U.S. patent application number 10/468969 was filed with the patent office on 2005-02-10 for resin impregnated filter media.
Invention is credited to Allen, Richard Frazer.
Application Number | 20050032445 10/468969 |
Document ID | / |
Family ID | 9909541 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050032445 |
Kind Code |
A1 |
Allen, Richard Frazer |
February 10, 2005 |
Resin impregnated filter media
Abstract
The present invention discloses a filter medium and a method of
manufacturing a filter medium. The filter medium is created using a
fabric substrate of a woven or non woven material. The substrate is
impregnated with a thermosetting resin that is subsequently heat
cured thereby encapsulating the fibers of the substrate. Further a
rheology modifier may be mixed with the resin before impregnation
to control the flow properties of the resin.
Inventors: |
Allen, Richard Frazer;
(Ilkley, GB) |
Correspondence
Address: |
BARLOW, JOSEPHS & HOLMES, LTD.
101 DYER STREET
5TH FLOOR
PROVIDENCE
RI
02903
US
|
Family ID: |
9909541 |
Appl. No.: |
10/468969 |
Filed: |
January 20, 2004 |
PCT Filed: |
February 19, 2002 |
PCT NO: |
PCT/GB02/00713 |
Current U.S.
Class: |
442/59 ;
442/6 |
Current CPC
Class: |
B01D 39/163 20130101;
B01D 2239/10 20130101; Y10T 442/20 20150401; Y10T 442/109
20150401 |
Class at
Publication: |
442/059 ;
442/006 |
International
Class: |
D03D 009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 27, 2001 |
GB |
0104748.9 |
Claims
1. A process of manufacturing a filter medium, comprising:
impregnating a substrate with thermosetting resin said substrate
being formed from intertwined yarns; and subsequently curing the
thermosetting resin by heating the impregnated substrate to the
curing temperature of the resin used, to thereby encapsulate the
yarns of the substrate with the resin so that the yarns are
mutually bonded where they contact each other.
2. A process according to claim 1 said resin is mixed with a
rheology modifier before application to control the viscosity and
flow properties of the resin.
3. A process according to claim 2 wherein the rheology modifier
comprises below 5% of the resin composition by weight.
4. A process according to claim 2 wherein the rheology modifier
comprises hydroxyl-ethyl cellulose.
5. A process according to claim 2 wherein the resin is diluted to
below 15% solids content before addition of the rheology
modifier.
6. A process according to claim 2 wherein the thermosetting resin
is selected from the group consisting of: phenolic, epoxy,
formaldehyde, amino furan, melamine, silicone, unsaturated
polyether, polyurethane, polyamide, fluorocarbon based
thermosetting resin, cross linked thermoplastic based thermosetting
resin and mixtures thereof.
7. A process according to claim 1 wherein the substrate is selected
from the group consisting of: woven fabric, non-woven fabric, spun
bonded yarns, thermo-bonded yarns, and melt blown polymeric
yarns.
8. A process according to claim 7 wherein the polymeric yarns are a
blend of two or more materials selected from the group consisting
of: polyester, polypropylene, polyamide, polyethylene, and
polyurethane.
9. A process according to claim 7 wherein the substrate includes a
metal or ceramic mesh screen.
10. A process according to claim 1 wherein the coated fabric is
subjected to an intermediate heating, before curing to a
temperature below the curing temperature to remove water or other
solvent.
11. A filter medium comprising a substrate of a fabric impregnated
with a thermosetting resin cured by subsequent heating of the
impregnated substrate to the curing temperature of the resin.
12. A filter medium according to claim 11 wherein said resin
contains a rheology modifier to control the viscosity and flow
properties of the resin.
13. A filter medium according to claim 12 wherein the rheology
modifier comprises below 5% of the resin composition by weight.
14. A filter medium according to claim 12 wherein the rheology
modifier comprises hydroxyl-ethyl cellulose.
15. A filter medium according to claim 12 wherein the resin is
diluted to below 15% solids content before addition of the rheology
modifier.
16. A filter medium according to of claim 11 wherein the
thermosetting resin is selected from the group consisting of:
phenolic, epoxy, formaldehyde, amino furan, melamine, silicone,
unsaturated polyether, polyurethane, polyamide, fluorocarbon based
thermosetting resin, cross linked thermoplastic based thermosetting
resin and mixtures thereof.
17. A filter medium according to claim 11 wherein the substrate is
selected from the group consisting of: woven fabric, non-woven
fabric, spun bonded yarns, thermo-bonded yarns, and melt blown
polymeric yarns.
18. A filter medium according to claim 17 wherein the polymeric
yarns are a blend of two or more materials selected from the group
consisting of: polyester, polypropylene, polyamide, polyethylene,
and polyurethane.
19. A filter medium according to claim 17 wherein the substrate
includes a metal or ceramic mesh screen.
Description
[0001] This invention relates to improved filter media of the kind
comprising a woven or non-woven substrate.
[0002] EP-A-0,741,815 discloses a method of making a fabric which
is suitable for use as a filter medium by applying a film of a
reticular polymer to a suitable substrate from a release sheet. The
resultant filter medium provides a micro porous filter, which has a
good wear resistance so long as the film endures. When the film is
abraded however, the substrate becomes vulnerable to wear and the
filter medium loses its micro-filtration capabilities.
[0003] In order to improve the effective lifetime of filter media,
it is desirable to improve the wear resistance of the filter
cloths, belts sleeves or the like, and if possible to reduce the
rate of deterioration of filtration capacity which tends to occur
where a relatively coarse base substrate is surface treated or
partially impregnated from one side or the other. There is a
general tendency for coatings, however applied, to sit on the
substrate as a discrete layer, or to penetrate only a comparatively
short distance into the substrate, so that when the coated
substrate is subjected to abrasion, the filter medium is impaired
quickly once the coating has been worn, even if only locally.
[0004] Japanese Patent Application No. 06301439, published under
No. 08131735, discloses filter medium comprising a blend of two
types of fibres, filter fibres and heat fusible fibres. The fibres
are joined together by partial fusion of the heat fusible fibres as
the filter medium is heated and shaped. Reinforcing materials are
attached to the Intersections of the two types of fibres, and the
reinforcement material may be for example a water-soluble phenol,
an epoxy resin, unsaturated polyester or a polyamide. This type of
filter medium is intended for example for cylindrical cartridge
filters or the like. It is not clear how the reinforcement
materials are introduced nor how they are caused to adhere only at
the intersections of the two types of fibre used. The use of a
non-woven substrate comprising a blend of two different fibre tpes
raises production costs, as the fibres first have to be blended.
Also the presence of a fusible component in the fibre blend
restricts the utility of the filter medium to lower temperature
uses, since high temperatures could cause further fusion of the
fusible fibres, leading to blinding of the filter pores by melted
fibre material.
[0005] It is an object of the invention to provide a filter medium
material and a process for manufacture of a filter medium material
with improved wear resistance, and greater dimensional stability
and which does not substantially suffer from the disadvantages
noted.
[0006] From a first aspect, the invention provides a process for
manufacturing a filter medium, comprising impregnating a woven or
non-woven subsrate with a thermosetting resin combined with
subsequent curing of the resin by heating the impregnated substrate
to a curing temperature appropriate for the resin used, whereby the
yarns or fibres of the substrate are encapsulated by the resin so
that the yarns or fibres are mutually bonded where they cross each
other.
[0007] In a preferred process according to the invention, the resin
is mixed with a rheology modifier before application to control the
viscosity and flow properties of the resin, and may be added to the
resin system which is preferably diluted to below 15% solids
content, for example 10% solids content, in an amount of below 5%
by weight of the rheology modifier for example 3% by weight. An
example of a rheology modifier, which may be used is hydroxy ethyl
cellulose.
[0008] From a second aspect, the invention provides a filter
medium, comprising a substrate of woven or non-woven fabric
impregnated with a thermosetting resin cured by subsequent heating
of the impregnated substrate to a curing temperature appropriate
for the resin used, the yarns or fibres of the substrate being
encapsulated by the resin so that the yarns or fibres are mutually
bonded where they cross each other.
[0009] The thermosetting resin may be any one or a mixture of any
two or more selected from:--a phenolic, epoxy, formaldehyde,
amino/furan, melamine, silicone, unsaturated polyester,
polyurethane, polyamide, fluorocarbon or cross linked thermoplastic
based thermosetting resin systems.
[0010] Further, other known additives can be added to the resin to
enhance supplementary propeties. Examples may include--carbon (to
give conductive or anti-static qualities), grafting binders which
attach PTFE onto the chain terminator of phenol end groups (to
improve cake release), or antibacterial agents such as
3-trimethoxysilyl, poly-dimethyloctadecyl ammonium chloride, and
silane quaternary salts (to minimise crystal or fungi build
up).
[0011] The thermosetting resin preferably penetrates the substrate,
to a depth, which will give the desired balance of dimensional
stability and flexibility and effectively encapsulates or coats the
fibres or yarns within the impregnated part of the fabric without
clogging the void spaces between the woven or felted yarns or
fibres. The void spaces may then be used if required to hold micro
porous materials such as flocculated, coagulated, foamed or other
micro porous materials.
[0012] The substrate may be a woven or non woven felt, spun bonded,
thermo bonded, or melt blown include polymeric yarns or fibres, and
these may be anyone or a blend of two or more of polyester (e.g.
PET) or polypropylene or other materials, such as polyamide (nylon)
or polyethylene or polyurethane. The substrate may also include a
metal or ceramic mesh or screen.
[0013] The resin may be applied as a liquid, by known means such as
knife-coating, spraying or lick coating or by immersion of the base
fabric in the coating material. The exposure of the fabric to the
resin liquid is preferably sufficiently prolonged to ensure the
desired depth penetration of the liquid into the base fabric. The
resin bearing liquid may be an aqueous or non-aqueous dispersion,
or emulsion, or the like of the resin in the liquid phase. Before
curing, the coated fabric is optionally subjected to an
intermediate heating, below the curing temperature to drive off
moisture or other solvent, and to effect fibre encapsulatlon that
is to ensure that the resin adheres to and `wets` the fibres or
yarns, without substantially impeding the voids of the fabric
structure. Curing of the resin is then effected, with typical
curing times from 5 minutes to one hour or more, and typical curing
temperatures from 100.degree. C. to 200.degree. C. Intermediate
heating and curing may be effected during a single pass, or the
steps may be carried out separately and not necessarily immediately
subsequently.
[0014] Examples of the method according to the invention, and of
the filter media produced thereby will now be particularly
described by way of example.
EXAMPLE I
[0015] A base fabric comprising a needled non-woven felt of PET
(polyethylene terephthalate) fibres was lick coated with an aqueous
phenolic thermosettable resin.
[0016] The felt was then heated for 10 to 20 minutes to close to
100.degree. C. In order to dry the felt by evaporating the aqueous
phase and soften the resin to cause it to wet the fibers
effectively, thereby encapsulating the fibres in the resin.
[0017] Following completion of the drying step the coated felt was
then heated to 106.degree. C. and maintained at this temperature
for 10 minutes, thereby effecting curing of the thermosetting
resin.
[0018] Tests showed that the resultant filter medium has only
slightly impaired flexibility and air permeability as compared to
the untreated felt further, dimensional stability and resistance to
abrasion was significantly improved.
EXAMPLE II
[0019] A base fabric comprising a woven polypropylene cloth was
coated with an aqueous phenolic thermosetting resin. The resin was
applied using a knife coating mettod.
[0020] The coated cloth was then heated to about 130.degree. C. and
maintained at this temperaure for 1 hour, thereby ensuring that the
resin wets the fibres effectively, causing encapsulation of the
fibres with the resin and also effecting subsequent curing of the
resin.
[0021] Again the resulting filter medium had improved dimensional
stability and abrasion resistance, and only slightly impaired
flexibility and air permeability as compared to the untreated
fabric.
[0022] The Method is also applicable to woven fabrics to coat the
yarns or fibres comprising the fabric.
[0023] FIG. 1 illustrates in a considerably magnified view what is
believed happens to the structure of the impregnated region of a
filter medium produced from a non-woven felt as described by
Example I.
[0024] FIG. 2 is a scanning electron micrograph of a coated
polyester needle felt as prepared by the Example I as set out
above;
[0025] FIG. 3 is a scanning electron micrgraph of uncoated
polypropylene cloth before treatment in accordance to the Example
II set out above;
[0026] FIG. 4 is a scanning electron micrograph of coated woven
multi filament polypropylene cloth in accordance with Example II
set out above;
[0027] FIG. 5 is a magnified view of two adjacent coated fibres
within a multi filament yarn and meniscus of the binding resin;
[0028] FIG. 6 is micrograph of a cross section through a coated
multifilament yarn within a coated woven polypropylene cloth;
[0029] FIG. 7 is a graph showing the effect on permeability and
filter throughput of a coating according to the invention;
[0030] FIG. 8 is a graph showing the improvement in dimensional
stability of a polypropylene belt material after treatment by
coating according to the invention; and
[0031] FIG. 9 is a graph showing the abrasion resistance of a
phenolic resin treated woven polypropylene compared to an untreated
substrate.
[0032] The impregnated fabric resulting from Example 1 as shown in
FIG. 1 consists of an array of randomly orientated fibres 20, some
of which are shown in sectional view. The coated fibres each
comprise a core 20 consisting of the fibre itself and a coating or
sheath 22 of the thermosetting resin produced by wetting of the
fibres by the resin during the drying stage of the method described
in the examples. Where the fibres 20 cross and contact each other,
the resin forms bridges or pools 24, which connect the fibres
firmly to each other. Once the resin has been cured the bonding
remains permanent.
[0033] FIG. 2 shows in a scanning election micrograph, part of a
coated polyester needled felt produced by method 1 set out above.
As shown, the coating 22 tends to collect in pools 24 about the
intermeshing zones of the fibres 20, with thickend sheath parts
extending along the fibres.
[0034] FIG. 3 shows uncoated yarns in a polypropylene cloth, which
have substantially no medium between yarns to give dimensional
stability and to prevent abrasion, which is already evidenced by
the presence of fibrils 25 on the yarn surfaces.
[0035] FIG. 4 shows by contrast shows such yarns after coating, and
it will be noted that fibrillation is less marked, and that bridges
of resin, e.g. 26, connect the yarns and inhibit them from moving
against each other, increasing stability and hereby reducing
abrasion. The meniscus of resin between yarns is show enlarged in
FIG. 5.
[0036] FIG. 6 shows how resin penetrates between the fibres of a
multiflament yarn, reducing internal wear within the yarn.
[0037] FIG. 7 compares, the filtrate through put (a measure of
permeability) of filter cloths which have and which not been
impregnated with a phenolic resin by the method of the invention.
It is noted that the decrease in permeability is marginal.
[0038] FIG. 8 similarly compares the dimensional stability of
treated and untreated polypropylene belt material, when tested by
tensioning in the direction of the weft yarns.
[0039] The treated belt (full line) shows greater dimensional
stability than the untreated belt, demonstrated in that a greater
force is necessary to produce the same "stretch". For example, when
the applied stress is 20 kgf/2.5 cm, then the treated belt shows a
strain (or elongation) of approximately 7% compared to greater than
12% for the untreated belt.
[0040] Finally FIG. 9 shows the result of comparative tests of a
treated and an untreated woven polypropylene substrate. The
untreated material showed a marked increase in permeability over
2000 abrasion cycles, signifying a loss of micro filtration, but
the treated material exhibited no noticeable deterioration.
[0041] The bonding thus produced increases the dimensional
stability hence the propensity of the yarns to be displaced and to
rub against each other is reduced lessening internal wear and
ultimately yarn breakage within the fabric. A similar effect is
present in woven base fabrics where the yarns are coated and pools
bridges are formed within the weave knuckles or in the case of
multi-filament or staple yarns, where parallel fibres contact each
other.
[0042] A further benefit is that the resin bridges or pools lock
the fibres, and the openings between fibres, relative to one
another thus providing more accurate and consistent pore sizes. The
pore sizes will remain constant throughout the life of the filter
media.
[0043] The properties of filter media according to and produced by
the method of the invention can be controlled by varying conditions
and materials.
[0044] The speed and degree of penetration of the resin into the
substrate can be controlled by varying the viscosity of the
coating. The solids content of the coating may be changed to vary
the thickness of the film encapsulating the yarns or fibres.
[0045] The properties of the resin used for coating are preferably
controlled depending upon the properties of the substrate by
dilution and rheology modifiers (which modify the flow properties
of the resin).
[0046] In an example a first sample of a 373 gm-2 nylon 66
monofilament duplex weave cloth was subjected to application of a
neat (unmodified) resin comprising 60% solids, 40% solven and
having a viscosity of 200 cPs.
[0047] This was found to have an excessive coat weight and low
permeability, due to the low surface area monofilament yarns being
encapsulated in a thick layer of resin.
[0048] A second sample of the cloth was subjected to application of
resin diluted to 10% solids, of lower viscosity (about 20cPs). This
resin bled through the entire cloth thickness and produced an
insufficient coat weight, with the yarns being incompletely
encapsulated.
[0049] A third sample of the cloth was subjected to the application
of a specially prepared resin mixture.
[0050] This resin sample was prepared by dilution of the resin to
10% solids and then thickening by addition of hydroxy-ethyl
cellulose as a rheology modifier (i.e to modify the flow properties
of the resin). The hydroxyl ethyl cellulose rheology modifier had
been prepared previously in accordance to manufactures guidelines
and was added slowly to the dilute resin with vigorous stirring to
give 3% by weight of rheology modifier in the resin mixture. The
viscosity of this mixture as applied to the third cloth sample was
4500 cPs. The coated fabric was cured in the usual manner in a
single pass through an oven at 160.degree. C., with dwell time 10
minutes.
[0051] With use of a rheology modifier and dilution of the resin it
was found that the resin system had an optimum solids content for
increased abrasion resistance and optimum viscosity for substrate
penetration, with minimal loss of substrate flexiblity and
permeability.
1 Sample 1 Sample 2 Sample 3 substrate 373 gm-2 nylon 66 as sample
1 as sample 1 monofilament duplex weave resin 60% solids 10% solids
10% solids rheology nil Nil hydroxy ethyl modifier cellulose 3%
viscosity 200 cPs 20 cPs 4500 cPs permeability low High good
encapsulation thick layer coat poor coat bled good weight excessive
through fabric encapsulation leaving without exces- insufficient
resin sive thickness
[0052] Drying conditions can determine the way or extent to which
the fibres are encapsulated with shorter drying times so that, the
coating will migrate less.
[0053] Advantages of the invention for example in relation to EPA
0,741,815 mentioned above include the fact that a single process
can provide a coating throughout a variable depth within the
substrate, and possibly the whole substrate matrix by if necessary
completely soaking the fabric with the liquid phase resin. Using
the method of the European Patent, if the abrasion resistance of
both sides of the fabric are to be improved, the resin has to be
applied separately to each side in a repeated process.
[0054] Experimental results show as noted above that the process of
the invention does not significantly change the filtrate throughput
of the filter medium. Air and liquid permeability is only slightly
reduced. Further the method of the invention can be used with low
surface energy materials such as polypropylene due to encapsulation
of individual fibres. The coating applied by the method known from
the said European Patent can be easily peeled off such surface, as
it does not adhere to them.
[0055] Because of the depth of penetration, the coating is
permanent, with a residue of coating throughout the full depth of
the coating and the cloth will continue to resist abrasion during
the cloth lifetime.
[0056] The void spaces between the yarns or fibres of the base
cloth are not substantially impeded by the coating, as evidenced by
the air permeability, and these can be filled to render the filter
medium micro porous by coagulated, flocculated, or micro porous
foamed materials as known in the art. The filter media of the
invention may be used In liquid or gas any filtration application
as cloths for drum, cartridge, and disc filter sleeves and bags or
other filters also conveyor belts, pulp dewatering belts,
corrugators belts, tower press belts and filter press cloths.
* * * * *