US20030127171A1 - Filter composite embodying glass fiber and synthetic resin fiber - Google Patents
Filter composite embodying glass fiber and synthetic resin fiber Download PDFInfo
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- US20030127171A1 US20030127171A1 US10/376,026 US37602603A US2003127171A1 US 20030127171 A1 US20030127171 A1 US 20030127171A1 US 37602603 A US37602603 A US 37602603A US 2003127171 A1 US2003127171 A1 US 2003127171A1
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- combination
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- filter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2003—Glass or glassy material
- B01D39/2017—Glass or glassy material the material being filamentary or fibrous
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
- B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2904—Staple length fiber
- Y10T428/2909—Nonlinear [e.g., crimped, coiled, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
- Y10T428/292—In coating or impregnation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2973—Particular cross section
- Y10T428/2975—Tubular or cellular
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/603—Including strand or fiber material precoated with other than free metal or alloy
- Y10T442/604—Strand or fiber material is glass
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/603—Including strand or fiber material precoated with other than free metal or alloy
- Y10T442/607—Strand or fiber material is synthetic polymer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
- Y10T442/612—Hollow strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/627—Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/627—Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
- Y10T442/631—Glass strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/668—Separate nonwoven fabric layers comprise chemically different strand or fiber material
- Y10T442/669—At least one layer of inorganic strand or fiber material and at least one layer of synthetic polymeric strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/67—Multiple nonwoven fabric layers composed of the same inorganic strand or fiber material
Definitions
- This invention relates generally to forming of fiber composites, for example as are used in air filtration; and more particularly, the invention concerns provision of a filter composite comprising multiple layers of porous materials, of such characteristics as enable the composite to be self-supporting, i.e., without need for wire backing or other auxiliary support adjacent areal extents of the composite.
- Such wireless composites are of great advantage, as respects ease of manufacture, use in filtering, and ease of disposal.
- Wire-supported filters require wire trimming, producing sharp edges which can and do injure hands of workers manufacturing filters.
- That composite basically comprises
- the synthetic resinous fibers may be distributed in mixed relation with the glass fibers of the first layer; or the synthetic resinous fibers may extend in a layer separate from but adjacent to the first layer glass fibers. Both such modes of synthetic fiber disposition may be employed in a filter composite employing glass fibers.
- the synthetic resinous fibers may comprise between 10% and 60% by volume of the total composite volume of both glass and synthetic resin fibers.
- the synthetic resinous fibers may typically consist of polyester resin.
- Another object is to provide an additional porous layer which blocks escape of fibers, to consist essentially of non-woven, synthetic fiber, examples being CEREX, non-woven NYLON or RAYON.
- the latter is provided as an air-laid, NYLON, or RAYON non-woven layer. That additional layer is typically bonded to the glass fiber layer during the manufacturing process.
- a further object includes provision of bonding resin adherent to the fibers in such layers, the filter composite being porous.
- the bonding resin typically is applied to saturate the described layer or layers, excess resin being removed, as by vacuum application to the composite, whereby porosity of the composite is maintained or provided.
- Yet another object is to provide a composite having synthetic resinous fibers with crimped or hollow shapes, and straight shafts, and wherein the bulk of the glass fibers have:
- the filter composite typically has weight between 0.01 and 0.05 lbs, per square foot; and thickness between 0.02 and 0.10 inches.
- a yet further object includes:
- the bonding resin consists essentially of thermoplastic resin adapted to be heated during reforming of the filter to selected shape.
- the filter typically assumes selected shape after heating, reforming, and cooling of the resin; and one advantageous shape comprises folds or pleats, as may be chosen by the user following filter material manufacture and sale.
- FIGS. 1 - 4 are sections taken through filter composites embodying the invention, and are preferred.
- a first porous layer 10 of glass fibers (of random orientation) is formed or provided.
- the fibers may be deposited onto a porous conveyor belt 11 traveling lengthwise as indicated by arrow 12 .
- Layer 10 may include a non-woven glass fiber porous, mat 13 transported by the conveyor belt, and the glass fibers may be deposited as a sub-layer 10 b on the mat 13 .
- Mat 13 may alternatively be deposited on top of layer 10 , as indicated by broken lines 13 ′.
- Synthetic resin fibers are substantially uniformly and homogeneously mixed in, or dispersed into the glass fibers in the sub-layer 10 b, thereby building up its thickness for enhanced collection and partially entrapment during use as a filter.
- the synthetic fibers may for example consist of polyester resin, or other man-made fibers such as NYLON and/or RAYON and others, and preferably have bulky form, as produced by crimping of the synthetic resin fibers before they are mixed in with the glass fiber.
- the synthetic fibers may be hollow to increase their bulk. The overall thickness t of layer 10 of glass fibers thereby is substantially enhanced for improved filtering of particulate.
- the synthetic fibers in the mix may have various diameters, i.e. denier between 1.6 and 40, and they preferably provide volumetrically between about 10% and 60% of the overall volume of the layer 10 .
- the fibers have at least one of the following shapes
- the length of the bulk of the synthetic fiber lie between 0.25 and 2.0 inches.
- the overall thickness t of a fiber is typically between 0.010 and 0.100 inches.
- the bulk of the glass fibers in layer 10 b typically have filament diameters between 1 and 16 microns, and lengths between 0.25 and 1.50 inches.
- the filter composite has weight between 0.01 and 0.05 lbs per square foot.
- FIG. 2 shows a glass fiber layer 20 like layer 10 of FIG. 1, except that the synthetic resinous fibers extend in a separate porous layer 21 adjacent or attached by adhesive bonding, to one side of layer 20 instead of being mixed in or distributed within layer 20 .
- the objective of increasing the thickness of the overall composite 22 without increasing the filter weight per unit area is still attained.
- the synthetic resinous and glass fibers themselves have the same physical characteristics as referred to above.
- the thickness of synthetic fiber layer 21 is such that volumetrically the synthetic fiber constitute between 10% and 60% of the volume of the overall composite of layers 20 and 21 , per unit area of the composite.
- FIG. 3 is like FIG. 1, (synthetic fibers mixed into glass fibers) except that a thin flexible layer 100 of porous material (as for example NYLON or RAYON, or other man-made fibers) is attached, as by porous adhesive bonding, as at 40 to one side of the composite layer 10 , for containing (preventing pass-through escape of) very small diameter fibers in 10 .
- Layer 100 has a surface weight of between 0.4 and 0.5 oz. per square yard, its thickness being between 0.001 and 0.005 inch.
- the NYLON, and/or RAYON layer 100 may be supported by a porous belt 24 during formation of the composite. Fiber layer 10 , containing synthetic fiber as described, is progressively deposited on the layer 100 during endwise travel of belt 24 .
- the layer 100 may be substantially thinner than the layer 10 .
- the FIG. 3 filter composite is a preferred form of the invention.
- FIG. 4 is like FIG. 2, except that layer 100 a of porous material (as for example CEREX, or non-woven NYLON or RAYON) is attached, as by porous adhesive bonding, to one side of the composite 22 .
- Layer 100 a functions and has the characteristics of layer 100 as described above, in regards to FIG. 3.
- Composite 22 includes glass fiber layer 20 and synthetic fiber layer 21 .
- bonding resin may be applied, as by fluid curtain coating application to the composite, to saturate and bind the multiple layers together. Excess resin is removed as by vacuum application to the composite, as it progressively moves with a supporting porous belt, through vacuum application apparatus. The composite then passes through an oven, for drying and curing of the product. Subsequently, the composite is removed from the belt, and cut to size and rolled up into jumbo rolls.
- the bonding resin advantageously consists of a water resistant thermoplastic resin.
- the filter composite in its variously described forms has sufficient thickness to be resiliently and yieldably bendable during gas flow impingement on said composite, at gas flow velocity between 35 and 2000 ft 3 per minute.
- the method of forming a filter media composite typically includes the steps:
- the bonding resin typically consists of thermoplastic resin and the method may also include reforming the media composite to selected shape and heating the reformed media composite to cause the composite to maintain said selected shape.
- the bonding resin may for certain purposes consist of thermosetting resin, as where resin softening during reforming is not required, or where reforming is not required.
Abstract
A filter composite comprises a first layer of glass fibers having random orientation, and synthetic resinous fibers extending in close association with the glass fibers, the glass fibers having:
i) diameters between 1 and 16 microns
ii) lengths between about ¼ and 1½ inches the synthetic fibers having denier between 1.6 and 40, and length between ¼ and 2 inches.
Description
- This invention relates generally to forming of fiber composites, for example as are used in air filtration; and more particularly, the invention concerns provision of a filter composite comprising multiple layers of porous materials, of such characteristics as enable the composite to be self-supporting, i.e., without need for wire backing or other auxiliary support adjacent areal extents of the composite. Such wireless composites are of great advantage, as respects ease of manufacture, use in filtering, and ease of disposal. Wire-supported filters require wire trimming, producing sharp edges which can and do injure hands of workers manufacturing filters.
- There is need for longer-life filters capable of efficiently filtering particulate from gas streams, and there is need for efficient, effective methods of producing such filters. There is also need for preventing escape of smaller diameter fibers from filter structures.
- The disclosures of U.S. Pat. Nos. 3,690,852 and 5,985,411 are incorporated herein, by reference.
- It is a major object of the invention to provide an improvement filter composites meeting the above needs. That composite basically comprises
- a) a first layer of glass fibers having random orientation, and
- b) synthetic resinous fibers extending in close association with the glass fibers.
- As will be seen, the synthetic resinous fibers may be distributed in mixed relation with the glass fibers of the first layer; or the synthetic resinous fibers may extend in a layer separate from but adjacent to the first layer glass fibers. Both such modes of synthetic fiber disposition may be employed in a filter composite employing glass fibers. Typically, the synthetic resinous fibers may comprise between 10% and 60% by volume of the total composite volume of both glass and synthetic resin fibers. The synthetic resinous fibers may typically consist of polyester resin.
- Another object is to provide an additional porous layer which blocks escape of fibers, to consist essentially of non-woven, synthetic fiber, examples being CEREX, non-woven NYLON or RAYON. The latter is provided as an air-laid, NYLON, or RAYON non-woven layer. That additional layer is typically bonded to the glass fiber layer during the manufacturing process.
- A further object includes provision of bonding resin adherent to the fibers in such layers, the filter composite being porous. The bonding resin typically is applied to saturate the described layer or layers, excess resin being removed, as by vacuum application to the composite, whereby porosity of the composite is maintained or provided.
- Yet another object is to provide a composite having synthetic resinous fibers with crimped or hollow shapes, and straight shafts, and wherein the bulk of the glass fibers have:
- i) diameters between 1 and 16 microns
- ii) lengths between ¼ and 1½ inches.
- The filter composite typically has weight between 0.01 and 0.05 lbs, per square foot; and thickness between 0.02 and 0.10 inches.
- A yet further object includes:
- a) providing a first layer of glass fibers having random orientation,
- b) providing an additional layer of non-woven NYLON or RAYON fibers extending adjacent that first layer,
- c) and providing and adhering bonding resin to fibers in such layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter.
- As will be seen, the bonding resin consists essentially of thermoplastic resin adapted to be heated during reforming of the filter to selected shape. The filter typically assumes selected shape after heating, reforming, and cooling of the resin; and one advantageous shape comprises folds or pleats, as may be chosen by the user following filter material manufacture and sale.
- These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
- FIGS.1-4 are sections taken through filter composites embodying the invention, and are preferred.
- In FIG. 1 a first
porous layer 10 of glass fibers (of random orientation) is formed or provided. The fibers may be deposited onto a porous conveyor belt 11 traveling lengthwise as indicated by arrow 12.Layer 10 may include a non-woven glass fiber porous,mat 13 transported by the conveyor belt, and the glass fibers may be deposited as a sub-layer 10 b on themat 13.Mat 13 may alternatively be deposited on top oflayer 10, as indicated bybroken lines 13′. Synthetic resin fibers are substantially uniformly and homogeneously mixed in, or dispersed into the glass fibers in the sub-layer 10 b, thereby building up its thickness for enhanced collection and partially entrapment during use as a filter. The synthetic fibers may for example consist of polyester resin, or other man-made fibers such as NYLON and/or RAYON and others, and preferably have bulky form, as produced by crimping of the synthetic resin fibers before they are mixed in with the glass fiber. Alternatively, the synthetic fibers may be hollow to increase their bulk. The overall thickness t oflayer 10 of glass fibers thereby is substantially enhanced for improved filtering of particulate. - The synthetic fibers in the mix may have various diameters, i.e. denier between 1.6 and 40, and they preferably provide volumetrically between about 10% and 60% of the overall volume of the
layer 10. The fibers have at least one of the following shapes - i) crimped
- ii) hollow
- iii) straight shafts
- iv) solid shafts
- The length of the bulk of the synthetic fiber lie between 0.25 and 2.0 inches. The overall thickness t of a fiber is typically between 0.010 and 0.100 inches.
- The bulk of the glass fibers in layer10 b typically have filament diameters between 1 and 16 microns, and lengths between 0.25 and 1.50 inches. The filter composite has weight between 0.01 and 0.05 lbs per square foot.
- FIG. 2 shows a
glass fiber layer 20 likelayer 10 of FIG. 1, except that the synthetic resinous fibers extend in a separateporous layer 21 adjacent or attached by adhesive bonding, to one side oflayer 20 instead of being mixed in or distributed withinlayer 20. The objective of increasing the thickness of theoverall composite 22 without increasing the filter weight per unit area is still attained. The synthetic resinous and glass fibers themselves have the same physical characteristics as referred to above. The thickness ofsynthetic fiber layer 21 is such that volumetrically the synthetic fiber constitute between 10% and 60% of the volume of the overall composite oflayers - FIG. 3 is like FIG. 1, (synthetic fibers mixed into glass fibers) except that a thin
flexible layer 100 of porous material (as for example NYLON or RAYON, or other man-made fibers) is attached, as by porous adhesive bonding, as at 40 to one side of thecomposite layer 10, for containing (preventing pass-through escape of) very small diameter fibers in 10.Layer 100 has a surface weight of between 0.4 and 0.5 oz. per square yard, its thickness being between 0.001 and 0.005 inch. The NYLON, and/orRAYON layer 100 may be supported by aporous belt 24 during formation of the composite.Fiber layer 10, containing synthetic fiber as described, is progressively deposited on thelayer 100 during endwise travel ofbelt 24. Thelayer 100 may be substantially thinner than thelayer 10. The FIG. 3 filter composite is a preferred form of the invention. - FIG. 4 is like FIG. 2, except that layer100 a of porous material (as for example CEREX, or non-woven NYLON or RAYON) is attached, as by porous adhesive bonding, to one side of the composite 22. Layer 100 a functions and has the characteristics of
layer 100 as described above, in regards to FIG. 3.Composite 22 includesglass fiber layer 20 andsynthetic fiber layer 21. - In each of FIGS. 2, 3 and4 above bonding resin may be applied, as by fluid curtain coating application to the composite, to saturate and bind the multiple layers together. Excess resin is removed as by vacuum application to the composite, as it progressively moves with a supporting porous belt, through vacuum application apparatus. The composite then passes through an oven, for drying and curing of the product. Subsequently, the composite is removed from the belt, and cut to size and rolled up into jumbo rolls. The bonding resin advantageously consists of a water resistant thermoplastic resin.
- The filter composite in its variously described forms has sufficient thickness to be resiliently and yieldably bendable during gas flow impingement on said composite, at gas flow velocity between 35 and 2000 ft3 per minute.
- The method of forming a filter media composite typically includes the steps:
- a) providing a first layer of glass fibers having random orientation,
- b) providing an additional layer of synthetic resinous fibers extending adjacent said first layer,
- c) and providing and adhering bonding resin to fibers in said layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter.
- The bonding resin typically consists of thermoplastic resin and the method may also include reforming the media composite to selected shape and heating the reformed media composite to cause the composite to maintain said selected shape.
- The bonding resin may for certain purposes consist of thermosetting resin, as where resin softening during reforming is not required, or where reforming is not required.
Claims (33)
1. In a filter composite the combination comprising
a) a first layer of glass fibers having random orientation, and
b) synthetic resinous fibers extending in close association with said glass fibers,
c) said glass fibers having:
i) diameters between 1 and 16 microns
ii) lengths between about ¼ and 1½ inches
d) said synthetic fibers having denier between 1.6 and 40, and length between ¼ and 2 inches.
2. The combination of claim 1 wherein said synthetic resinous fibers are distributed in a homogeneous mix with said first layer glass fibers.
3. The combination of claim 1 wherein said synthetic resinous fibers together comprise between 10 and 60% by volume of the total composite volume.
4. The combination of claim 2 wherein the composite includes an additional layer of non-woven NYLON or RAYON fiber extending adjacent said first layer.
5. The combination of claim 4 wherein said non-woven glass fiber layer consists of non-woven NYLON or RAYON laminated onto the layer of glass fibers.
6. The combination of claim 5 wherein said synthetic resinous fibers together comprise between 10 and 60% by volume of the total composite volume.
7. The combination of claim 1 wherein said synthetic resinous fibers extend in a second layer adjacent said first layer.
8. The combination of claim 7 wherein the composite includes an additional layer of non-woven NYLON or RAYON fiber extending adjacent one of said first and second layers.
9. The combination of claim 8 wherein said non-woven glass fiber layer consists of NYLON or RAYON.
10. The combination of claim 4 including bonding resin adherent to the fibers in said layers, the filter composite being porous.
11. The combination of claim 8 including bonding resin adherent to the fibers in said layers, the filter composite being porous.
12. The combination of claim 10 wherein the bonding resin saturates said layers.
13. The combination of claim 11 wherein the bonding resin saturates said layers.
14. The combination of claim 1 wherein said synthetic resinous fibers consist of polyester resin, or other man-made fibers.
15. The combination of claim 1 wherein said synthetic resinous fibers have one or more of the following shapes:
i) crimped
ii) hollow
iii) straight shafts
iv) solid shafts
16. The combination of claim 4 wherein said synthetic resinous fibers consist of one of the following:
i) polyester resin
ii) other man-made fibers
17. The combination of claim 4 wherein said synthetic resinous fibers have one of the following shapes:
i) crimped
ii) hollow
iii) straight shafts
iv) solid shafts
18. The combination of claim 1 wherein the bulk of said glass fibers have:
i) diameters between 1 and 16 microns
ii) lengths between ¼ and 1½ inches.
19. The combination of claim 1 wherein the filter composite has weight between 0.01 and 0.05 lbs, per square foot.
20. The combination of claim 8 wherein the filter composite has weight between 0.01 and 0.05 lbs per square foot.
21. The combination of claim 1 wherein the filter composite has sufficient thickness to be self supporting during gas flow impingement on said composite, at gas flow velocity between 35 and 2,000 feet per minute.
22. The combination of claim 8 wherein the filter composite has sufficient thickness to be self supporting gas flow impingement on said composite at gas flow velocity between 35 and 2,000 feet3 per minute.
23. The combination of claim 1 wherein the composite overall thickness is between 0.010 and 0.100 inches.
24. The combination of claim 8 wherein the composite overall thickness is between 0.010 and 0.100 inches.
25. In a filter composite, the combination comprising
a) a first layer of glass fibers having random orientation,
b) an additional layer of non-woven glass fiber extending adjacent said first layer,
c) and including bonding resin adherent to fibers in said layers, the fiber composite being porous,
d) and wherein the bulk of said glass fibers have:
i) diameters between 1 and 16 microns
ii) lengths between ¼ and 1½ inches.
26. The combination of claim 25 wherein the additional layer faces the first layer, and consists of NYLON or RAYON.
27. The combination of claim 25 wherein the bonding resin consists essentially of thermoplastic resin adapted to be heated during reforming of the filter to selected shape.
28. The combination of claim 27 wherein the filter has been reformed to selected shape, said selected shape including pleats.
29. The combination of claim 25 wherein the resin is thermosetting.
30. The method of forming a filter media composite which includes the steps:
a) providing a first layer of glass fibers having random orientation,
b) providing an additional layer of synthetic resinous or other man-made fibers extending adjacent said first layer,
c) and providing and adhering bonding resin to fibers in said layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter.
31. The method of claim 30 wherein the bonding resin consists essentially of thermoplastic resin, and including reforming the media composite to selected shape and heating the reformed media composite to cause the composite to maintain said selected shape.
32. The method of claim 30 wherein the bonding resin is thermosetting.
33. The method of claim 30 wherein an additional layer is positioned to face the first layer, and consists of a non-woven fiber backer.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/376,026 US20030127171A1 (en) | 2000-06-20 | 2003-02-28 | Filter composite embodying glass fiber and synthetic resin fiber |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/597,080 US6555489B1 (en) | 2000-06-20 | 2000-06-20 | Filter composite embodying glass fiber and synthetic resin fiber |
US10/376,026 US20030127171A1 (en) | 2000-06-20 | 2003-02-28 | Filter composite embodying glass fiber and synthetic resin fiber |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/597,080 Division US6555489B1 (en) | 2000-06-20 | 2000-06-20 | Filter composite embodying glass fiber and synthetic resin fiber |
Publications (1)
Publication Number | Publication Date |
---|---|
US20030127171A1 true US20030127171A1 (en) | 2003-07-10 |
Family
ID=24390011
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/597,080 Expired - Fee Related US6555489B1 (en) | 2000-06-20 | 2000-06-20 | Filter composite embodying glass fiber and synthetic resin fiber |
US10/376,026 Abandoned US20030127171A1 (en) | 2000-06-20 | 2003-02-28 | Filter composite embodying glass fiber and synthetic resin fiber |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/597,080 Expired - Fee Related US6555489B1 (en) | 2000-06-20 | 2000-06-20 | Filter composite embodying glass fiber and synthetic resin fiber |
Country Status (2)
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US (2) | US6555489B1 (en) |
DE (1) | DE10128857A1 (en) |
Cited By (2)
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US7427575B2 (en) | 2004-06-02 | 2008-09-23 | Owens Corning Intellectual Capital, Llc | Faced fibrous insulation |
WO2019065625A1 (en) * | 2017-09-29 | 2019-04-04 | 株式会社クラレ | Liquid permeable member |
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US20050284065A1 (en) * | 2004-06-02 | 2005-12-29 | Shaffer Roy E | Faced fibrous insulation |
WO2006017703A1 (en) * | 2004-08-05 | 2006-02-16 | Akers Biosciences, Inc. | Blood separator and method of separating a fluid fraction from whole blood |
US8021457B2 (en) | 2004-11-05 | 2011-09-20 | Donaldson Company, Inc. | Filter media and structure |
US8057567B2 (en) | 2004-11-05 | 2011-11-15 | Donaldson Company, Inc. | Filter medium and breather filter structure |
BRPI0520889B1 (en) * | 2004-11-05 | 2020-11-03 | Donaldson Company, Inc. | method of filtering a liquid stream and method of filtering a heated fluid |
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ATE442893T1 (en) | 2005-02-22 | 2009-10-15 | Donaldson Co Inc | AEROSOL SEPARATOR |
MX2009009046A (en) | 2007-02-22 | 2009-10-14 | Donaldson Co Inc | Filter element and method. |
EP2125149A2 (en) | 2007-02-23 | 2009-12-02 | Donaldson Company, Inc. | Formed filter element |
US20080233825A1 (en) * | 2007-03-21 | 2008-09-25 | Mohamed Walid Gamaleldin | Articles Including High Modulus Fibrous Material |
US8673040B2 (en) | 2008-06-13 | 2014-03-18 | Donaldson Company, Inc. | Filter construction for use with air in-take for gas turbine and methods |
US8267681B2 (en) | 2009-01-28 | 2012-09-18 | Donaldson Company, Inc. | Method and apparatus for forming a fibrous media |
WO2011017457A2 (en) * | 2009-08-04 | 2011-02-10 | The Xextex Corporation | High efficiency low pressure drop synthetic fiber based air filter made completely from post consumer waste materials |
US20150096444A1 (en) * | 2013-10-04 | 2015-04-09 | Bha Altair, Llc | Nonwoven felt with hollow specialty polymer fibers for air filtration |
US20150096443A1 (en) * | 2013-10-04 | 2015-04-09 | Bha Altair, Llc | Nonwoven felt with hollow commodity polymer fibers for air filtration |
CN106795055A (en) | 2014-10-10 | 2017-05-31 | Fp创新研究中心 | Composition, panel and sheet material and its production method comprising mineral filler |
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Also Published As
Publication number | Publication date |
---|---|
US6555489B1 (en) | 2003-04-29 |
DE10128857A1 (en) | 2002-02-28 |
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Legal Events
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