiber with a polyethylene terephthalate (PET) core and a polyethylene (PE) sheath.

11. The filter media of claim 9 wherein said second substrate layer is made from the filter media of claim 1 wherein said second substrate layer is made from fiber material of a weight in the range 0.25 oz./sq. yd. to 5.0 oz./sq. yd. and selected from the group including glass, melt blown polypropylene (PP), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), ethylene-chlorotrifluorethylene (ECTFE) polyethylene terephthalate (PET) polyester and polyethylene (PE).

17. The filter media of claim 16 wherein said first substrate layer is made from the filter media of claim 1 wherein said first substrate layer is made from fiber material of a weight in the range of 0.5 oz./sq. yd. to 12 oz./sq. yd. and selected from the group including spun bond polyethylene terephthalate (PET) polyester, polyphenylene sulfide (PPS), or polypropylene (PP), a bicomponent fiber with a polybutylene terephthalate (PBT) sheath and a polyethylene terephthalate (PET) core and a bicomponent fiber with a polyethylene terephthalate (PET) core and a polyethylene (PE) sheath.

18. The filter media of claim 16 wherein said second substrate layer is made from the filter media of claim 1 wherein said second substrate layer is made from fiber material of a weight in the range 0.25 oz./sq. yd. to 5.0 oz./sq. yd. and selected from the group including glass, melt blown polypropylene (PP), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), ethylene-chlorotrifluorethylene (ECTFE) polyethylene terephthalate (PET) polyester and polyethylene (PE).

9. A cleanable and pleated filter media that has a HEPA filtration rating, said filter media comprising:

a porous primary filtration layer, said primary filtration layer comprising a microporous expanded polytetrafluoroethylene tending to be less than HEPA rated after a pleating operation, said primary filtration layer capable of releasing accumulated particulates upon said filter media being exposed to an external cleaning force;

a first substrate layer attached to said primary filtration layer to maintain the shape of said filter media, said first substrate layer comprising a spun bond filtration media and being less than HEPA rated; and

a second substrate layer attached to said first substrate layer to serve as a secondary filtration media in the event that said primary filtration layer is damaged, said second substrate layer comprising a melt blown filtration media and being less than HEPA rated;

wherein said filter media has an air flow regeneration of at least 99% immediately subsequent to being cleaned by loosening accumulated particulates from a filtering surface of said primary filtration layer.

12. The filter media of claim 9 wherein said porous primary filtration layer is bonded to said first substrate layer.

13. The filter media of claim 9 wherein said porous primary filtration layer is thermally laminated to said first substrate layer.

14. The filter media of claim 9 wherein said first substrate layer is adhesively bonded to said second substrate layer.

15. The filter media of claim 9 wherein said first substrate layer is thermally laminated to said second substrate layer.

16. A cleanable and pleated filter media that has a HEPA filtration rating, said filter media comprising:

a porous primary filtration layer, said primary filtration layer comprising a microporous expanded polytetrafluoroethylene tending to be less than HEPA rated upon being damaged, said primary filtration layer capable of releasing accumulated particulates upon said filter media being exposed to an external cleaning force;

a first substrate layer bonded to said primary filtration layer to maintain the shape of said filter media, said first substrate layer comprising a spun bond filtration media and being less than HEPA rated; and

a second substrate layer adhesively bonded to said first substrate layer to serve as a secondary filtration layer upon damage to said primary filtration layer. said second substrate layer comprising a melt blown filtration media and being less than HEPA rated;

wherein said filter media has an air flow regeneration of at least 99% immediately subsequent to being cleaned by loosening accumulated particulates from a filtering surface of said primary filtration layer.