Integrated paper comprising fibrillated fibers and active particles immobilized therein

• US 7,655,112 B2
• Filed: 09/19/2003
• Issued: 02/02/2010
• Est. Priority Date: 01/31/2002
• Status: Expired due to Term

• Current Assignee: KX Technologies, LLC (Berkshire Hathaway Incorporated)
• Original Assignee: KX Technologies, LLC (Berkshire Hathaway Incorporated)
• Inventors: Koslow, Evan E.
• Primary Examiner(s): FORTUNA, JOSE A
• Application Number:
  US10/666,878
• Publication Number:
  US 20040178142A1
• Time in Patent Office: 2,328 Days
• Field of Search: 162/158, 1621811-1814, 162/181.6, 162/181.8, 162/149, 162/146, 162/157.1, 162/164.1, 162161-162, 162/157.3, 162/115, 428/357, 428/393, 428/402, 428/221, 210/257.2, 210/501, 210/764, 210/502.1, 442414-415
• US Class Current: 162/161
• CPC Class Codes: A61L 2/0017 Filtration
• CPC Class Codes: A61L 2/0082 using chemical substances
• CPC Class Codes: A61L 2/022 Filtration
• CPC Class Codes: A61L 9/16 using physical phenomena
• CPC Class Codes: B01D 2201/34 Seals or gaskets for filtering elements for removable closures, lids, caps or filter heads B01D2201/304
• CPC Class Codes: B01D 29/15 arranged for inward flow filtration
• CPC Class Codes: B01D 29/41 mounted transversely on the tube
• CPC Class Codes: B01D 37/02 Precoating the filter medium; Addition of filter aids to the liquid being filtered devices for feeding reagents C02F1/685 and sub-groups; filter aids
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: B01D 39/18 the material being cellulose or derivatives thereof cork or peat B01D39/1646 ; making filter paper D21F11/14
• CPC Class Codes: B01D 39/2017 the material being filamentary or fibrous
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/28028 Particles immobilised within fibres or filaments
• CPC Class Codes: B01J 20/2803 Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
• CPC Class Codes: B01J 20/28078 Pore diameter
• CPC Class Codes: B01J 20/3212 consisting of a polymer obtained by reactions otherwise than involving only carbon to carbon unsaturated bonds
• CPC Class Codes: B01J 20/3234 Inorganic material layers
• CPC Class Codes: B01J 20/3236 containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts
• CPC Class Codes: B01J 20/3295 Coatings made of particles, nanoparticles, fibers, nanofibers
• CPC Class Codes: C02F 1/004 using large scale industrial sized filters
• CPC Class Codes: C02F 1/281 : using inorganic sorbents
• CPC Class Codes: C02F 1/283 : using coal, charred products, or inorganic mixtures containing them
• CPC Class Codes: C02F 1/42 : by ion-exchange ion-exchange in general B01J
• CPC Class Codes: C02F 1/444 : by ultrafiltration or microfiltration
• CPC Class Codes: C02F 1/505 : by oligodynamic treatment
• CPC Class Codes: C02F 1/76 : with halogens or compounds of halogens C02F1/4674 takes precedence
• CPC Class Codes: C02F 2303/04 : Disinfection
• CPC Class Codes: C02F 2307/04 : as part of a pitcher or jug
• CPC Class Codes: C12H 1/0408 : with the aid of inorganic added material
• CPC Class Codes: C12H 1/0424 : with the aid of a polymer
• CPC Class Codes: D21H 15/02 : characterised by configuration
• CPC Class Codes: D21H 17/67 : Water-insoluble compounds, e.g. fillers, pigments
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component

Abstract

An integrated paper having capabilities and functionalities provided by both the fiber and the active agent ingredients, and a method of immobilizing the active agents within the integrated paper. A tight pore structure with a mean pore diameter of less than about 2 microns provides short diffusion distances from a fluid to the surface of the paper ingredients by adsorption or diffusive interception, making it an excellent medium for fluid filtration. A microbiological interception enhancing agent may be added. The integrated paper may be formed using wet laid paper-making processes. Devices utilizing the integrated paper are used in fluid filtration.

Claims

1. An integrated paper having active particles immobilized therein, said integrated paper comprising of:

a plurality of fibrillated fibers immobilized within said integrated paper, said fibers fibrillated at a temperature greater than about 30°

C., wherein said fibrillated fibers have an average fiber diameter of less than about 1000 nm;

active agents immobilized within said integrated paper wherein the average diameter of said fibrillated fibers is less than an average particle size of said active agents to physically entrap said active agents within said integrated paper, said active agents selected from the group consisting of metals, metal salts, metal oxides, alumina, carbon, activated carbon, silicates, ceramics, zeolites, diatomaceous earth, activated bauxite, fuller'"'"'s earth, calcium sulfate, titanium dioxide, magnesia, magnesium hydroxide, magnesium oxide, manganese oxides, iron oxides, perlite, talc, clay, bone char, calcium hydroxide, calcium salts, or combinations thereof;

binder fibers or particles; and

a microbiological interception enhancing agent on at least a portion of at least some of said fibrillated fibers and said active agents immobilized within said integrated paper, such that, said microbiological interception enhancing agent is also immobilized within and resides throughout the entire thickness of said integrated paper, said microbiological interception enhancing agent comprising a biologically active metal precipitated with a counter ion of a cationic material that is residing on said at least portion of said fibrillated fibers and said active agents that are residing within and throughout the entire thickness of said integrated paper to form a colloidal metal precipitate within and throughout said integrated paper that are on a surface of said at least portion of said fibrillated fibers and/or said active agents,

wherein said integrated paper has a mean pore size of less than or equal to about 2 microns and said fibrillated fibers and said active agents have different settling velocities such that said integrated paper has an asymmetric structure when formed by wet-laid processes.

2. An integrated paper of claim 1 wherein said fibrillated fibers comprise Lyocell.

3. An integrated paper of claim 2 wherein the lyocell has an average fiber diameter of less than about 400 nm.

4. An integrated paper of claim 1 wherein said active agents have an average particle size of less than or equal to about 1 micron to about 5000 microns.

5. The integrated paper of claim 1 wherein said fibrillated fibers have an average fiber diameter of less than about 400 nm;

and

said active agents further being selected from silver oxide particles admixed with said fibrillated fibers.

6. An integrated paper of claim 5 wherein the fibrillated fibers comprise a liquid crystal polymer.

7. The integrated paper of claim 1 wherein said fibrillated fibers have an average fiber diameter of less than about 400 nm;

and

said active agents further being selected from one or more acid neutralizing agents admixed with said fibrillated fibers;

wherein said integrated paper can withstand a hot and corrosive environment of a lube oil filter, and wherein said one or more acid neutralizing agents are selected from the group consisting of magnesium oxide, magnesium hydroxide, calcium sulfonate, magnesium sulfonate, calcium phenate, magnesium phenate, or combinations thereof.

8. An integrated paper of claim 7 further including binder fibers or particles.

9. The integrated paper of claim 1 wherein said colloidal metal precipitate includes a silver-amine-halide complex.

10. The integrated paper of claim 1 wherein said fibrillated fibers have an average diameter of less than or equal to 250 nm and a length of 1 mm to about 8 mm.

11. The integrated paper of claim 1 wherein said colloidal metal precipitate is physically trapped within a matrix of said cationic material.

12. The integrated paper of claim 1 wherein said colloidal metal precipitate is bound to said cationic material.

13. The integrated paper of claim 12 wherein said colloidal metal precipitate is bound to said cationic material by adsorption.

14. The integrated paper of claim 12 wherein said colloidal metal precipitate is bound to said cationic material by electrostatic forces.

15. An integrated paper comprising of:

a plurality of lyocell fibers immobilized within and throughout said integrated paper, said lyocell fibers fibrillated at a temperature greater than about 30°

C., wherein said fibrillated lyocell fibers have an average fiber diameter of less than or equal to about 400 nm;

activated carbon particles admixed with said fibrillated lyocell fibers and immobilized within and throughout said integrated paper, wherein the average diameter of said lyocell fibers is less than an average particle size of said active agents to physically entrap said active agents within said integrated paper, said integrated paper has a mean flow path of less than about 2 microns;

binder fibers or particles; and

a microbiological interception enhancing agent on at least a portion of at least some of said fibrillated lyocell fibers immobilized within said integrated paper, such that, said microbiological interception enhancing agent is also immobilized within and resides throughout said integrated paper, said microbiological interception enhancing agent comprising a biologically active metal precipitated with a counter ion of a cationic material that is residing within and throughout said integrated paper and on said at least portion of said fibrillated lyocell fibers to form a colloidal metal precipitate within and throughout said integrated paper and on a surface of said at least portion of said fibrillated lyocell fibers.

16. An integrated paper of claim 15 further including a heavy metal reducing agent.

17. An integrated paper of claim 16 wherein the heavy metal reducing agent is selected from the group consisting of particles of zeolite, silicate, or combinations thereof.

18. An integrated paper of claim 15 further including an arsenic reducing agent.

19. An integrated paper of claim 18 wherein the arsenic reducing agent is selected from the group consisting of particles of iron, oxides of manganese or iron, or combinations thereof.

20. An integrated paper comprising:

a plurality of fibrillated fibers having an average fiber diameter of less than about 1000 nm immobilized within said integrated paper;

active agents immobilized within said integrated paper and admixed with said plurality of fibrillated fibers, wherein the average diameter of said fibrillated fibers is less than an average particle size of said active agents to physically entrap said active agents within said integrated paper; and

a microbiological interception enhancing agent on at least a portion of at least some of said fibrillated fibers or said active agents, said microbiological interception enhancing agent comprising a biologically active metal precipitated with a counter ion of a cationic material that is residing on said at least portion of said fibrillated fibers or said active agents to form a colloidal metal precipitate on surfaces thereof, whereby said microbiological interception enhancing agent is immobilized within and resides throughout said integrated paper, wherein prior to forming said integrated paper using said fibrillated fibers or said active agents, said fibrillated fibers or said active agents are treated with said microbiological interception enhancing agent,

wherein said integrated paper has a mean flow path of less than about 2 microns.

21. An integrated paper having active particles immobilized therein, said integrated paper comprising of:

active agents physically entrapped within said integrated paper, said active agents residing within and throughout the entire thickness of said integrated paper;

a plurality of fibrillated fibers hydroentangled within said integrated paper, said fibrillated fibers having an average fiber diameter less than an average particle size of said active agents for the physical entrapment of said active agents within said integrated paper, said fibrillated fibers residing within and throughout the entire thickness of said integrated paper; and

a microbiological interception enhancing agent at least on a portion of some of said active agents and as such is also physically entrapped within said integrated paper by said plurality of fibrillated fibers, said microbiological interception enhancing agent comprising a biologically active metal precipitated with a counter ion of a cationic material residing on said portion of some of said active agents to form a colloidal metal precipitate residing within and throughout the entire thickness of said integrated paper.

22. The integrated paper of claim 21 further including additional of said microbiological interception enhancing agent on a portion of some of said fibrillated fibers, said microbiological interception enhancing agent comprising said biologically active metal precipitated with a counter ion of a cationic material residing on said portion of some of said fibrillated fibers to form said colloidal metal precipitate residing within and throughout the entire thickness of said integrated paper, whereby both some of said active agents and some of said fibrillated fibers have said microbiological interception enhancing agent.

23. The integrated paper of claim 21 wherein said fibrillated fibers and said active agents have different settling velocities such that said fibrillated fibers settle to one surface of the integrated paper and the active agents settle to the other surface of the integrated paper so that an asymmetric pore gradient exists through the thickness of the integrated paper.

24. The integrated paper of claim 23 wherein said asymmetric pore gradient provides an integrated paper having a pore structure from a prefiltration structure to a final polishing filter.

25. The integrated paper of claim 21 further including binder fibers or particles having an average diameter equal to or less than the average particle size of the active agents to physically entrap the active agents within the integrated paper.

26. The integrated paper of claim 21 wherein said fibrillated fibers have an average diameter of less than or equal to 250 nm.

27. The integrated paper of claim 21 wherein the active agents are present in an amount of up to about 50 weight percent based on a total weight of the integrated paper.

28. The integrated paper of claim 27 wherein the active agents are present in an amount of up to about 75 weight percent based on the total weight of the integrated paper.

29. The integrated paper of claim 21 wherein said integrated paper has a mean pore size of less than or equal to about 1 micron to provide supplemental direct mechanical interception of microbiological contaminants in combination with the microbiological interception enhancing agent.

30. The integrated paper of claim 29 wherein said mean pore size is less than or equal to about 0.5 microns to provide the supplemental direct mechanical interception of microbiological contaminants.

31. An integrated paper having active particles immobilized therein, said integrated paper comprising of:

active agents physically entrapped within said integrated paper, said active agents residing within and throughout the entire thickness of said integrated paper;

a plurality of fibrillated fibers hydroentangled within said integrated paper, said fibrillated fibers having an average fiber diameter less than an average particle size of said active agents for the physical entrapment of said active agents within said integrated paper, said fibrillated fibers residing within and throughout the entire thickness of said integrated paper; and

a microbiological interception enhancing agent at least on a portion of some of said hydroentangled fibrillated fibers, said microbiological interception enhancing agent comprising a biologically active metal precipitated with a counter ion of a cationic material residing on said portion of some of said fibrillated fibers to form a colloidal metal precipitate residing within and throughout the entire thickness of said integrated paper.

32. The integrated paper of claim 31 further including additional of said microbiological interception enhancing agent on a portion of some of said active agents and also being physically entrapped within said integrated paper by said plurality of fibrillated fibers.

33. The integrated paper of claim 31 wherein said fibrillated fibers and said active agents have different settling velocities such that said fibrillated fibers settle to one surface of the integrated paper and the active agents settle to the other surface of the integrated paper so that an asymmetric pore gradient exists through the thickness of the integrated paper.

34. The integrated paper of claim 33 wherein said asymmetric pore gradient provides an integrated paper having a pore structure from a prefiltration structure to a final polishing filter.

35. The integrated paper of claim 31 further including binder fibers or particles having an average diameter equal to or less than the average particle size of the active agents to physically entrap the active agents within the integrated paper.

36. The integrated paper of claim 31 wherein said fibrillated fibers have an average diameter of less than or equal to 250 nm.

37. The integrated paper of claim 31 wherein the active agents are present in an amount of up to about 50 weight percent based on a total weight of the integrated paper.

38. The integrated paper of claim 31 wherein said integrated paper has a mean pore size of less than or equal to about 1 micron to provide supplemental direct mechanical interception of microbiological contaminants in combination with the microbiological interception enhancing agent.

39. An integrated paper having active particles immobilized therein, said integrated paper comprising of:

active agents physically entrapped within said integrated paper, said active agents residing within and throughout the entire thickness of said integrated paper;

a plurality of fibrillated fibers hydroentangled within said integrated paper, said fibrillated fibers having an average fiber diameter less than an average particle size of said active agents for the physical entrapment of said active agents within said integrated paper, said fibrillated fibers residing within and throughout the entire thickness of said integrated paper; and

a microbiological interception enhancing agent on a portion of some of said active agents and as such also being physically entrapped within said integrated paper by said plurality of fibrillated fibers and on a portion of some of said hydroentangled fibrillated fibers, said microbiological interception enhancing agent comprising a biologically active metal precipitated with a counter ion of a cationic material residing on said portion of some of said active agents and said fibrillated fibers to form a colloidal metal precipitate residing within and throughout the entire thickness of said integrated paper.

40. The integrated paper of claim 39 wherein said fibrillated fibers and said active agents have different settling velocities such that said fibrillated fibers settle to one surface of the integrated paper and the active agents settle to the other surface of the integrated paper so that an asymmetric pore gradient exists through the thickness of the integrated paper.

41. The integrated paper of claim 40 wherein said asymmetric pore gradient provides an integrated paper having a pore structure from a prefiltration structure to a final polishing filter.

42. The integrated paper of claim 39 further including binder fibers or particles having an average diameter equal to or less than the average particle size of the active agents to physically entrap the active agents within the integrated paper.

43. The integrated paper of claim 39 wherein said fibrillated fibers have an average diameter of less than or equal to 250 nm.

44. The integrated paper of claim 39 wherein the active agents are present in an amount of up to about 50 weight percent based on a total weight of the integrated paper.

45. The integrated paper of claim 39 wherein said integrated paper has a mean pore size of less than or equal to about 1 micron to provide supplemental direct mechanical interception of microbiological contaminants in combination with the microbiological interception enhancing agent.