Filter media

• US 6,554,881 B1
• Filed: 10/27/2000
• Issued: 04/29/2003
• Est. Priority Date: 10/29/1999
• Status: Expired due to Term

• Current Assignee: Hollingsworth & Vose Company
• Original Assignee: Hollingsworth & Vose Company
• Inventors: Healey, David Thomas
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): PHAM, MINH CHAU THI
• Application Number:
  US09/698,584
• Time in Patent Office: 914 Days
• Field of Search: 555/28, 55D/IG.39, 156/62.4, 156/62.6, 156/62.8, 264/DIG.48, 428/219, 428/311.11, 428/311.51, 428/315.5, 428/338, 428/359, 428/364, 428/373
• US Class Current: 55/528
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: Y10S 264/48 Processes of making filters
• CPC Class Codes: Y10S 55/05 Methods of making filter
• CPC Class Codes: Y10S 55/39 Electrets separator
• CPC Class Codes: Y10T 428/249962 Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
• CPC Class Codes: Y10T 428/249964 Fibers of defined composition
• CPC Class Codes: Y10T 428/249978 Voids specified as micro
• CPC Class Codes: Y10T 428/268 Monolayer with structurally defined element
• CPC Class Codes: Y10T 428/2904 Staple length fiber
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2929 Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]

Abstract

A filter media having a synthetic microfiber polymer fine fiber web wherein the diameter of the fibers is between about 0.8 to about 1.5 microns. The filter media is acceptable for use in ASHRAE applications. Constructions with a low DP backing, support or prefilter layers of coarse fiber provide large area filter webs of high efficiency and a stale and high threshold value of alpha above eleven.

Claims

1. A filter media comprising:

at least one coarse spunbond polymer fiber support layer; and

a meltblown polyolefin microfiber polymer web mated to the coarse spunbond polymer fiber support layer, the meltblown polyolefin microfiber polymer web being formed of fine fibers having a diameter less than about 1.5 microns;

wherein the filter media is effective for use in heating, refrigeration, ventilation, and exhaust duct filtering applications, and has a base alpha value of at least about 11 throughout the useful life of the filter media, even after decay of any charge that may be present.

2. The filter media of claim 1, wherein the coarse spunbond polymer fiber support layer is formed from fibers having a diameter in the range of about 5 microns to 15 microns.

3. The filter media of claim 1, wherein the meltblown polyolefin microfiber polymer web has a web basis weight in the range of about 6 g/m² to 25 g/m².

4. The filter media of claim 1, wherein the coarse spunbond polymer fiber support has a web basis weight in the range of about 34 g/m² to 55 g/m².

5. The filter media of claim 1, wherein the meltblown polyolefin microfiber polymer web is formed from polymers selected from the group consisting of polyethylene, polypropylene, polybutylene, polyisobutylene, and ethylene-alpha-olefin copolymers.

6. The filter media of claim 1, wherein the meltblown polyolefin microfiber polymer web is meltblown onto the coarse spunbond polymer fiber support layer to form a mechanically bonded, enmeshed web.

7. The filter media of claim 1, further comprising a pre-filter spunbond layer mated to the coarse spunbond polymer fiber support.

8. The filter media of claim 7, further comprising a coarse, spunbond backing layer mated to the meltblown polyolefin microfiber polymer web.

9. The filter media of claim 7, wherein the pre-filter spunbond layer is formed from fibers having a diameter in the range of about 5 microns to 15 microns.

10. The filter media of claim 7, wherein the pre-filter spunbond layer has a web basis weight in the range of about 5 g/m² to 10 g/m².

11. The filter media of claim 1, further comprising a coarse meltblown microfiber pre-filter layer mated to the meltblown polyolefin microfiber polymer web.

12. The filter media of claim 11, wherein the coarse meltblown microfiber pre-filter layer is formed from fibers having a diameter in the range of about 5 microns to 20 microns.

13. The filter media of claim 11, wherein the coarse meltblown microfiber pre-filter layer has a web basis weight in the range of about 50 g/m² to 100 g/m².

14. The filter media of claim 1, wherein the filter media is charged to form an electret.