Cleanable high efficiency filter media structure and applications for use
First Claim
1. A filter media comprising a nanofiber layer and a high efficiency substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%.
1 Assignment
0 Petitions
Accused Products
Abstract
We claim an improved cartridge, typically in cylindrical or panel form that can be used in a dry or wet/dry vacuum cleaner. The cartridge is cleanable using a stream of service water, or by rapping on a solid object, or by using a compressed gas stream, but can provide exceptional filtering properties even for submicron particulate in the household or industrial environment. The cartridge has a combination of nanofiber filtration layer on a substrate. The nanofiber and substrate are engineered to obtain a maximum efficiency at reasonable pressure drop and permeability. The improved cartridge constitutes at least a substrate material and at least a layer comprising a non-woven, fine fiber separation layer. The nanofiber layer has a fiber diameter of about 0.05 to 0.5 micron, a nanofiber layer basis weight of about 3×10−7 to 6×10−5 gram-cm−2, an air permeability of about 1 to 1000 ft/min at 0.5 inch (water) ΔP, and a pore size of about 0.01 to 100 microns. The substrate layer is preferably pleated, comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a thickness of about 0.001 to 0.2 inches, the overall filter having a permeability of about 1 to 200 ft-min−1 of 0.5 inch (water) ΔP, an efficiency in removing a 0.76 micron particle at 10 ft-min−1 of about 10 to 99.99995%. The cartridge is configured to permit an air flow rate from about 5 to 600 cubic feet per minute. The nanofiber and substrate material are selected such that the cartridge can simply be rinsed in a service water stream, rapped on a solid object, or blown off with compressed gas to remove accumulated dust cake or particulate load.
206 Citations
135 Claims
-
1. A filter media comprising a nanofiber layer and a high efficiency substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 126, 127, 128, 129)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
-
14. A filter cartridge comprising a filter element comprising a nanofiber layer and a substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%, the cartridge having an overall design flow rate between about 5 and 10000 cubic feet per minute. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 130, 131, 132)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
-
29. A vacuum cleaner comprising a 0.65 to 500 HP motor driving an air stream having a flow rate of 5 to 600 ft-min−
- 1 through a filter, the filter comprising a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a layer thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%.
- 1 through a filter, the filter comprising a nanofiber layer and a high efficiency substrate layer;
-
30. A filter arrangement comprising a media pack having an element comprising first and second opposite flow faces and a plurality of flutes wherein in said media pack;
-
(a) each of said flutes have a first end portion adjacent to said first flow face and a second end portion adjacent to said second flow face;
(b) selected ones of said flutes being open at said first end portion and closed at said second end portion; and
selected ones of said flutes being closed at said first end portion and open at said second end portion(c) said element comprising a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 10 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%. - View Dependent Claims (31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 133, 134, 135)
-
-
43. A method for filtering air, the method comprising:
(a) directing air through a media pack at a rate of 5 to 10,000 cfm, the pack comprising a substrate having first and second opposite flow faces, the element comprising a plurality of flutes wherein in said media pack;
(i) said flutes have a first end portion adjacent to the first flow face and a second end portion adjacent to the second flow face;
(ii) selected ones of the flutes being open at the first end portion and closed at the second end portion; and
selected ones of the flutes being closed at the first end portion and open at the second end portion;
(iii) the element comprises a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a layer thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%.- View Dependent Claims (44, 45, 46, 47, 48, 49, 50, 51, 52, 53)
-
54. An air filter assembly comprising:
-
(a) a housing including an air inlet, an air outlet, a spacer wall separating said housing into a filtering chamber and a clean air chamber;
said spacer wall including a first air flow aperture therein;
(b) a first filter construction positioned in air flow communication with said first air flow aperture in said spacer wall;
said first filter construction including an extension of a pleated filter media composite defining a filter construction inner clean air chamber;
(i) said first filter construction being oriented with said filter inner clean air chamber in air flow communication with said spacer wall first air flow aperture;
(ii) said pleated filter element comprising a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%; and
(d) a pulse-jet cleaning system oriented to direct a pulse of air into said filter construction inner clean air chamber. - View Dependent Claims (55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65)
-
-
66. A method for filtering air, the method comprising:
-
(a) directing the air through an inlet of a housing and into a filtering chamber;
the housing including a spacer wall separating the filtering chamber from a clean air chamber;
the spacer wall including a first air flow aperture therein;
(b) after directing the air into the filtering chamber, directing the air through an extension of a pleated filter composite of a first filter construction and into a filter construction inner clean air chamber;
the first filter construction being positioned in air flow communication with the first air flow aperture in the spacer wall;
the extension of a pleated filter media composite defining the filter construction inner clean air chamber;
(i) the first filter construction being oriented with the filter inner clean air chamber in air flow communication with the spacer wall first air flow aperture;
(ii) the filter composite comprising a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%; and
(c) after directing the air through an extension of a pleated filter media composite of a first filter construction and into a filter construction inner clean air chamber, directing the air into the clean air chamber and out of the housing. - View Dependent Claims (67, 68, 69, 70, 71, 72, 73)
-
-
74. A filter structure for filtering air in a gas turbine intake system, the intake air having an ambient temperature and a humidity of at least 50% RH, the structure comprising, in an air intake of a gas turbine system, at least one filter element, the filter element having a media pack forming a tubular construction and construction defining an open filter interior;
- the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite including a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%. - View Dependent Claims (75, 76, 77, 78)
- the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite including a nanofiber layer and a high efficiency substrate layer;
-
79. A method for filtering air in a gas turbine intake system, the turbine operating at a temperature of about 140°
- F. to 350°
F., the intake air having an ambient temperature and a humidity of at least 50% RH, the method comprising the steps of;
(a) installing a filter proximate an air intake of a gas turbine system, the filter comprising at least one filter element, the filter element having a media pack forming a tubular construction defining a open filter interior;
the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite, comprising a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%; and
(b) directing intake air into an air intake of a gas turbine system - View Dependent Claims (80, 81, 82, 83, 84, 85)
- F. to 350°
-
86. A method for filtering air in a gas turbine intake system, an intake air having an ambient temperature and a humidity of at least 50% RH,
(a) directing intake air into an air intake of a gas turbine system having at least one filter element, the filter element having a media pack forming a tubular construction and construction defining a open filter interior; - the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite including a substrate at least partially covered by a layer of fine fibers, comprising a nanofiber layer and a high efficiency substrate layer;
the nanofiber layer having a fiber diameter of 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gram-cm−
2, an average pore size of about 0.01 to 100 microns and a layer thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%; and
(b) directing the air through the media pack of the filter element and into the open filter interior to clean the air. - View Dependent Claims (87, 88, 89, 90, 91)
- the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite including a substrate at least partially covered by a layer of fine fibers, comprising a nanofiber layer and a high efficiency substrate layer;
-
92. A filtration system for an enclosed locus of human habitation, the system comprising a filter cartridge comprising a filter element comprising a nanofiber layer and a substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%, the cartridge having an overall design flow rate between about 5 and 10000 cubic feet per minute. - View Dependent Claims (93, 94, 95, 96, 97, 98)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
-
99. A filtration system for an enclosed portion of a human transportation conveyance, the system comprising a filter cartridge comprising a filter element comprising a nanofiber layer and a substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to 99.99995%, the cartridge having an overall design flow rate between about 5 and 10000 cubic feet per minute. - View Dependent Claims (100, 101, 102, 103, 104, 105, 106, 107)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
-
108. A filtration system for a personal respirator, the system comprising a mask enclosing at least the mouth and nose, the mask comprising at least one air intake the intake, the intake comprising a filter cartridge comprising a filter element comprising a nanofiber layer and a substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%, the cartridge having an overall design flow rate between about 0.2 and 3 cubic feet per minute. - View Dependent Claims (109, 110, 111, 112, 113, 114)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
-
115. A filtration system for a liquid having entrained particulate loading, the system comprising a conduit for a stream of the liquid and placed across the stream a filter cartridge comprising a filter element comprising a nanofiber layer and a substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%, the cartridge having an overall design flow rate between about 5 and 10000 cubic feet per minute. - View Dependent Claims (116, 117, 118, 119, 120)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
-
121. A filtration system for a liquid having entrained particulate loading, the system comprising a stream of the liquid having a crossflow path across filter surface, the filter comprising a filter element comprising a nanofiber layer and a substrate layer;
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
10−
7 to 6×
10−
5 gm-cm−
2, an average pore size of about 0.01 to 100 micron and a thickness of about 0.05 to 50 microns;
the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−
2 to 350 lb-3000 ft−
2, a layer thickness of about 0.001 to 0.2 inch, the overall filter substrate having a permeability of about 1 to 200 ft-min−
1 at 0.5 inch (water) Δ
P, an efficiency in removing a 0.1 micron particle at 10 ft-min−
1 of about 35 to 99.99995% and an efficiency in removing a 0.76 micron particle at 10 ft-min−
1 of about 80 to greater than 98%, the cartridge having an overall design flow rate between about 5 and 10000 cubic feet per minute;
the filter passing a portion of the fluid and retaining the particulate. - View Dependent Claims (122, 123, 124, 125)
- the nanofiber layer having a fiber diameter of about 0.05 to 0.5 micron, a basis weight of about 3×
Specification