Multi-layered filter media
First Claim
Patent Images
1. A filter media, comprising:
- a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size;
a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size, and wherein the second plurality of fibers are formed by a melt-blown process; and
a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer has a density of greater than or equal to about 0.75 kg/m3 and less than or equal to about 1.25 kg/m3,wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size,wherein the first layer, the second layer, and the third layer are discrete layers, andwherein the second layer is positioned between the first and third layers.
2 Assignments
0 Petitions
Accused Products
Abstract
Fiber webs that may be used as filter media are provided. In some embodiments, the filter media may include multiple layers. Each layer may be designed to have separate functions in the filter media. For example, a first layer may be provided for improving dust holding capacity, a second layer for improving efficiency, and a third layer for providing support and strength to the media. By designing the layers to have separate functions, each layer may be optimized to enhance its function without negatively impacting the performance of another layer of the media.
189 Citations
98 Claims
-
1. A filter media, comprising:
-
a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size; a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size, and wherein the second plurality of fibers are formed by a melt-blown process; and a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer has a density of greater than or equal to about 0.75 kg/m3 and less than or equal to about 1.25 kg/m3, wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size, wherein the first layer, the second layer, and the third layer are discrete layers, and wherein the second layer is positioned between the first and third layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
-
-
34. A filter media, comprising:
-
a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size; a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size; and a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer comprises a plurality of perforations, wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size, wherein the first layer, the second layer, and the third layer are discrete layers, and wherein the second layer is positioned between the first and third layers. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63)
-
-
64. A filter media, comprising:
-
a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size; a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size; and a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer has a density of greater than or equal to about 0.75 kg/m3 and less than or equal to about 1.25 kg/m3, wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size, wherein the first layer, the second layer, and the third layer are discrete layers, and wherein the second layer is positioned between the first and third layers. - View Dependent Claims (65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95)
-
-
96. A filter media, comprising:
-
a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size; a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size; and a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer comprises a plurality of perforations, and wherein the perforations cover greater than or equal to about 5% and less than or equal to about 20% of the surface area of the third layer, wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size, wherein the first layer, the second layer, and the third layer are discrete layers, and wherein the second layer is positioned between the first and third layers.
-
-
97. A filter media, comprising:
-
a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size; a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size; and a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer comprises a plurality of perforations, and wherein the plurality of perforations have an average diameter of greater than or equal to about 0.5 mm and less than or equal to about 5 mm, wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size, wherein the first layer, the second layer, and the third layer are discrete layers, and wherein the second layer is positioned between the first and third layers.
-
-
98. A filter media, comprising:
-
a first layer comprising a first plurality of fibers, wherein the first layer has a first air permeability and a first mean flow pore size; a second layer comprising a second plurality of fibers having an average fiber diameter of less than or equal to about 1 micron, wherein the second layer has a second air permeability and a second mean flow pore size; and a third layer comprising a third plurality of fibers, wherein the third plurality of fibers comprises cellulose fibers, wherein the third layer has a third air permeability and a third mean flow pore size, and wherein the third layer comprises a plurality of perforations, and wherein the plurality of perforations have an average protrusion length of greater than or equal to about 1 mm and less than or equal to about 5 mm, wherein each of the first and third air permeabilities is higher than the second air permeability and/or wherein each of the first and third mean flow pore sizes is higher than the second mean flow pore size, wherein the first layer, the second layer, and the third layer are discrete layers, and wherein the second layer is positioned between the first and third layers.
-
Specification