U.S. patent application number 09/106506 was filed with the patent office on 2002-03-07 for structured surface filtration media.
Invention is credited to INSLEY, THOMAS I., JOHNSTON, RAYMOND P..
Application Number | 20020027101 09/106506 |
Document ID | / |
Family ID | 22311777 |
Filed Date | 2002-03-07 |
United States Patent
Application |
20020027101 |
Kind Code |
A1 |
INSLEY, THOMAS I. ; et
al. |
March 7, 2002 |
STRUCTURED SURFACE FILTRATION MEDIA
Abstract
A filtration media having at least one structured polymeric
layer, wherein a structured surface is defined within the layer.
Layers may be configured as a stack that has the structured
surfaces defining a plurality of ordered inlets open through a face
of the stack and corresponding ordered fluid pathways, thereby
forming an ordered, porous volume. The ordered fluid pathway may be
defined by a plurality of flow channels formed within the
structured surfaces of the structured layers, or may be defined by
a plurality of protuberances formed in an ordered pattern within
the structured surfaces of the structured layers.
Inventors: |
INSLEY, THOMAS I.; (WEST
LAKELAND TOWNSHIP, MN) ; JOHNSTON, RAYMOND P.; (LAKE
ELMO, MN) |
Correspondence
Address: |
KARL G HANSON
3M OFFICE OF INTELLECTUAL
PROPERTY COUNSEL
P O BOX 33427
ST PAUL
MN
551333427
|
Family ID: |
22311777 |
Appl. No.: |
09/106506 |
Filed: |
June 18, 1998 |
Current U.S.
Class: |
210/488 ;
210/490; 210/492; 210/767 |
Current CPC
Class: |
B01D 39/1692
20130101 |
Class at
Publication: |
210/488 ;
210/490; 210/492; 210/767 |
International
Class: |
B01D 029/05; B01D
029/07 |
Claims
What is claimed is:
1. A filtration media comprising: a plurality of polymeric
structured layers having a structured surface defined within each
layer, the plurality of structured layers configured as a stack
with the structured surfaces defining a plurality of ordered inlets
open through a face of the stack and corresponding ordered fluid
pathways forming an ordered, porous volume.
2. The filtration media of claim 1, wherein the ordered fluid
pathways are defined by a plurality of flow channels formed within
the structured surfaces of the structured layers.
3. The filtration media of claim 2, wherein the plurality of flow
channels are defined by a series of peaks, each peak having two
sidewalls.
4. The filtration media of claim 3, wherein the sidewalls of
adjacent peaks of the flow channels are separated by a planar
floor.
5. The filtration media of claim 3, wherein the sidewalls of
adjacent peaks of the flow channels are separated by at least one
sub-peak, the sub-peak defining a plurality of sub-channels within
each flow channel.
6. The filtration media of claim 3, wherein the peaks comprise
heads that overhang adjacent flow channels and the structured
layers comprising flow channels with headed peaks face one another,
the headed peaks of one facing structured layer engaging with the
headed peaks of the other facing structured layer.
7. The filtration media of claim 2, wherein the flow channels of a
structured layer each comprise a cross-sectional characteristic,
the cross-section characteristic of at least a portion of the flow
channels varying across the surface of the structured layer.
8. The filtration media of claim 2, wherein one flow channel of a
structured layer is configured differently from another flow
channel of the same structured layer.
9. The filtration media of claim 8, wherein a flow channel of one
structured layer is configured differently from a flow channel of
another structured layer.
10. The filtration media of claim 2, wherein the flow channels of
one structured layer are offset relative to the flow channels of an
adjacent structured layer within the stack.
11. The filtration media of claim 1, wherein the ordered fluid
pathways are defined by a plurality of discrete protuberances
formed in an ordered pattern within the structured surfaces of the
structured layers.
12. The filtration media of claim 11, wherein the ordered pattern
of discrete protuberances is an aligned array.
13. The filtration media of claim 11, wherein at least two of the
structured layers face one another, the discrete protuberances of
the facing layers engaging in an ordered manner.
14. The filtration media of claim 1, wherein at least a portion of
the plurality of structured layers are bonded together.
15. The filtration media of claim 1, further comprising a cap layer
covering at least a portion of one of the plurality of structured
layers.
16. The filtration media of claim 15, wherein the cap layer
comprises the top most layer of the stack of structured layers.
17. The filtration media of claim 1, further comprising at least
one additional layer located between two adjacent structured layers
for the purpose of enhancing filtration performance.
18. The filtration media of claim 17, wherein the two adjacent
structured layers face one another with the additional layer in
between them.
19. The filtration media of claim 17, wherein the additional layer
is an electret.
20. The filtration media of claim 17, wherein the additional layer
comprises a material for providing at least one of the filtration
benefits of enhanced particle removal, oil and water repellency,
odor removal, organic matter removal, ozone removal, disinfection,
drying, and fragrance introduction.
21. The filtration media of claim 17, wherein the additional layer
comprises more than one additional layer located between two
adjacent structured layers.
22. The filtration media of claim 17, wherein the additional layer
comprises more than one additional layer, each additional layer
located between different pairs of adjacent structured layers.
23. The filtration media of claim 1, wherein every structured layer
of the stack is formed from the same polymeric material.
24. The filtration media of claim 1, wherein at least a portion of
the plurality of structured polymeric layers are formed from
polytetrafluoroethylene.
25. The filtration media of claim 1, wherein at least a portion of
the plurality of structured polymeric layers are formed from
polypropylene.
26. The filtration media of claim 1, wherein at least a portion of
the plurality of structured layers are treated for the purpose of
enhancing filtration performance.
27. The filtration media of claim 26, wherein the structured layers
comprise electret material.
28. The filtration media of claim 26, wherein the structured layers
comprise material for providing at least one of the filtration
benefits of enhanced particle removal, oil and water repellency,
odor removal, organic matter removal, ozone removal, disinfection,
drying, and fragrance introduction.
29. A method of filtering comprising: providing a filtration media,
the filtration media comprising a plurality of polymeric structured
layers having a structured surface defined within each layer, the
plurality of structured layers configured as a stack with the
structured surfaces defining a plurality of ordered inlets open
through a face of the stack and corresponding ordered fluid
pathways forming an ordered, porous volume; positioning the
filtration media in a fluid flow path; passing fluid through the
filtration media; and removing particles from the fluid in the
filtration media.
30. The method of claim 29, wherein providing a filtration media
further comprises slicing the stack of structured layers and
providing at least a portion of the sliced stack to form a
filtration media of a specified thickness.
31. The method of claim 29, wherein providing a filtration media
further comprises treating at least a portion of the plurality of
structured layers to provide at least one the filtration benefits
of enhanced particle removal, oil and water repellency, odor
removal, organic matter removal, ozone removal, disinfection,
drying, and fragrance introduction.
32. The method of claim 31, wherein treating comprises charging at
least a portion of the plurality of structured layers to form an
electret.
33. The method of claim 31, wherein treating comprises metallizing
at least a portion of the plurality of structured layers, and
actively charging the metallized layers by connecting the
metallized layers to a voltage source during filtering.
34. The method of claim 31, wherein treating comprises surface
coating at least a portion of the plurality of structured
layers.
35. The method of claim 31, wherein treating comprises adding at
least one additional layer between adjacent structured layers for
the purpose of providing the filtration benefits.
36. The method of claim 29, wherein providing the filtration media
further comprises directing fluid flow to a specific destination by
configuring the ordered fluid pathways within the filtration
media.
37. A method of making and using a filtration media comprising:
providing a plurality of structured layers having a structured
surface defined within each layer; stacking the plurality of
structured layers with the structured surfaces defining a plurality
of ordered inlets open through a face of the stack and
corresponding ordered fluid pathways, thereby forming an ordered,
porous volume; positioning the ordered, porous volume in a fluid
flow path; passing fluid through the ordered, porous volume; and
removing particles from the fluid in the ordered, porous
volume.
38. The method of claim 37, further comprising bonding at least a
portion of the plurality of structured layers within the ordered,
porous volume.
39. The method of claim 37, further comprising slicing the stack of
structured layers and providing at least a portion of the sliced
stack to form an ordered, porous volume of a specified
thickness.
40. The method of claim 37, further comprising treating at least a
portion of the plurality of structured layers to provide at least
one of the filtration benefits of enhanced particle removal, oil
and water repellency, odor removal, organic matter removal, ozone
removal, disinfection, drying, and fragrance introduction.
41. The method of claim 40, wherein treating comprises charging at
least a portion of the plurality of structured layers to form an
electret.
42. The method of claim 40, wherein treating comprises metallizing
at least a portion of the plurality of structured layers, and
actively charging the metallized layers by connecting the
metallized layers to a voltage source during use of the filtration
media.
43. The method of claim 40, wherein treating comprises surface
coating at least a portion of the plurality of structured
layers.
44. The method of claim 40, wherein treating comprises adding at
least one additional layer between adjacent structured layers for
the purpose of providing the filtration benefits.
45. The method of claim 37, further comprising directing fluid flow
to a specific destination by configuring the ordered fluid pathways
within the ordered, porous volume.
46. A filtration media comprising: at least one polymeric
structured layer having a first major surface with a structured
surface defined within the layer, the structured surface providing
plural ordered fluid pathways, and at least a portion of the
structured surface having a treatment for enhancing its particle
removal capability as compared to a similar structured polymeric
layer without said treatment.
47. The filtration media of claim 46, wherein the structured layer
comprises an electret.
48. The filtration media of claim 46, wherein at least a portion of
the structured layer is electrostatically charged.
49. The filtration media of claim 46, wherein at least a portion of
the structured layer is treated with a tacky substance.
50. The filtration media of claim 46, further comprising a cap
layer covering at least a portion of the structured layer.
51. The filtration media of claim 46, further comprising a
plurality of polymeric structured layers, each having a first major
surface with a structured surface defined within the layer, the
plurality of structured layers are configured as a stack with the
structured surfaces defining a plurality of ordered inlets open
through a face of the stack and corresponding ordered fluid
pathways forming an ordered, porous volume.
Description
[0001] The present invention relates to a filtration media and
device comprising at least a layer having a structured surface that
defines highly ordered fluid pathways.
BACKGROUND
[0002] An important segment of filtration media and filtering
device development for removing particles from a fluid stream has
been in the nonwoven fiber technology area. From the use of webs
derived from meltblown microfibers to that of microdenier staple
fibers, the trend has been to decrease fiber size in order to
increase available surface area per unit volume of web. These
nonwovens are generally polymeric based, entanglement bonded, low
density webs that incorporate micron or near micron size
fibers.
[0003] The principle mechanisms that control particle removal from
a fluid stream by a fibrous filter are direct interception,
inertial impaction, diffusion, and electrostatic attraction.
Particle collection by interception occurs when a particle
following a gas streamline strikes and is captured by the filtering
surface. Inertial impaction results when particles deviate from the
fluid stream to strike the fibers. Impacted particles in both cases
adhere to the fibers by forces such as Van der Walls' forces.
Diffusional collection occurs when the Brownian motion of very
small particles enhances the probability of their contact with the
filtering surface. This motion causes the particles to deviate from
fluid stream lines and collect on the individual filter fibers.
Electrostatic collection is an important mechanism whereby charged
particles are attracted to oppositely charged collection surfaces
by coulombic attraction.
[0004] Fibrous fluid filters, especially gas filters, typically
combine all four capture mechanisms. Nonwoven filters incorporate
the advantages of these fibrous filters due to their inherent
properties. However, limitations with nonwovens as filtration media
also stem from their inherent properties. Nonwoven webs by
definition are randomly formed structures that have limited
geometric order. Limited order is caused by the variability between
individual fibers and the degree of fiber to fiber conformation
within the web. This limited order is manifested by gross
irregularities caused by the formation of macrostructures known as
shingles and fiber nests. Web macrostructures have local
concentrations of fibers that cause pore size variability as well
as mass variability across the webs. As a result, relatively large
openings between the fibers allow particles through that should
have been excluded, and small openings fill and become ineffective.
In filter media design these limitations are moderated by the use
of additional material at the cost of higher flow resistance across
the filter. These effects can be compounded during use in
filtration applications by the force of the applied fluid, which
can alter the web structure and thus the efficacy of the filtration
device. In addition, pressure loading of the web, wherein the web
is mechanically formed into product, for example, a pleated
structure, can also cause additional deformation of the fibers and
web, resulting in a decrease in filtration efficacy.
[0005] Other limitations of high surface area nonwoven webs as
filtration media occur when the filter employs thin flat layers of
nonwoven web, such as in respirators, or the filter employs pleated
layers in a more three-dimensional arrangement, such as in room,
furnace or computer filters. Because of their respective usages,
the fluid velocity across the face of the respirator type filters
tends to be lower, whereas the fluid velocity across the face of
circulating air filters, i.e. the room, furnace or computer
filters, tends to be higher. In both situations, however, the
nonwoven web material typically performs as a surface loading
filter, thereby eventually resulting in surface blinding. In
surface binding, the first encountered layers of filter material
fill and clog with particulate matter removed from the fluid
stream. Therefore, the filters are not effectively using the
greater portion of the filter mass, and thus the filters'
performance is limited based on filter surface area rather than
filter volume.
[0006] The use of multiple layers to increase filter efficiency,
especially in respirator type filters, can cause an increase in
flow resistance across the media as the fluid passes through the
filter layers. Flow resistance is a function of the gas face
velocity and the relationship of the size, orientation, and number
of torturous channels through the filter. Generally, a filter media
with more uniformly distributed surface area will achieve greater
overall filtration efficiency permitting the use of less material
and, in turn, reduce flow resistance across the media.
[0007] Flow resistance across a filter media is a general design
constraint for any filtration device. Flow resistance is
particularly problematic in lower face velocity applications
because the fluid velocity is low even before filtering, and any
resistance to flow within the filter will have a dramatic effect on
its output. This flow resistance can cause problems with the
overall fluid handling system in which the filter is used.
[0008] Pleated structures of smaller fiber nonwoven webs are often
used in the higher face velocity applications to reduce flow
resistance and improve service life. This is because there is more
filtering surface in a given volume, thereby increasing the
percentage of surface openings per frame area of filter. When the
nonwoven web is composed of microfibers, however, pleated
structures can sometimes reduce web loft, (see U.S. Pat. No.
5,656,368 to Braun et al.) and may be limited by the size of the
microfibers used because smaller fibers are more likely to cause
surface blinding. Larger fibers may cause the filter to suffer from
reduced overall filtering capacity due to a decrease in the actual
fiber surface area.
[0009] Another means of improving filter efficiency is through
treatment of the filter fibers to make them more attractive to the
particles or the like to be removed from a fluid stream. Treatment
methods include both passive and active electrostatic charging of
the fibers, application of tacky material to the fibers,
application of chemical additives such as catalysts or other
reactive agents, as well as application of other types of
additives, including deodorizers, drying agents, disinfectants,
fragrances, and ozone removing agents. Although treatment methods
can enhance particle capture by the fibers, the filters are still
subject to the deficiencies associated with random media, such as
surface blinding and the flow resistance limitations discussed
above. Examples of treated filter media include commercial filter
products known as electrets, such as those available from 3M
Company under the trade designation "Filtrete".
[0010] Other types of filter media available for particle removal
from a fluid stream include woven and knit materials. These types
of materials tend to have a more ordered structure, thereby making
them less susceptible to the limitations inherent in nonwovens.
These materials, however, have their own problems with controlling
structures fidelity due to variability in constituent fiber
material, fiber formation and web construction. In addition, other
problems include limitations such as small enough pore formation,
constituent material costs, and manufacturing costs.
SUMMARY OF THE INVENTION
[0011] The present invention overcomes the disadvantages and
shortcomings of the prior art by providing a filtration media or
filtration device that is efficient, is capable of depth-bed
loading, functions at a low flow resistance, and has a high
collection capacity. More specifically, the present invention
provides a filtration media comprising at least a layer having a
structured surface that defines highly ordered fluid pathways.
Preferably, the filtration media of the present invention comprises
a stack of layers having structured surfaces defining a highly
ordered array of filter openings and fluid pathways through the
filtration media.
[0012] The structured surfaces of the layers may comprise features
defining channels that form the fluid pathways, or may comprise
features such as discrete protuberances that form the fluid
pathways. The filter openings defined by the stacked structured
layers remove particles by exclusion. Non-exclusion removal of
particles is facilitated by the surface area of the structured
surface features.
[0013] Filtration media in accordance with the present invention
has the advantage of being efficient and having a high capacity
because it uses the full volume by performing as a depth-bed
filter, instead of as a surface filter. It is easily and
economically manufactured from a variety of materials, including
inexpensive, flexible or rigid polymers. The structured surface
features of the filtration media are highly controllable,
predictable and ordered, and are formable with high reliability and
repeatability using known microreplication or other techniques. The
filtration media can be produced in a high variety of
configurations to meet the filtration requirements of a given
application. This variety is manifested in: structured surface
feature possibilities--discrete channels, open channels, or
protuberances; channel configurations--wide, narrow, `V` shaped,
and/or sub-channels; stack configurations--bonded or unbonded,
facing layers, non-facing layers, added layers, aligned channels,
offset channels, and/or channel patterns; and filter openings--pore
size, pore configuration, or pore pattern. In addition, the layers
may be treated for enhanced filtration or other purposes.
[0014] The aforementioned advantages are achieved by a filtration
media formed from at least one polymeric layer having a structured
surface defined within it. Layers may be configured as a stack with
the structured surfaces of the layers defining a plurality of
ordered inlets open through a face of the stack and corresponding
ordered fluid pathways, or may be a single layer with a structured
surface having a cap layer, or may be an uncapped layer having a
structured surface. In a stacked or capped arrangement, the layers
thus form an ordered, porous volume. The ordered fluid pathways of
the filtration media may be defined by a plurality of flow channels
formed within the structured surfaces of the layers, or they may be
defined by a plurality of discrete protuberances formed within the
structured surfaces of the layers.
[0015] The plurality of flow channels are preferably defined by a
series of peaks, each having two sidewalls. The peaks may be
separated by a planar floor or by sub-peaks forming sub-channels
within the flow channels. The peaks may have heads that overhang
adjacent flow channels. The flow channels of a layer having a
structured surface may be all the same or may be different. Each
layer of the filtration media may have the same flow channel
configuration, or may be different. The flow channels on adjacent
layers may be aligned or may be offset.
[0016] Pairs of layers of the filtration media may face one
another, and facing layers may engage one another. Layers may have
structured surfaces defined on both faces. Additional layers may be
added to the stack. A cap layer may cover a portion of the top of
the layer, and additional layers may be placed between adjacent
layers of the stack. The layers of the stack, or a layer and a cap
layer, may be bonded together. The layers may be formed from the
same or different polymeric materials. The filtration media may be
treated to enhance particle removal or to provide other benefits
such as providing oil and water repellency, removing odors,
removing organic matter, removing ozone, disinfecting, drying, and
introducing fragrance. Treatment may include charging of the layers
to form an electret, surface coating of the layers, or addition of
treated layers.
[0017] The aforementioned advantages may also be achieved by a
method of filtering using the filtration media of the present
invention. This method includes providing the filtration media,
positioning the filtration media in a fluid flow path, passing a
fluid through the filtration media, and removing particles from the
fluid in the filtration media. This method may further comprise
slicing a portion of a stack of layers having structured surfaces
into a specific thickness to use as the filtration media, treating
a portion of the layers to provide filtration benefits, and
directing fluid flow to a specific destination by configuring the
ordered fluid pathways within the filtration media.
[0018] In addition, these advantages may be achieved by a method of
making and using the filtration media of the present invention.
This method provides at least one layer having a structured surface
defining highly ordered fluid pathways. The method may provide a
plurality of layers having structured surfaces defining highly
ordered fluid pathways by stacking the plurality of layers with the
structured surfaces to define a plurality of ordered inlets open
through a face of the stack and corresponding ordered fluid
pathways and thereby forming an ordered, porous volume. The method
also includes positioning the ordered, porous volume in a fluid
flow path, passing fluid through the ordered, porous volume, and
removing particles from the fluid in the ordered, porous volume.
This method may also further comprise bonding of a portion of the
layers, slicing a portion of the layers into a specific thickness,
treating a portion of layers to provide filtration benefits, and
directing fluid flow to a specific destination by configuring the
ordered fluid pathways within the filtration media.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of a stack of layers having
structured surfaces forming a filtration media in accordance with
the present invention;
[0020] FIG. 2 is an end view of a stack of layers having structured
surfaces forming the filtration media of FIG. 1;
[0021] FIG. 3 is a perspective view of filtration media formed from
layers having structured surfaces;
[0022] FIG. 4 is an enlargement of a portion of the filtration
media shown in FIG. 3;
[0023] FIG. 5 is an end view of stacked layers having structured
surfaces illustrating an alternative layer configuration that may
be used for filtration media in accordance with the present
invention;
[0024] FIG. 6 is an end view of stacked layers having structured
surfaces illustrating another alternative layer configuration that
may be used for filtration media in accordance with the present
invention;
[0025] FIG. 7 is an end view of a layer having a structured surface
illustrating one particular channel configuration that may be used
for filtration media in accordance with the present invention;
[0026] FIG. 8 is an end view of a layer having a structured surface
illustrating another channel configuration that may be used for
filtration media in accordance with the present invention;
[0027] FIG. 9 is an end view of a layer having a structured surface
illustrating yet another channel configuration that may be used for
filtration media in accordance with the present invention;
[0028] FIG. 10 is an end view of a stack of layers having
structured surfaces wherein facing layers engage by means of headed
channels;
[0029] FIG. 11 is an end view of a stack of layers having
structured surfaces with additional layers interposed between
facing and non-facing layers;
[0030] FIG. 12 is a perspective view of a portion of a layer having
a structured surface that has discrete, headed protuberances formed
in an ordered array; and
[0031] FIG. 13 is a front view of a respirator mask using
filtration media in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] With reference to the attached figures, like components are
labeled with like numerals throughout the several figures. FIGS.
1-4 illustrate filtration media 10 that includes stacked layers 12.
Each layer 12 has a structured surface 13 on at least one of its
two major surfaces, where a structured surface 13 comprises a
surface with a topography (the surface features of an object, place
or region thereof). In this embodiment, the structured surfaces 13
comprise a plurality of channels 25 formed within the layers 12
preferably as shown in a consistent, ordered manner. These channels
25 are defined by a series of peaks 28 formed of sidewalls 26 with
or without a planar floor 30 in between them. Together the stacked
layers 12 form a three dimensional, highly ordered, porous
filtration media 10 wherein fluid, such as air, can flow through
the media 10 via ordered fluid pathways, as defined by the channels
25, so that particulate or other matter can be removed from the
fluid by exclusion and/or adherence to the structured surfaces. By
ordered, it is meant that the pathways defined through the media
are predetermined. As exemplified below, each pathway need not be
the same as another of the same layer or a different layer. Each
pathway is, however, predetermined in the sense that each pathway
is set by a predetermined design of the structured surface 13 of
each layer 12. A porous media is one that merely permits fluid flow
through the media by way of more than a single flow path. FIGS. 3
and 4 are electron micrograph illustrations of an embodiment of a
filtration media 10 in accordance with the present invention
defining a highly ordered array of channels 25 made up from many
layers 12.
[0033] The layers 12 may each comprise similar or different
flexible, semi-rigid, or rigid material, which may be chosen
depending on the particular application of the filtration media 10.
Preferably, each of the layers 12 comprise a polymeric material
because such material is typically less expensive and because such
polymeric material can be accurately formed with a structured
surface 13. The use of a polymeric layer 12 in the form of, for
example, a film layer can provide a structured surface defining a
large number of and high density of fluid flow channels 25 on a
major surface thereof Thus, a highly ordered porous filtration
media of the invention is amenable to being manufactured with a
high level of accuracy and economy.
[0034] As shown in FIGS. 1-4, this filtration media 10 is formed by
stacking of the layers 12, one on top of another. In this manner,
any number of layers 12 can be stacked together to form a
filtration media 10 having adequate height and porous area designed
specifically based upon the particular application. One advantage
of direct stacking of layers 12 on each other is that the second
major surface 11 of each layer 12 provides a cap on the channels 25
of the lower adjacent layer 12. Therefore, each channel 25 may
become a discrete pathway for fluid flow through the filtration
media 10.
[0035] A layer 12 may be bonded to the peaks 28 of some or all of
the structured surface 13 of an adjacent layer to enhance the
creation of discrete pathways from the channels 25. This can be
done using conventional adhesives that are compatible with the
materials of the layers 12, or this can be done using heat bonding,
ultrasonic bonding, mechanical devices, or the like. Bonds may be
provided entirely along the peaks 28 to the adjacent surface 11, or
may be spot bonds provided in accordance with an ordered pattern,
or randomly. Alternatively, the layers 12 may simply be stacked
upon one another whereby the structural integrity of the stack
adequately enhances the creation of discrete flow channels 25.
[0036] To close off some, but preferably all of the channels 25 of
the uppermost layer 12, a cap layer 20 may also be provided, as
shown in FIG. 1. This cap layer 20 may be bonded or unbonded in the
same or a different manner as the inter-layer bonding described
above. The material for cap layer 20 can be the same or different
from the material of the layers 12.
[0037] The embodiments of the filtration media 10 shown in FIGS. 1,
3 and 4 comprise ordered linear channels. These channels may be
aligned in a precise array, that is the channels of each layer line
up with the channels of the other layers, thereby presenting a
regular, aligned pore pattern. Alternatively, these channels may be
offset in a regular, repeating manner, or they may be offset in a
controlled manner. In addition, other channel and layer
configurations are contemplated.
[0038] FIGS. 3 and 4 illustrate an embodiment in accordance with
the present invention where numerous layers 12 of filtration media
80 having structured surfaces 13 are stacked in a controlled and
ordered manner but not necessarily in an aligned manner. The
resulting stack of layers 12 has been sliced, forming a volume of
controlled depth. FIG. 4 depicts an enlargement of a portion of the
filtration media 80 of FIG. 3. Each structured surface 13 comprises
consistent channels 25 defined by peaks 28 separated by a floor 30.
The floor 30 comprises secondary channels 34. (This type of channel
configuration will be discussed more below in relation to FIG. 9.)
The resulting filtration media 80 provides a highly ordered, porous
surface through which a fluid to be filtered would flow. Each
available channel 25 then provides a fluid pathway through the
controlled depth of the filtration media 80.
[0039] FIG. 5 illustrates an embodiment where each layer 41 to 44
of filtration media 40 has a different channel configuration, and
the layers 41 to 44 are arranged in varying repeat patterns with
respect to each other. As can be seen, layer 41 comprises
consistent wide channels 47, layer 42 comprises narrower consistent
channels 48, layer 43 comprises a repeating pattern of wide 47 then
narrow 48 channels, and layer 44 comprises a repeating pattern of
two narrow 48, then one wide 47 channels. Channel repeat patterns
could also be random, or the selection of layers comprising the
stack could be done in a pattern or in a random fashion. In any
case, these configurations would still create ordered pathways
because the opening sizes and channel structures formed would be as
expected. FIG. 6 illustrates an embodiment of a filtration media 45
wherein the channels 49 of each layer 46 are consistent, but the
relationship of the layers 46 to each other is an alternating
pattern. The choice of channel configurations, number of channels,
and or layer relationships depends on the particular application
for which the filtration media is desired.
[0040] FIG. 11 illustrates an embodiment wherein filtration media
60 comprises similar layers 62, 63 and 70 having channels 64
defined by peaks 65 within structured surface 61. However, the
layers 62, 63 and 70 differ in their orientation and repeat pattern
with respect to each other. Layer 62 is an upward facing layer,
whereas layers 63 and 70 are downward facing layers. These layers
62, 63 and 70 are all arranged in a varying stack configuration,
including additional layers 66, 68 and 69. As illustrated, layers
may be arranged to face one another, may be back-to-back, or may be
stacked in the same orientation. In addition, the repeat pattern
with respect to one another can provide for aligned channels or
offset channels, in numerous variations. As is evident from FIGS.
5, 6 and 11, the channel and layer configurations available with
the present invention provide versatility and adaptability to meet
any filtration requirement.
[0041] Although the embodiment of FIG. 1 is shown with structured
surfaces 13 comprising multiple peaks 28 and wide floors 30,
continuously provided from one side edge 14 to the other side edge
15, other channel configurations are contemplated. In most cases,
it will be desirable to provide a series of peaks 28 entirely from
one edge 14 of the layer 12 to the other edge 15; however, for some
applications, it may be desirable to extend the peaks 28 only along
a portion of the structured surface 13 on any given layer 12. In
addition, a specific application for the filtration media 10 may
determine the number, type and size of the channels 25 provided to
meet the filtration requirements.
[0042] For example, as shown in FIG. 7, channels 16 are defined by
a continuous series of peaks 18 which are not separated by a floor.
Therefore, the sidewalls 17 of each successive peak 18 converge to
define a line at the base of the channel 16. A filtration media 10'
formed from stacks of layers 12 having this type of channel 16 is
shown in FIG. 2. In FIG. 8, the channels 25 are defined by a
continuous series of peaks 27 that are separated by a wide, flat
floor 30. Each peak 27 is flattened at the top, thereby
facilitating bonding to an adjacent layer. In FIG. 9 (as well as in
FIGS. 3 and 4), wide channels 32 are defined between peaks 29, but
instead of providing a planar floor between channel sidewalls 31, a
plurality of smaller sub-peaks 33 are provided. These sub-peaks 33
thus define secondary channels 34 therebetween. Sub-peaks 33 may or
may not rise to the same level as peaks 29, and as illustrated,
create a first wide channel 32 including smaller channels 34
distributed therein. The peaks 29 and sub-peaks 33 need not be
evenly distributed with respect to themselves or each other. This
configuration has the added advantage of increasing the amount of
channel surface area upon which particulate matter may impinge
during filtration. Moreover, the smaller channels 34 can be used to
control fluid flow through the wider channels 32.
[0043] Although FIGS. 1-11 illustrate elongated,
linearly-configured channels, the channels may be provided in many
other configurations. For example, the channels could have varying
cross-sectional widths along the channel length; that is, the
channels could diverge and/or converge along the length of the
channel. The channel sidewalls could also be contoured rather than
being straight in the direction of extension of the channel, or in
the channel height. Generally, any channel configuration that can
provide at least multiple discrete channel portions that extend
from a first point to a second point within the filtration media
are contemplated.
[0044] The structured surface filtration media may be particularly
useful where it is desirable to circulate a particular fluid
through the media to influence a characteristic of the fluid by its
contact with the structured surface(s). That is, the fluid may be
treated by its passing through the channels defined by the
surfaces(s). Fluid treatment might include chemical, catalytic, and
ionization reactions promoted by constituents placed on, in, or
through the channel surfaces. Ionization reactions may include
reactions promoted by e-beam, actinic light, and ultraviolet
radiation. Separation treatments such as by sorption of fluid
constituents onto properly prepared channel surfaces would be
effective due to the high ratio of channel surface area to channel
volume. The same attributes could be used to permit the sensing or
detecting of a passing fluid where the surface layer(s) act as the
fluid interface component in a sensor or detector system. A fluid
detection system might monitor fluid conductivity, pH, temperature,
or composition. Alternately, a fluid influenced by the surrounding
environment as it circulates through the channels could be
monitored as part of a detection system where the device would
itself function as an element in a sensor or detection system. The
surface of the flow channels could also be functionalized to
respond or detect these physical conditions. Heating or cooling
could be used to thermally treat the fluid. Fluid streams of
different composition also could be made to merge together to
interact and treat one another as a means to cause a reaction,
dilution, or blending. An observation, detection, or analytical
device such as a microscope or spectrometer, remote to the media
may be used to analyze fluid as it passes in a thin film through
the channels. In any case, as with any of the noted embodiments,
the structure can be made from flexible, semi-rigid, or rigid
materials.
[0045] In another embodiment of filtration media 50, as shown in
FIG. 10, the structured surface 51 comprises channels 52 that are
defined by a series of peaks 54 having heads 56 which overhang
adjacent channels 52. Although these peaks 54 and heads 56 are
shown as a mushroom-like feature, any headed configuration is
contemplated. The facing layers 58 and 59 comprising such channels
52 are stacked together by offsetting the channels 52 of the layers
58 and 59, and engaging the peaks 54 and heads 56 of one layer 58
with the peaks 54 and heads 56 of the other layer 59. Thus, the
peak 54 and head 56 of one layer 58 is located within a channel 52
of the other layer 59. A plurality of these engaged layers 58 and
59 are then stacked together to form the filtration media 50.
Alternatively, the layers 58 and 59 may be non-facing layers
stacked together such that the non-structured surface 57 serves as
a cap for an adjacent layer. (Not shown). As with the other
embodiments discussed above, the layers may or may not be bonded
together as a stack. The resulting channel structure of this
embodiment has the advantage of increasing the channel surface area
in contact with the fluid being filtered, thus improving
particulate removal.
[0046] Alternatively, the filtration media 50 may be formed from
stacked layers 80 wherein the structured surfaces 82 comprise
ordered arrays of discrete, headed protuberances 84, as shown in
FIG. 12, instead of headed channels. These protuberances 84 also
may be formed as mushroom-like structures, but other headed
structures are contemplated. The protuberances 84 may be formed in
an aligned array on the structured surface 82, or they may be
formed in an offset array or other ordered pattern. Layers 80
comprising these protuberances 84 may be stacked together by facing
the layers 80, and engaging the protuberances 84 of one layer 80
among the protuberances 84 of the other layer 80, similar to layers
58 and 59 of FIG. 10. The protuberances of one layer need not be
the same as the protuberances of an adjacent layer. Alternatively,
the layers 80 may be non-facing layers stacked together such that
the non-structured surface 83 serves as a cap for an adjacent
layer. Whether the layers 58, 59 and 80 are formed from headed
channels or discrete protuberances, ordered fluid pathways through
the filtration media 50 are provided. These types of layers provide
the added advantage of increasing the percentage of openings per
volume without decreasing the surface area, i.e., decreasing
percent solidity with respect to face surface area, thereby
improving filtration efficacy without increasing flow
resistance.
[0047] In some embodiments of the present invention, the structured
surfaces 13 of filtration media 10 are microstructured surfaces
that define discrete flow channels, including those contemplated
above. As used here, aspect ratio means the ratio of a channel's
length to its hydraulic radius, and hydraulic radius is the
wettable cross-sectional area of a channel divided by its wettable
channel circumference. When an embodiment of the present invention
comprises discrete flow channels, each channel may have a minimum
aspect ratio (length/hydraulic radius) of 10:1, in some embodiments
exceeding approximately 100:1, and in other embodiments at least
about 1000:1. At the top end, the aspect ratio could be
indefinitely high but generally would be less than about
1,000,000:1. Likewise with such embodiments, a hydraulic radius of
a channel is preferably no greater than about 300 .mu.m. In many
embodiments, it can be less than 100 .mu.m, and may be less than 10
.mu.m. Although smaller is generally better for many applications
(and the hydraulic radius could be submicron in size), the
hydraulic radius typically would not be less than 1 .mu.m for most
embodiments. These ratios are exemplary, and are not intended to be
limiting.
[0048] The structured surface 13 of each layer 12 can also be
provided with a very low profile. Thus, filtration media layers are
contemplated where the structured polymeric layer has a thickness
of less than 5000 micrometers, and even possibly less than 1500
micrometers. To do this, the channels may be of a channel is
preferably no greater than about 300 .mu.m. In many and that have a
peak distance of about 10 to 2000 micrometers. It is understood,
however, that the specific peak heights and peak distances are not
as important as an overall percent solidity to surface area
relationship in the resulting filtration media. It might be
advantageous in certain applications where flow resistance is
critical to increase the pore size, such as by increasing the
channel cross-section, thereby reducing the percentage particle
capture but increasing the fluid flow through the filter. In other
applications, it might be more advantageous to decrease pore size
and increase pore quantity to particularly take advantage of
particle exclusion and expanded surface area, as opposed to
particle capture mechanisms. The present invention has the distinct
advantage of providing the ability to customize the filtration
media in a very controlled and predictable manner, thereby allowing
production of these types of application specific filtration
media.
[0049] Microstructured surfaces useful in some embodiments of the
present invention provide flow systems in which the volume of the
system is highly distributed. That is, the fluid volume that passes
through such flow systems is distributed over a large area. This
feature is highly beneficial for many filtering applications. Such
microstructured surfaces can be made by known techniques including
microreplication, which as used in this application means the
production of a microstructured surface through a process where the
structured surface features retain an individual feature fidelity
during manufacture, from product-to-product, that varies no more
than about 50 .mu.m. The microreplicated surfaces preferably are
produced such that the structured surface features retain an
individual feature fidelity during manufacture, from
product-to-product which varies no more than 25 .mu.m.
[0050] Referring back to FIGS. 1, 3 and 4, at least some, if not
all of the channels 25 are open on the face side 22 of the
filtration media 10, forming pores in the face surface 24. Fluid
passes into the filtration media 10 at the face surface 24,
preferably traveling through the channels 25 and exiting at the
back side 23 of the filtration media 10. At a minimum, the
structured surfaces of the present invention provide controlled and
ordered fluid pathways through the filtration media. The amount of
surface area available for filtration purposes is therefore
determined by the volume of the filtration media. In other words,
the structured surface features of the filtration media layers,
such as the length of the channels and the channel configurations,
define the useable surface area, and not just the face surface.
[0051] A single layer provided with a structured surface may also
comprise a functional filter media in accordance with the present
invention. Specifically, its structured surface may function to
remove particles from a fluid stream by any and all of the removal
mechanisms discussed below provided that the flow of fluid to be
treated (filtered) is caused to stream through pathways defined by
the surface structure. The particle removal mechanisms may be
enhanced by any of the treatments discussed below as well. For
example, a single layer having any of the structured surfaces
disclosed and contemplated in this application could be provided as
a surface layer of any conduit so long as the fluid to run within
the conduit is directed to run at least somewhat within the
structured surface.
[0052] The mechanisms for particle removal available in fibrous
filters are also available the filtration media of the present
invention but without the inherent limitations of fibrous filter
media. Direct interception is dependent on pore size, and pore
size, in turn, is dependent on structured surface features, such as
channel cross-section and configuration. Under the present
invention, structured surface features such as channels can be
produced in widely varying sizes and configurations in a
consistent, controlled and predictable manner unavailable in
fibrous, and especially nonwoven, filters. A filtration media of
stacked structured layers provides a highly ordered and
mechanically stable porous surface without the pore size
variability and gross irregularities of nonwoven webs. Any pore
size variability or irregularities are planned and controlled based
on the ultimate filtration needs for which the filtration media of
the present invention is intended. As a result, the fluid stream is
subjected to uniform treatment as it passes through the face
surface of the filtration media, thus enhancing its filtering
efficiency.
[0053] Inertial impaction and diffusional interception also occur
in the filtration media of the present invention. Both of these
removal mechanisms are dependent on the available surface area
within the filtration media. In fibrous filters, the surface area
of the individual fibers provides this surface area. In the present
invention, (whether a single layer or a stack of layers) this
surface area is provided by the surface area of the structured
surface features including channels whose surface area is defined
by channel configuration and length. As the fluid stream passes
through a stacked layer filtration media via ordered fluid
pathways, particles smaller than the face surface pore size will
impact on the sidewalls, floors, caps and other features of the
structured surfaces due to their density or Brownian motion, as
described above for the fibrous filters. Use of structured surfaces
comprising channels with various channel configurations may enhance
this ability. Restricting the fluid flow to discrete channels using
bonded layers may further enhance this ability, or it may be
further enhanced by not restricting channel-to-channel fluid flow.
Fluid flow would then be allowed between channels to a limited
extent, thus increasing the surface area which comes in contact
with or adjacent to the fluid stream.
[0054] Unlike the fibrous filters, however, the filtration media of
the present invention does not serve as a surface loading filter
that is subject to surface blinding, but instead serves as a
depth-bed filter using the entire filtration media volume to
improve its filtering efficiency and capacity, yet still functions
at a low flow resistance. This feature is due to the low percent
solidity achievable with the present invention, as well as a lower
likelihood of through-channel blockage, and the consistency of the
pores and channels over the whole face surface area resulting from
the controlled and predictable formation process. This ability to
serve as a depth-bed filter can be further improved by the choice
of structured surfaces including channel configuration, such as
those shown in FIGS. 4, 9, and 10, where the available surface area
within each channel is increased by additional sub-channels or
other structural additions. Therefore, the capacity and efficiency
of the filtration media of the present invention is greatly
improved over that of a fibrous filter having the same face surface
area in both low and high face velocity applications.
[0055] Additional advantages of the inventive filtration media
include the ability to be manufactured in wide ranges of pore sizes
and depths with accuracy and reliability. It can be produced with
the feature sizes, bulk density and the materials base currently
applied to nonwoven and fibrous filters, but it has the added
advantages described above. While traditional fibrous filter media
can be pleated or used flat, the filtration media of the present
invention may be may be formed into a multitude of self-supporting
configurations. It may be conformed into shapes, laid over objects,
have force applied without crushing and closing the channels. In
addition, the filtration media's ability to be employed in
three-dimensional form, rather than the planar form of fibrous
filters, offers an array of new end-product configurations,
especially due to its ability to serve as a rigid structural
element in a design. Filtration media of the present invention also
has the added advantage of not being susceptible to breakage caused
by manipulation of the filtration media by, for example, pleating,
handling, or assembly. Fiber breakage in traditional fibrous
filters can cause a number of problems, especially in clean room
application. Another advantage is the ability to form the
structured surfaces of the layers so as to direct the flow path in
a desired manner.
[0056] An example of the filtration media being used in an end
product is shown in FIG. 13. A respirator mask having dual filters
is shown with the filtration media of the present invention being
used as the filters. Use of the filtration media in this type of
application reduces the bulk and weight of the mask by eliminating
the need for filter canisters that commonly are needed to obtain
the necessary filter capacity of the mask.
[0057] In order to enhance filtering capabilities or to effect a
desired result, the inventive filtration media may be treated in
numerous ways. One treatment example is shown in FIG. 11.
Filtration media 60 comprises a stack of layers 62, 63 and 70.
Interposed between facing layers 62 and 63 is an additional layer
66 serving as a cap layer for at least some of the channels 64 of
each layer 62 and 63. More than one type of additional layer may be
provided between subsequent groupings of facing layers, as shown by
additional layers 66 and 68. In addition, the same or different
additional layers 69 may be provided between non-facing layers 70
to improve particle removal or provide other benefits. Any type,
size, configuration and relationship of structured surface features
are contemplated for use with additional layers 66, 68 or 69. These
additional layers 66, 68 and 69 may be formed of the same or
similar material as the other structured layers 62, 63 or 70, or
they may comprise other materials that may provide enhanced
particle removal or other desired benefits, and are effective for
the purpose contemplated.
[0058] Materials that enhance particle removal or achieve other
desired benefits may include, either alone or fixed to a substrate:
adsorbents, such as activated carbon, zeolite or aluminocilicate
for removing organic molecules or deodorization; deodorizing
catalysts such as copper-ascorbic acid for decomposition of
malodorous substances; drying agents such as silica gel, zeolite,
calcium chloride, or active aluminal; a disinfecting agent such as
a UV germicidal system; fragrances such as gloxal, methacrylic acid
esters or perfumes; or ozone removing agents including metals such
as Mg, Ag, Fe, Co, Ni, Pt. Pd, or Rn, or an oxide supported on a
carrier such as alumina, silica-alumina, zirconia, diatomaceous
earth, silica-zirconium, or titania. Any of the listed materials,
and others which are not listed but would be suitable to meet a
desired purpose and be effective with the present invention, may be
used in any combination
[0059] Another type of treatment available to filtration media of
the present invention is either passive or active electrostatic
charging of the filtration material. Electrostatic charging
enhances the filtration media's ability to remove particulate
matter from a fluid stream by increasing the attraction between
particles smaller than the pore size and the surface area of the
structured surfaces, thus enhancing the third mechanism for
particle removal. Non-impinging particles passing close to
sidewalls are more readily pulled from the fluid stream, and
impinging particles are adhered more strongly. Electrostatic
charging may be provided by an electret, which is a piece of
dielectric material that exhibits an electrical charge that
persists for extended time periods. Electret chargeable materials
include nonpolar polymers such as polytetrafluoroethylene (PTFE)
and polypropylene. Generally, the net charge on an electret is zero
or close to zero and its fields are due to charge separation and
not caused by a net charge. Through the proper selection of
materials and treatments, an electret can be configured that
produces an external electrostatic field. Such an electret can be
considered an electrostatic analog of a permanent magnet.
[0060] Several methods are used to charge dielectric materials, any
of which may be used to charge the filtration media of the present
invention, including corona discharge, heating and cooling the
material in the presence of a charged field, contact
electrification, spraying the web with charged particles, and
impinging a surface with water jets or water droplet streams. In
addition, the chargeability of the surface may be enhanced by the
use of blended materials. Examples of charging methods are
disclosed in the following patents: U.S. Pat. No. Re, 30,782 to van
Turnhout et al., U.S. Pat. No. Re. 31,285 to van Turnhout et al.,
U.S. Pat. No. 5,496,507 to Angadjivand et al., U.S. Pat. No.
5,472,481 to Jones et al., U.S. Pat. No. 4,215,682 to Kubik et al.,
U.S. Pat. No. 5,057,710 to Nishiura et al., U.S. Pat. No. 4,592,815
to Nakao, and U.S. Pat. No. 4,798,850 to Brown.
[0061] Types of active charging include the use of a film with a
metallized surface on one face that has a high voltage applied to
it. This could be accomplished in the present invention by the
addition of such metallized layer adjacent a structured layer, or
the application of a metal coating on the nonstructured surface of
a structured layer. Filtration media comprising such metallized
layers could then be mounted in contact with an electrical voltage
source resulting in electrical flow through the metallized media
layers. Examples of such active charging are disclosed in U.S. Pat.
No. 5,405,434 to Inculet.
[0062] Another type of treatment available to the filtration media
of the present invention is the use of fluorochemical additives in
the form of material additions or material coatings can improve the
filter's ability to repel oil and water, as well as enhance the
filter's ability to filter oily aerosols. Examples of such
additives are found in U.S. Pat. No. 5,472,481 to Jones et al.,
U.S. Pat. No. 5,099,026 to Crater et al., and U.S. Pat. No.
5,025,052 to Crater et al.
[0063] In addition, the filtration media may be embedded, coated,
or otherwise treated with a tacky substance designed to attract and
adhere impinging particles. The filtration media may also be
embedded, coated or otherwise treated with a chemical reactant, or
other compound, designed to react in some manner with the fluid
stream either to enhance filtration, or to produce an additional
result. These types of compounds and results are similar to those
listed above for treatment by added layers. These compounds may
include adsorbents, such as activated carbon, zeolite or
aluminocilicate for removing organic molecules or deodorization,
deodorizing catalysts such as copper-ascorbic acid for
decomposition of malodorous substances; drying agents such as
silica gel, zeolite, calcium chloride, or active aluminal; a
disinfecting agent such as a UV germicidal system; fragrances such
as gloxal, methacrylic acid esters or perfumes; or ozone removing
agents including metals such as Mg, Ag, Fe, Co, Ni, Pt, Pd, or Rn,
or an oxide supported on a carrier such as alumina, silica-alumina,
zirconia, diatomaceous earth, silica-zirconium, or titania.
[0064] The making of structured surfaces, and in particular
microstructured surfaces, on a polymeric layer such as a polymeric
film are disclosed in U.S. Pat. Nos. 5,069,403 and 5,133,516, both
to Marentic et al. Structured layers may also be continuously
microreplicated using the principles or steps described in U.S.
Pat. No. 5,691,846 to Benson, Jr. et al. Other patents that
describe microstructured surfaces include U.S. Pat. No. 5,514,120
to Johnston et al., 5,158,557 to Noreen et al., 5,175,030 to Lu et
al., and 4,668,558 to Barber.
[0065] Structured polymeric layers produced in accordance with such
techniques can be microreplicated. The provision of microreplicated
structured layers is beneficial because the surfaces can be mass
produced without substantial variation from product-to-product and
without using relatively complicated processing techniques.
"Microreplication" or "microreplicated" disclosed in U.S. Pat. Nos.
5,069,403 and 5,133,516, both to Marentic et al. structured surface
features retain an individual feature fidelity during or steps
described in U.S. Pat. No. 5,691,846 to Benson, Jr. et al. Other
patents that describe microstructured surfaces include U.S. Pat.
No. 5,514,120 to surface features retain an individual feature
fidelity during manufacture, from product-to-product, which varies
no more than 25 .mu.m.
[0066] Filtration media layers for any of the embodiments of the
present invention can be formed from a variety of polymers or
copolymers including thermoplastic, thermoset, and curable
polymers. As used here, thermoplastic, as differentiated from
thermoset, refers to a polymer which softens and melts complicated
processing techniques. "Microreplication" or "microreplicated"
solidified through many cycles. A thermoset polymer, on the other
hand, irreversibly solidifies when heated and cooled. A cured
polymer system, in which polymer chains are interconnected or
crosslinked, can be formed at room temperature through use of
chemical agents or ionizing irradiation.
[0067] Polymers useful in forming any of the structured layers or
articles of the invention include but are not limited to
polyolefins such as polyethylene and polyethylene copolymers,
polyvinylidene diflouride (PVDF), and polytetrafluoroethylene
(PTFE). Other polymeric materials include acetates, cellulose
ethers, polyvinyl alcohols, polysaccharides, polyolefins,
polyesters, polyamids, poly(vinyl chloride), polyurethanes,
polyureas, polycarbonates, and polystyrene. Structured layers can
be cast from curable resin materials such as acrylates or epoxies
and cured through free radical pathways promoted chemically, by
exposure to heat, UV, or electron beam radiation.
[0068] There are applications where flexible filter media is
desired. Flexibility may be imparted to a structured polymeric
layer using polymers described in U.S. Pat. Nos. 5,450,235 to Smith
et al. and 5,691,846 to Benson, Jr. et al. The whole polymeric
layer need not be made from a flexible polymeric material. A
portion of a layer, for example, could comprise a flexible polymer,
whereas the structured portion or portion thereof could comprise a
more rigid polymer. The patents cited in this paragraph describe
use of polymers in this fashion to produce flexible products that
have microstructured surfaces.
[0069] Polymeric materials including polymer blends can be modified
through melt blending of plasticizing active agents such as
surfactants or antimicrobial agents. Surface modification of the
structured surfaces can be accomplished through vapor deposition or
covalent grafting of functional moieties using ionizing radiation.
Methods and techniques for graft-polymerization of monomers onto
polypropylene, for example, by ionizing radiation are disclosed in
U.S. Pat. Nos. 4,950,549 and 5,078,925. The polymers may also
contain additives that impart various properties into the polymeric
structured layer. For example, plasticisers can be added to
decrease elastic modulus to improve flexibility.
[0070] The filtration media of the present invention starts with
the desired materials from which the layers are to be formed.
Suitable sheets of these materials having the required thickness or
thicknesses are formed with the desired surface topography by such
methods as microreplication (i.e. by casting a film onto a
patterned roll or belt). A single layer with a structured surface
can function as a filter provided the flow of gas to be treated is
caused to stream through the fluid pathways defined by the surface
structure. Single or multiple layers can additionally be employed
as filters when covered or stacked. Stacked layers are oriented in
a predetermined pattern or relationship, with or without additional
layers, to build up a suitable volume of layers. These layers may
be bonded together, as described above, or may be depended upon to
retain their relationship without bonding. The resulting volume of
layers is then converted, by slicing or otherwise, into filtration
media of a desired thickness. This filtration media may then be
mounted, or otherwise assembled into a final useable format. Any
desired treatments, as described above, may be applied at any
appropriate stage of the manufacturing process. In addition,
filtration media in accordance with the present invention may be
combined with other filtering material, such as a layer of nonwoven
fibrous material over the face surface, or may be combined with
other non-filtering material to facilitate such things as handling,
mounting, assembly or use.
[0071] Preferred embodiments of the invention may use thin flexible
polymer films that have parallel linear topographies as the
microstructure-bearing element. For purposes of this invention, a
"film" is considered to be a thin (less than 5 mm thick) generally
flexible sheet of polymeric material. The economic value in using
inexpensive films with highly defined microstructure-bearing film
surfaces is great. Flexible films can be used in combination with a
wide range of other materials and can be used unsupported or in
conjunction with a supporting body where desired. The filter media
formed from such microstructured surfaces and other layers, if
provided, may be flexible for many applications but also may be
associated with a rigid structural body where applications
warrant.
[0072] In those embodiments where the structured layer or layers of
a filter media of the invention include microstructured channels,
such devices may employ a multitude of channels per device. As
shown in some of the embodiments illustrated above, such
microstructured layers can easily possess more than 10 or 100
channels per layer. Some applications may have more than 1,000 or
10,000 channels per layer.
[0073] All of the patents and patent applications cited above are
wholly incorporated by reference into this document. Also, this
application also wholly incorporates by reference the following
patent applications that are commonly owned by the assignee of the
subject application and filed on even date herewith: U.S. patent
application Ser. No. (attorney docket number 53199USA2A), to Insley
et al. and entitled "Microchanneled Active Fluid Transport
Devices"; U.S. patent application Ser. No. (attorney docket number
53634USA8A), to Insley et al. and entitled "Microchanneled Active
Fluid Heat Exchanger"; U.S. patent application Ser. No. (attorney
docket number 53633USA1A), to Insley et al. and entitled
"Microstructured Separation Device"; and U.S. patent application
Ser. No. (attorney docket number 53631USA9A), to Insley et al. and
entitled "Fluid Guide Device Having an Open Microstructured Surface
for Attachment to a Fluid Transport Device."
[0074] Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *