U.S. patent application number 14/012711 was filed with the patent office on 2014-03-06 for multi-phase filter medium.
This patent application is currently assigned to Hollingsworth & Vose Company. The applicant listed for this patent is Hollingsworth & Vose Company. Invention is credited to Douglas M. Guimond, Mark Snyder.
Application Number | 20140060762 14/012711 |
Document ID | / |
Family ID | 41528595 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140060762 |
Kind Code |
A1 |
Guimond; Douglas M. ; et
al. |
March 6, 2014 |
MULTI-PHASE FILTER MEDIUM
Abstract
Multi-phase filter media, as well as related articles,
components, filter elements, and methods, are disclosed.
Inventors: |
Guimond; Douglas M.;
(Pepperell, MA) ; Snyder; Mark; (Nashua,
NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hollingsworth & Vose Company |
East Walpole |
MA |
US |
|
|
Assignee: |
Hollingsworth & Vose
Company
East Walpole
MA
|
Family ID: |
41528595 |
Appl. No.: |
14/012711 |
Filed: |
August 28, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13304678 |
Nov 27, 2011 |
8545587 |
|
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14012711 |
|
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12488033 |
Jun 19, 2009 |
8357220 |
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13304678 |
|
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61112617 |
Nov 7, 2008 |
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Current U.S.
Class: |
162/125 |
Current CPC
Class: |
B01D 39/1615 20130101;
Y10T 442/664 20150401; Y10T 442/659 20150401; Y10T 442/695
20150401; B01D 39/163 20130101; B01D 39/1623 20130101 |
Class at
Publication: |
162/125 |
International
Class: |
B01D 39/16 20060101
B01D039/16 |
Claims
1. (canceled)
2. A method of forming an article, comprising: disposing through a
wet laid process a first dispersion containing first and second
pluralities of fibers in a first solvent onto a wire for forming a
first phase; while the first plurality of fibers and second
plurality of fibers are on the wire, disposing a second dispersion
containing third and fourth pluralities of fibers in a second
solvent onto the first and second pluralities of fibers for forming
a second phase; at least partially removing the first and second
solvents, thereby forming an article comprising the first and
second phases, wherein the first phase has a lower air permeability
than the second phase, wherein the air permeability of the first
plurality of fibers is higher than the air permeability of the
second plurality of fibers, wherein the air permeability of the
third plurality of fibers is higher than the air permeability of
the fourth plurality of fibers, wherein the first plurality of
fibers are made from an organic polymeric material, and wherein a
weight ratio of the first plurality of fibers to the second
plurality of fibers in the article is from about 50:50 to about
97:3, wherein the basis weight ratio of the first phase to the
second phase is from about 30:70 to about 70:30, and wherein the
article is configured as a filter medium.
3. A method of forming an article, comprising: disposing through a
wet laid process a first dispersion containing first and second
pluralities of fibers in a first solvent onto a wire for forming a
first phase; while the first plurality of fibers and second
plurality of fibers are on the wire, disposing a second dispersion
containing third and fourth pluralities of fibers in a second
solvent onto the first and second pluralities of fibers for forming
a second phase; applying a vacuum to the first and second
dispersions to remove at least portions of the first and second
solvents, thereby forming an article comprising the first and
second phases, wherein the air permeability of the first plurality
of fibers is higher than the air permeability of the second
plurality of fibers, wherein the air permeability of the third
plurality of fibers is higher than the air permeability of the
fourth plurality of fibers, wherein the first plurality of fibers
are made from an organic polymeric material, and wherein a weight
ratio of the first plurality of fibers to the second plurality of
fibers in the article is from about 50:50 to about 97:3, wherein
the basis weight ratio of the first phase to the second phase is
from about 30:70 to about 70:30, and wherein the article is
configured as a filter medium.
4. A method of forming an article, comprising: disposing through a
wet laid process a first dispersion containing first and second
pluralities of fibers in a first solvent onto a wire for forming a
first phase; while the first plurality of fibers and second
plurality of fibers are on the wire, disposing a second dispersion
containing third and fourth pluralities of fibers in a second
solvent onto the first and second pluralities of fibers for forming
a second phase; at least partially removing the first and second
solvents, thereby forming an article comprising the first and
second phases, wherein the first phase has a lower air permeability
than the second phase, wherein the basis weight ratio of the first
phase to the second phase is from about 30:70 to about 70:30,
wherein the article is configured as a filter medium, and wherein
the filter medium has a mean flow pore size of at least about 25
microns and at most about 1,000 microns.
5. The method of claim 2, wherein the air permeability of the first
or third plurality of fibers is from about 50 CFM to about 350
CFM.
6. The method of claim 2, wherein the air permeability of the
second or fourth plurality of fibers is from about 5 CFM to about
50 CFM.
7. The method of claim 2, wherein the article includes a weight
ratio of the first and second pluralities of fibers of from about
50:50 to about 90:10, and a weight ratio of the third and fourth
pluralities of fibers of from about 10:90 to about 50:50.
8. The method of claim 2, wherein the first or third plurality of
fibers have an average fiber length of from about 1.5 mm to about 6
mm.
9. The method of claim 2, wherein the second or fourth plurality of
fibers have an average fiber length of from about 0.5 mm to about 2
mm.
10. The method of claim 2, wherein the first or third plurality of
fibers comprise softwood fibers, cotton fibers, polyester fibers,
polyvinyl alcohol binder fibers, or rayon fibers, and the second or
fourth plurality of fibers comprise hardwood fibers, polyethylene
fibers, or polypropylene fibers.
11. The method of claim 10, wherein the first or third plurality of
fibers comprise softwood fibers, and the second or fourth plurality
of fibers comprise hardwood fibers.
12. The method of claim 2, wherein the article has a mean flow pore
size of from about 3 microns to about 1,000 microns.
13. The method of claim 2, wherein the article has a mean flow pore
size of from about 25 microns to about 125 microns.
14. The method of claim 2, wherein the article has a mean flow pore
size of from about 25 microns to about 1,000 microns.
15. The method of claim 2, wherein the article has a dust holding
capacity from about 0.3 g to about 3 g measured according to a
Palas flat sheet test.
16. The method of claim 2, wherein the third pluralities of fibers
are made from an organic polymeric material.
17. The method of claim 2, wherein the article comprises an
interface between the first and second phases that is substantially
free of an adhesive.
18. The method of claim 2, wherein the first plurality of fibers
are hardwood or softwood fibers, and the fourth plurality of fibers
are hardwood or softwood fibers.
19. The method of claim 2, wherein the article has an air
permeability of between about 2 CFM and about 160 CFM.
20. The method of claim 2, wherein the article has a transition
phase between the first and second phases, wherein the transition
phase comprises at least a portion of the first plurality of
fibers, at least a portion of the second plurality of fibers, at
least a portion of the third plurality of fibers, and at least a
portion of the fourth plurality of fibers, and wherein at least a
portion of the first plurality of fibers, at least a portion of the
second plurality of fibers, at least a portion of the third
plurality of fibers, and at least a portion of the fourth plurality
of fibers are intermingled with each other.
21. The method of claim 2, wherein the step of at least partially
removing the first and second solvents comprises applying a vacuum
to the first and second dispersions to remove at least portions of
the first and second solvents simultaneously.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S.
application Ser. No. 13/304,678, filed Nov. 27, 2011, which is a
divisional of U.S. application Ser. No. 12/488,033 (now U.S. Pat.
No. 8,357,220), filed Jun. 19, 2009, which claims priority to U.S.
Provisional Application No. 61/112,617 filed on Nov. 11, 2008 and
entitled "Multi-Phase Filter Medium", which are hereby incorporated
by reference in their entireties.
TECHNICAL FIELD
[0002] This disclosure relates to multi-phase filter media, as well
as related articles, components, filter elements, and methods.
BACKGROUND
[0003] Filter media are used in a variety of systems. The media are
typically used to remove undesirable materials (e.g., particles)
from a liquid or gas by passing the liquid or gas through the
media.
SUMMARY
[0004] In one aspect, this disclosure features an article that
includes first and second phases. The first phase includes a first
plurality of fibers and a second plurality of fibers different from
the first plurality of fibers. The second phase includes a third
plurality of fibers and a fourth plurality of fibers different from
the third plurality of fibers. The third plurality of fibers are
the same as or different from the first or second plurality of
fibers. The fourth plurality of fibers are the same as or different
from the first or second plurality of fibers. The air permeability
of the first plurality of fibers is higher than the air
permeability of the second plurality of fibers. The air
permeability of the third plurality of fibers is higher than the
air permeability of the fourth plurality of fibers. The air
permeability of the fibers is defined in the Detailed Description
section below. At least one of the first, second, third, and fourth
pluralities of fibers are made from an organic polymeric material.
The basis weight ratio of the first phase to the second phase is
from about 30:70 to about 70:30. The article is configured as a
filter medium.
[0005] In another aspect, this disclosure features an article that
includes first and second phases. The first phase includes a first
plurality of fibers and a second plurality of fibers different from
the first plurality of fibers. The second phase includes a third
plurality of fibers and a fourth plurality of fibers different from
the third plurality of fibers. The third plurality of fibers are
the same as or different from the first or second plurality of
fibers. The fourth plurality of fibers are the same as or different
from the first or second plurality of fibers. The pressure drop of
the first plurality of fibers is lower than the pressure drop of
the second plurality of fibers. The pressure drop of the third
plurality of fibers is lower than the pressure drop of the fourth
plurality of fibers. The pressure drop of the fibers is defined in
the Detailed Description section below. At least one of the first,
second, third, and fourth pluralities of fibers are made from an
organic polymeric material. The basis weight ratio of the first
phase to the second phase is from about 30:70 to about 70:30. The
article is configured as a filter medium.
[0006] In another aspect, this disclosure features an article that
includes first and second phases. The first phase includes a first
plurality of softwood fibers. The second phase includes a first
plurality of hardwood fibers. The basis weight ratio of the first
phase to the second phase is from about 30:70 to about 70:30. The
article is configured as a filter medium.
[0007] In another aspect, this disclosure features an article that
includes first and second phases. The first phase includes first
and second pluralities of fibers. The first plurality of fibers are
prepared from a material (e.g., softwood fibers) different from a
material (e.g., hardwood fibers or a different type of softwood
fibers) used to prepare the second plurality of fibers. The second
phase includes third and fourth pluralities of fibers. The third
plurality of fibers are prepared from a material (e.g., softwood
fibers) different from a material (e.g., hardwood fibers or a
different type of softwood fibers) used to prepare the fourth
plurality of fibers. The third plurality of fibers are the same as
or different from the first or second plurality of fibers. The
fourth plurality of fibers are the same as or different from the
first or second plurality of fibers. The air permeability of the
first plurality of fibers is higher than the air permeability of
the second plurality of fibers. The air permeability of the third
plurality of fibers is higher than the air permeability of the
fourth plurality of fibers. The basis weight ratio of the first
phase to the second phase is from about 30:70 to about 70:30. The
article is configured as a filter medium.
[0008] In still another aspect, this disclosure features an article
that includes first and second phases. The first phase includes
first and second pluralities of fibers. The first plurality of
fibers are prepared from a material (e.g., softwood fibers)
different from a material (e.g., hardwood fibers or a different
type of softwood fibers) used to prepare the second plurality of
fibers. The second phase includes third and fourth pluralities of
fibers. The third plurality of fibers are prepared from a material
(e.g., softwood fibers) different from a material (e.g., hardwood
fibers or a different type of softwood fibers) used to prepare the
fourth plurality of fibers. The third plurality of fibers are the
same as or different from the first or second plurality of fibers.
The fourth plurality of fibers are the same as or different from
the first or second plurality of fibers. The pressure drop of the
first plurality of fibers is lower than the pressure drop of the
second plurality of fibers. The pressure drop of the third
plurality of fibers is lower than the pressure drop of the fourth
plurality of fibers. The basis weight ratio of the first phase to
the second phase is from about 30:70 to about 70:30. The article is
configured as a filter medium.
[0009] In still another aspect, this disclosure features an article
that includes first and second phases. The first phase includes a
first plurality of fibers and a second plurality of fibers
different from the first plurality of fibers. The second phase
includes a third plurality of fibers and a fourth plurality of
fibers different from the third plurality of fibers. The third
plurality of fibers are the same as or different from the first or
second plurality of fibers. The fourth plurality of fibers are the
same as or different from the first or second plurality of
fibers.
[0010] The air permeability of the first plurality of fibers is
higher than the air permeability of the second plurality of fibers.
The air permeability of the third plurality of fibers is higher
than the air permeability of the fourth plurality of fibers. At
least one of the first, second, third, and fourth pluralities of
fibers are made from an organic polymeric material. The first phase
has a higher air permeability than the second phase. The basis
weight ratio of the first phase to the second phase is about 30:70
or greater. The article is configured as a filter medium.
[0011] In yet another aspect, this disclosure features a filter
element that includes one of the articles described above.
[0012] In a further aspect, this disclosure features a method that
includes (1) disposing through a wet laid process a first
dispersion containing first and second pluralities of fibers
described above in a first solvent onto a wire to form a first
phase, (2) while the first and second pluralities of fibers are on
the wire, disposing a second dispersion containing third and fourth
pluralities of fibers described above in a second solvent onto the
first and second pluralities of fibers to form a second phase, and
(3) at least partially removing the first and second solvents,
thereby resulting in one of the articles described above.
[0013] Embodiments can include one or more of the following
features. The air permeability of the first or third plurality of
fibers can be from about 50 CFM to about 350 CFM (e.g., from about
100 CFM to about 200 CFM). The air permeability of the second or
fourth plurality of fibers can be from about 5 CFM to about 50 CFM
(e.g., from about 15 CFM to about 25 CFM).
[0014] The weight ratio of the first and second pluralities of
fibers can be from about 50:50 to about 90:10 (e.g., from about
50:50 to about 70:30 or from about 60:40 to about 70:30). The
weight ratio of the third and fourth pluralities of fibers can be
from about 10:90 to about 50:50 (e.g., from about 25:75 to about
50:50 or from about 30:70 to about 50:50).
[0015] The pressure drop of the first or third plurality of fibers
can be from about 5 Pa to about 300 Pa (e.g., from about 20 Pa to
about 100 Pa). The pressure drop of the second or fourth plurality
of fibers can be from about 300 Pa to about 1,000 Pa (e.g., from
about 250 Pa to about 500 Pa).
[0016] The first or third plurality of fibers can have an average
fiber length from about 1.5 mm to about 6 mm. The second or fourth
plurality of fibers can have an average fiber length from about 0.5
mm to about 2 mm.
[0017] The first or third plurality of fibers can include softwood
fibers (e.g., fibers obtained from mercerized southern pine,
northern bleached softwood kraft, southern bleached softwood kraft,
or chemically treated mechanical pulps), cotton fibers, polyester
fibers, polyvinyl alcohol binder fibers, or rayon fibers. The
second or fourth plurality of fibers can include hardwood fibers
(e.g., fibers obtained from Eucalyptus), polyethylene fibers, or
polypropylene fibers.
[0018] The basis weight ratio of the first and second phases can be
from about 30:70 to about 70:30, from about 40:60 to about 60:40,
or from about 30:70 to about 90:10. In certain embodiments, the
basis weight ratio of the first and second phases is about 30:70 or
greater (e.g., about 40:60 or greater, about 50:50 or greater, or
about 60:40 or greater). In some cases, the first phase has a
higher air permeability than the second phase.
[0019] The article can further include a binder (e.g., polyvinyl
acetate, an epoxy, a polyester, a polyvinyl alcohol, an acrylic
such as a styrene acrylic, or a phenolic resin). The binder can be
at least about 2% or at most about 35% of the basis weight of the
article.
[0020] The article can have an average pore size from about 3
microns to about 1,000 microns (e.g., from about 25 microns to
about 125 microns).
[0021] The article can have a dust holding capacity from about 0.3
g to about 3 g (e.g., from about 1 g to about 3 g) measured
according to a Palas flat sheet test.
[0022] The article can have an initial dust capture efficiency from
about 25% to about 99.5% (e.g., from about 60% to about 99.5%).
[0023] The first and third pluralities of fibers can be prepared
from the same material, or the second and fourth pluralities of
fibers can be prepared from the same material. The first and second
pluralities of fibers can be prepared from the same material, or
the third and fourth pluralities of fibers can be prepared from the
same material.
[0024] The first plurality of fibers can be prepared from a
material different from a material used to prepare the second
plurality of fibers, or the third plurality of fibers can be
prepared from a material different from a material used to prepare
the fourth plurality of fibers.
[0025] Each of the first, second, third, and fourth pluralities of
fibers can be made from an organic polymeric material.
[0026] The first or second phase can include one or more additional
pluralities of fibers.
[0027] The interface between the first and second phases can be
substantially non-linear or substantially free of an adhesive.
[0028] The filter element can include a radial filter element, a
panel filter element, or a channel flow element.
[0029] The filter element can include a gas turbine filter element,
a dust collector element, a heavy duty air filter element (e.g.,
containing a filter medium in which the weight ratio of the first
and second pluralities of fibers is from about 85:15, and the
weight ratio of the third and fourth pluralities of fibers is from
about 49:51), an automotive air filter element (e.g., containing a
filter medium in which the first phase includes three pluralities
of fibers with a weight ratio of about 83:10:7, and the second
phase includes three pluralities of fibers with a weight ratio of
about 40:35:25), a HVAC air filter element, a HEPA filter element,
a vacuum bag filter element, a fuel filter element, or an oil
filter element.
[0030] The first phase can further include a second plurality of
hardwood fibers, the second plurality of hardwood fibers being the
same as or different from the first plurality of hardwood
fibers.
[0031] The second phase can further include a second plurality of
softwood fibers, the second plurality of softwood fibers being the
same as or different from the first plurality of softwood
fibers.
[0032] Embodiments can provide one or more of the following
advantages.
[0033] Without wishing to be bound by theory, it is believed that,
by blending fibers with different characteristics in one or more
phases, one can obtain a filter medium having a multi-phase
structure (e.g., having phases with different air permeabilities
and/or pressure drops) with significantly improved dust holding
capacity and/or dust capture efficiency without substantial
degradation in mechanical strength compared to a filter medium
having a single phase structure (e.g., having a uniform air
permeability and/or pressure drop within the structure).
[0034] Other features, objects, and advantages of the invention
will be apparent from the description, drawings, and claims.
DESCRIPTION OF DRAWINGS
[0035] FIG. 1 is a cross-sectional view of a filter medium;
[0036] FIG. 2 is a cross-sectional view of a pleated filter
medium;
[0037] FIG. 3 is partial cut-away perspective view of a filter
element including a filter medium.
[0038] FIG. 4 is a scanning electron microscope graph illustrating
a cross-sectional view of a dual phase filter medium.
[0039] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0040] This disclosure relates to multi-phase filter media, as well
as related articles, components, filter elements, and methods. FIG.
1 is a cross-sectional view of an exemplary filter medium 10 that
includes a first phase 12 and a second phase 16. FIG. 2 depicts a
typical pleated configuration of filter medium 10. FIG. 3 shows a
cut-away perspective of an exemplary filter element 100 including a
filter housing 101, a filter cartridge 102, an inner screen 108 and
an outer screen 103. Filter medium 10 is disposed in filter
cartridge 102. During use, a gas or liquid enters element 100 via
an opening 104 and then passes through inner screen 108, filter
medium 10 and outer screen 103. The gas or liquid then exits filter
element 100 via opening 106. FIG. 4 is a scanning electron
microscope graph illustrating a cross-sectional view of an
exemplary filter medium 10.
I. FILTER MEDIUM
[0041] As shown in FIG. 1, filter medium 10 includes a first phase
12 and a second phase 16. In some embodiments, first phase 12 has a
larger air permeability and/or a smaller pressure drop than those
of second phase 16. Such a phase 12 is hereinafter referred to as
an open phase, and such a phase 16 is hereinafter referred to as a
tight phase. The order of open and tight phases in filter medium 10
is not critical. In some embodiment, first phase 12 can be a tight
phase and second phase 16 can be an open phase.
[0042] Without wishing to be bound by theory, it is believed that a
filter medium having a multi-phase structure (e.g., having phases
with different air permeabilities and/or pressure drops) exhibits
significantly improved dust holding capacity and/or dust capture
efficiency compared to a filter medium having a single-phase
structure (e.g., having a uniform air permeability and/or pressure
drop within the structure).
[0043] A. Open Phase
[0044] An open phase in filter medium 10 typically includes a first
plurality of fibers and a second plurality of fibers, although in
some embodiments, only a first plurality of fibers is used to form
the open phase.
[0045] In some embodiments, the first plurality of fibers have an
air permeability larger than that of the second plurality of
fibers. For example, the first plurality of fibers can have an air
permeability from about 50 cubic feet per minute ("CFM") to about
350 CFM (e.g., from about 100 CFM to about 200 CFM), and the second
plurality of fibers can have an air permeability from about 5 CFM
to about 50 CFM (e.g., from about 8 CFM to about 37 CFM or from
about 15 CFM to about 25 CFM). As used herein, air permeability of
fibers is determined by measuring the air permeability of a hand
sheet produced exclusively by such fibers and having a basis weight
of 100 g/m.sup.2 according to ISO 9237.
[0046] In some embodiments, the first plurality of fibers have a
pressure drop smaller than that of the second plurality of fibers.
For example, the first plurality of fibers can have a pressure drop
from about 5 Pascals ("Pa") to about 300 Pa (e.g., from about 10 Pa
to about 250 Pa or from about 20 Pa to about 100 Pa), and the
second plurality of fibers can have a pressure drop from about 300
Pa to about 1,000 Pa (e.g., from about 350 Pa to about 500 Pa). As
used herein, pressure drop of fibers is determined by using a gas
having a face velocity of 40 cm/s on a hand sheet produced
exclusively by such fibers and having a basis weight of 100
g/m.sup.2 according to ASTM F778-88.
[0047] In some embodiments, the first plurality of fibers have an
average fiber length larger than that of the second plurality of
fibers. For example, the first plurality of fibers can have an
average fiber length from about 1.5 mm to about 6 mm (e.g., from
about 2.5 mm to about 4.5 mm), and the second plurality of fibers
can have an average fiber length from about 0.5 mm to about 2 mm
(e.g., from about 0.7 mm to about 1.5 mm).
[0048] In general, the materials that can be used to form the first
and second pluralities of fibers can vary as desired. In some
embodiments, the first plurality of fibers are made from softwood
fibers, cotton fibers, glass fibers, polyester fibers, polyvinyl
alcohol binder fibers, or rayon fibers. Exemplary softwood fibers
include fibers obtained from mercerized southern pine ("mercerized
southern pine fibers or HPZ fibers"), northern bleached softwood
kraft (e.g., fibers obtained from Robur Flash ("Robur Flash
fibers")), southern bleached softwood kraft (e.g., fibers obtained
from Brunswick pine ("Brunswick pine fibers")), or chemically
treated mechanical pulps ("CTMP fibers"). For example, HPZ fibers
can be obtained from Buckeye Technologies, Inc., Memphis, Tenn.;
Robur Flash fibers can be obtained from Rottneros AB, Stockholm,
Sweden; and Brunswick pine fibers can be obtained from
Georgia-Pacific, Atlanta, Ga.
[0049] In some embodiments, the second plurality of fibers are made
from hardwood fibers, polyethylene fibers, or polypropylene fibers.
Exemplary hardwood fibers include fibers obtained from Eucalyptus
("Eucalyptus fibers"). Eucalyptus fibers are commercially available
from, e.g., (1) Suzano Group, Suzano, Brazil ("Suzano fibers"), (2)
Group Portucel Soporcel, Cacia, Portugal ("Cacia fibers"), (3)
Tembec, Inc., Temiscaming, QC, Canada ("Tarascon fibers"), (4)
Kartonimex Intercell, Duesseldorf, Germany, ("Acacia fibers"), (5)
Mead-Westvaco, Stamford, Conn. ("Westvaco fibers"), and (6)
Georgia-Pacific, Atlanta, Ga. ("Leaf River fibers"). In general,
softwood fibers have a relatively large air permeability, small
pressure drop, and large average fiber length compared to hardwood
fibers.
[0050] In some embodiments, an open phase can include a mixture of
softwood fibers and hardwood fibers. In certain embodiments, the
open phase can include only one type of fibers (e.g., softwood
fibers) uniformly distributed within the open phase.
[0051] In some embodiments, an open phase can include a mixture of
fibers with different characteristics (e.g., different air
permeabilities and/or pressure drops). Fibers with different
characteristics can be made from one material (e.g., by using
different process conditions) or different materials.
[0052] In some embodiments, the first plurality of fibers can be
formed from a material identical to the material used to form the
second plurality of fibers. In such embodiments, the first and
second pluralities of fibers can be prepared by using different
preparation methods, or different conditions in the same
preparation method, such that they have different characteristics
(e.g., different air permeabilities or pressure drops). In certain
embodiments, the first and second pluralities of fibers can be
formed of the same material and also have the same characteristics.
In some embodiments, the first plurality of fibers can be formed
from a material different from the material used to form the second
plurality of fibers.
[0053] Generally, the weight ratio of the first and second
plurality of fibers can vary depending on the desired properties of
filter medium 10. An open phase in filter medium 10 typically
includes fibers with a larger air permeability and/or a smaller
pressure drop in an amount larger than the amount of fibers with a
smaller air permeability and/or a larger pressure drop. For
example, a weight ratio of the first and second pluralities of
fibers described above can range from about 50:50 to about 97:3
(e.g., from about 50:50 to about 70:30 or from about 60:40 to about
70:30). As used herein, the weight of the first or second plurality
of fibers refers to the initial weight of each group of fibers in a
composition (e.g., a pulp) used to prepare the open phase. In
certain embodiments, an open phase in filter medium 10 can include
fibers with a larger air permeability and/or a smaller pressure
drop in an amount equal to or smaller than the amount of fibers
with a smaller air permeability and/or a larger pressure drop.
[0054] In some embodiments, an open phase can include one or more
pluralities of fibers in addition to the first and second
pluralities of fibers. Each of the additional pluralities of fibers
can have characteristics (e.g., air permeability and/or pressure
drop) different from the first or second plurality of fibers, or
can be prepared from a material different from those used to
prepare the first or second plurality of fibers. In some
embodiments, an additional plurality of fibers can be prepared from
a material identical to a material used to form one of the first
and second pluralities of fibers, but still have characteristics
different from those of the first or second plurality of
fibers.
[0055] B. Tight Phase
[0056] A tight phase in filter medium 10 typically includes a third
plurality of fibers and a fourth plurality of fibers.
[0057] In some embodiments, the third plurality of fibers can have
the same characteristics (e.g., air permeability and/or pressure
drop) or be made from the same type of material as the first or
second plurality of fibers described above, and the fourth
plurality of fibers can have the same characteristics or be made
from the same type of material as the first or second plurality of
fibers described above.
[0058] In some embodiments, the third plurality of fibers can have
one or more characteristics (e.g., air permeability and/or pressure
drop), or be made from a type of material, different from those of
the first or second plurality of fibers, and the fourth plurality
of fibers can have one or more characteristics, or be made from a
type of material, different from those of the first or second
plurality of fibers.
[0059] In some embodiments, a tight phase can include a mixture of
softwood fibers and hardwood fibers. In certain embodiments, the
tight phase can include only one type of fibers (e.g., hardwood
fibers) uniformly distributed within the tight phase.
[0060] In some embodiments, a tight phase can include a mixture of
fibers with different characteristics (e.g., different air
permeabilities and/or pressure drops). Fibers with different
characteristics can be made from one material (e.g., by using
different process conditions) or different materials.
[0061] In some embodiments, the third plurality of fibers can be
formed from a material identical to the material used to form the
fourth plurality of fibers. In such embodiments, the third and
fourth pluralities of fibers can be prepared by using different
preparation methods, or different conditions in the same
preparation method, such that they have different characteristics
(e.g., different air permeability or pressure drop). In certain
embodiments, the third and fourth pluralities of fibers can be
formed of the same material and also have the same characteristics.
In some embodiments, the third plurality of fibers can be formed
from a material different from the material used to form the fourth
plurality of fibers.
[0062] Generally, the weight ratio of the third and fourth
plurality of fibers can vary depending on the desired properties of
filter medium 10 or its intended uses. A tight phase in filter
medium 10 typically includes fibers with a higher air permeability
and/or a smaller pressure drop in an amount smaller than the amount
of fibers with a smaller air permeability and/or a larger pressure
drop. For example, a weight ratio of the third and fourth
pluralities of fibers described above can range from about 3:97 to
about 50:50 (e.g., from about 25:75 to about 50:50 or from about
70:30 to about 50:50). As used herein, the weight of the third or
fourth plurality of fibers refers to the initial weight of each
group of fibers in a composition (e.g., a pulp) used to prepare the
tight phase. In some embodiments, a tight phase in filter medium 10
can include fibers with a higher air permeability and/or a smaller
pressure drop in an amount larger than or equal to the amount of
fibers with a smaller air permeability and/or a larger pressure
drop.
[0063] In some embodiments, a tight phase can include one or more
pluralities of fibers in addition to the third and fourth
pluralities of fibers. Each of the additional pluralities of fibers
can have characteristics (e.g., air permeability or pressure drop)
different from the third or fourth plurality of fibers, or can be
prepared from a material different from those used to prepare the
third or fourth plurality of fibers. In some embodiments, an
additional plurality of fibers can be prepared from a material
identical to a material used to form one of the third and fourth
pluralities of fibers, but still have characteristics different
from those of the third or fourth plurality of fibers.
[0064] In general, the weight ratio of the open and tight phases in
filter medium 10 can vary as desired. For example, a basis weight
ratio of the open and tight phases can range from about 10:90 to
about 90:10 (e.g., from about 30:70 to about 70:30, from about
40:60 to about 60:40, or from about 30:70 to about 90:10). In
certain embodiments, the basis weight ratio of the open and tight
phases is about 30:70 or greater (e.g., about 40:60 or greater,
about 50:50 or greater, or about 60:40 or greater). As used herein,
basis weight of an open or tight phase refers to the weight of the
phase over a unit area (e.g., per square meter). For example, the
basis weight of an open or tight phase can have a unit of grams per
square meter.
[0065] C. Filter Medium Properties
[0066] In general, the thickness of filter medium 10 can vary as
desired. For example, filter medium 10 can have a thickness from
100 microns to 2,000 microns (e.g., from 300 microns to 1,000
microns or from 400 microns to 750 microns). The thickness may be
determined according to the standard TAPPI T411.
[0067] Generally, filter medium 10 can have any desired basis
weight. For example, filter medium 10 can have a basis weight of at
least about 10 g/m.sup.2 (e.g., at least about 50 g/m.sup.2 or at
least about 100 g/m.sup.2) and/or at most about 500 g/m.sup.2 (e.g.
at most about 250 g/m.sup.2 or at most about 200 g/m.sup.2). As
used herein, basis weight of a filter medium refers to the weight
of the medium over a unit area (e.g., per square meter). A typical
unit for the basis weight is g/m.sup.2.
[0068] The air permeability of filter medium 10 can usually be
selected as desired. For example, the air permeability of filter
medium 10 can be at least about 2 CFM (e.g., at least about 5 CFM,
at least about 10 CFM, or at least about 30 CFM) and/or at most
about 200 CFM (e.g., at most about 160 CFM, at most about 120 CFM,
or at most about 80 CFM). As used herein, air permeability of a
filter medium is determined according to ISO 9237.
[0069] The average pore size of filter medium 10 can vary as
desired. For example, filter medium 10 can have an average pore
size from at least about 3 microns (e.g., at least about 10
microns, at least about 25 microns, or at least about 100 microns)
and/or at most about 1,000 microns (e.g., at most about 500
microns, or at most about 125 microns). As used herein, the average
pore size refers to the mean flow pore size measured by using a
Coulter Porometer as described in ASTM F316-03.
[0070] Filter medium 10 can exhibit good ability to capture dust.
For example, filter medium 10 can have an initial dust capture
efficiency of at least about 25% (e.g., at least about 60%, at
least about 80%, at least about 85%, or at least about 90%) and/or
at most about 99.5% (e.g., at most about 98% or at most about 95%)
measured according to a Palas flat sheet test. A description of the
Palas flat sheet test used to determine an initial dust capture
efficiency is provided in the test protocol section below.
[0071] Filter medium 10 can also have good dust holding properties.
For example, filter medium 10 can have a dust holding capacity
(DHC) of at least about 0.3 g (e.g., at least about 1 g or at least
about 2 g) and/or at most about 3 g (e.g., at most about 2.5 g or
at most about 2 g) according to a Palas flat sheet test. A
description of the Palas flat sheet test to determine a dust
holding capacity is provided in the test protocol section below. As
another example, filter medium 10 can have a specific dust holding
capacity of at least about 0.001 g/g (e.g., at least about 0.004
g/g) and/or at most about 1.0 g/g (e.g., at most about 0.9 g/g). As
used herein, specific dust holding capacity can be calculated by
dividing a DHC of a filter medium over a unit weight (e.g., per
gram) of the filter medium. Alternatively, specific dust holding
capacity can be calculated by dividing a DHC of a filter medium
over a unit thickness (e.g., per millimeter) of the filter medium.
In some embodiments, filter medium 10 has both good dust capture
and good dust holding properties. As an example, filter medium 10
can have an initial dust capture efficiency of at least about 25%
(e.g., at least about 60%, at least about 80%, at least about 85%,
or at least about 90%) and a dust holding capacity of at least
about 0.3 g (e.g., at least about 1 g or at least about 2 g).
[0072] In some embodiments, at least one of the first, second,
third, and fourth pluralities of fibers described above are made
from an organic polymeric material (e.g., softwood fibers, cotton
fibers, hardwood fibers, or synthetic organic polymers such as
polyester or rayon). In certain embodiments, more than one (e.g.,
two, three, or all) of the first, second, third and fourth
pluralities of fibers are made from an organic polymeric
material.
[0073] In some embodiments, filter medium 10 can further include a
binder distributed throughout the filter medium. In general,
including a binder in a filter medium can significantly increase
its strength (e.g., tensile strength measured according to ISO
1924-2 or Mullen Burst strength measured according to DIN 53113).
The binder can include a polymeric material, such as polyvinyl
acetate, an epoxy, a polyester, a polyvinyl alcohol, an acrylic
(e.g., a styrene acrylic), or a phenolic resin. In some
embodiments, the binder can be at least about 2% and/or at most
about 35% (e.g., at most about 25%, at most about 15%, or at most
about 5%) of the basis weight of filter medium 10. In general, the
binder can be present in filter medium 10 with out without the
presence of cross-linking agents (e.g., melamine, hexamine, or an
epoxy hardener) or other additives (e.g., silicones, fluorocarbons,
or catalysts such as ammonium chloride).
[0074] Filter medium 10 typically includes an interface between
first phase 12 and second phase 16. In some embodiments, when
filter medium 10 is prepared in a continuous wet laid process
(e.g., forming first phase 12 and second phase 16 in a continuous
liquid-based coating process), the interface can take the form of a
transition phase which includes at least a portion of each of the
first, second, third, and fourth pluralities of fibers intermingled
with each other. Without wishing to be bound by theory, it is
believed that the interface in filter medium 10 prepared by such a
process can be substantially non-linear due to the interaction
between the fibers in first phase 12 and second phase 16. For
example, FIG. 4 shows a scanning electron microscope graph of a
dual phase filter medium, in which the interface is substantially
non-linear. Further, as no adhesive is typically used in a wet laid
process, the interface is typically substantially free of any
adhesive. First and second phases which include an interface that
is substantially free of an adhesive may be joined by, for example,
physical interactions between the fibers in each of the phases, or
by other suitable methods that do not involve the use of an
adhesive to join the phases. In some cases, first and second phases
which include an interface that is substantially free of an
adhesive are not joined by lamination.
[0075] In some embodiments, filter medium 10 can include one or
more phases in additional to first phase 12 and second phase 16. An
additional phase can be the same as or different from first phase
12 or second phase 16.
II. FILTER ELEMENTS AND SYSTEMS
[0076] Filter element 100 can be any of a variety of filter
elements. Examples of filter elements include gas turbine filter
elements, dust collector elements, heavy duty air filter elements,
automotive air filter elements, HVAC air filter elements, HEPA
filter elements, vacuum bag filter elements, fuel filter elements,
and oil filter elements (e.g., lube oil filter elements or heavy
duty lube oil filter elements).
[0077] Filter element 100 can also be in any suitable form, such as
radial filter elements, panel filter elements, or channel flow
elements. A radial filter element can include pleated filter media
that are constrained within two open wire meshes in a cylindrical
shape. During use, fluids can flow from the outside through the
pleated media to the inside of the radial element.
[0078] When filter element 100 is a heavy duty air filter element,
each of the open and tight phases in a single filter medium 10 can
include a mixture of softwood fibers (e.g., Robur Flash fibers) and
hardwood fibers (e.g., Suzano fibers). The weight ratio of the open
and tight phases can be about 30:70 or greater. The weight ratio of
the softwood fibers and hardwood fibers in the open phase can be,
for example, about 85:15, and the weight ratio of the softwood
fibers and hardwood fibers in the tight phase can be, for example,
about 49:51.
[0079] When filter element 100 is an automotive air filter element,
each of the open and tight phases in a single filter medium 10 can
include a mixture of softwood fibers and hardwood fibers (e.g.,
Suzano fibers). The weight ratio of the open and tight phases can
be about 50:50. The weight ratio of the softwood fibers and
hardwood fibers in the open phase can be about 93:7, and the weight
ratio of the softwood fibers and hardwood fibers in the tight phase
can be about 65:35. Each of the open and tight phases can be made
from two types of different softwood fibers (e.g., Robur Flash
fibers and HPZ fibers). The weight ratio of the two types of
different softwood fibers in the open phase can be about 83:10
(e.g., about 83% mercerized southern pine fibers and about 10% of
Robur Flash fibers). The weight ratio of the two types of different
softwood fibers in the tight phase can be about 40:25 (e.g., about
40% HPZ fibers and about 25% of Robur Flash fibers).
[0080] When filter element 100 is a fuel filter element, each of
the open and tight phases in a single filter medium 10 can include
a mixture of softwood fibers and hardwood fibers. The weight ratio
of the open and tight phases can be about 50:50. The weight ratio
of the softwood fibers and hardwood fibers in the open phase can be
about 60:40, and the weight ratio of the softwood fibers and
hardwood fibers in the tight phase can be about 6:94. The open
phase can be made from two types of different softwood fibers with
a weight ratio of about 40:20 (e.g., about 40% HPZ fibers and about
20% of Robur Flash), and a type of hardwood fibers (e.g., about 40%
of Suzano fibers). The tight phase can be made of three types of
different hardwood fibers with a weight ratio of about 48:36:10
(e.g., about 48% Suzano fibers, about 36% of Tarascon fibers, and
about 10% Acacia fibers) and a type of softwood fibers (e.g., about
6% HPZ fibers).
[0081] The orientation of filter medium 10 relative to gas flow
through a filter element/filter system can generally be selected as
desired. In some embodiments, second phase 16 is upstream of first
phase 12 in the direction of gas flow through a filter element. In
certain embodiments, second phase 16 is downstream of first phase
12 in the direction of gas flow through a filter element. As an
example, when the gas filter element is a gas turbine filter
element or a heavy duty air filter element, second phase 16 can be
upstream of first phase 12 in the direction of gas flow through the
filter element. As another example, when improved depth filtration
is desired, second phase 16 can be downstream of first phase 12 in
the direction of gas flow through the filter element.
III. METHODS OF MANUFACTURING FILTER MEDIUM
[0082] In general, filter medium 10 can be made by any suitable
methods. In some embodiments, filter medium 10 can be prepared by a
wet laid process as follows: First, a first dispersion (e.g., a
pulp) containing first and second pluralities of fibers in a
solvent (e.g., an aqueous solvent such as water) can be applied
onto a wire conveyor in a papermaking machine (e.g., a fourdrinier
or a rotoformer) to form first phase 12 supported by the wire
conveyor. A second dispersion (e.g., another pulp) containing third
and fourth pluralities of fibers in a solvent (e.g., an aqueous
solvent such as water) is then applied onto first phase 12. Vacuum
is continuously applied to the first and second dispersions of
fibers during the above process to remove the solvent from the
fibers, thereby resulting in an article containing first phase 12
and second phase 16. The article thus formed is then dried and, if
necessary, further processed (e.g., calendered) by using known
methods to form multi-phase filter medium 10. In some embodiments,
first phase 12 and second phase 16 in a multi-phase filter medium
10 do not have macroscopic phase separation as shown in a
conventional multi-layer filter medium (e.g., where one layer is
laminated onto another layer in the filter medium), but instead
contain an interface in which microscopic phase transition occurs
depending on the fibers used or the forming process (e.g., how much
vacuum is applied).
[0083] In some embodiments, a polymeric material can be impregnated
into filter medium 10 either during or after filter medium 10 is
being manufactured on a papermaking machine. For example, during
the manufacturing process described above, after the article
containing first phase 12 and second phase 16 is formed and dried,
a polymeric material in a water based emulsion or an organic
solvent based solution can be adhered to an application roll and
then applied to the article under a controlled pressure by using a
size press or gravure saturator. The amount of the polymeric
material impregnated into filter medium 10 typically depends on the
viscosity, solids content, and absorption rate of filter medium 10.
As another example, after filter medium 10 is formed, it can be
impregnated with a polymeric material by using a reverse roll
applicator following the just-mentioned method and/or by using a
dip and squeeze method (e.g., by dipping a dried filter media into
a polymer emulsion or solution and then squeezing out the excess
polymer by using a nip). A polymeric material can also be applied
to filter medium 10 by other methods known in the art, such as
spraying or foaming.
[0084] In general, filter medium 10 can be prepared by a continuous
manufacturing process (e.g., a roll-to-roll manufacturing process)
or can be prepared in a non-continuous, batch-to-batch manner.
[0085] The following examples are illustrative only and not
intended as limiting.
IV. EXAMPLES
A. Test Protocols
[0086] Initial Dust Capture Efficiency and Dust Holding
Capacity
[0087] A 100 cm.sup.2 surface area of a filter medium was
challenged with a fine dust (0.1-80 .mu.m) at a concentration of
200 mg/m.sup.3 with a face velocity of 20 cm/s for one minute. The
dust capture efficiency was measured using a Palas MFP2000
fractional efficiency photodetector. The dust capture efficiency
was [(1-[C/C0])*100%], where C was the dust particle concentration
after passage through the filter and C0 was the particle
concentration before passage through the filter. The dust capture
efficiency was measured after one minute and is referred to herein
as the initial dust capture efficiency. The dust holding capacity
is measured when the pressure reaches 1,800 Pa, and is the
difference in the weight of the filter medium before the exposure
to the fine dust and the weight of the filter medium after the
exposure to the fine dust. This test is referred to herein as a
Palas flat sheet test.
[0088] Liquid Filtration Efficiency Test and Liquid Filtration
Retention Efficiency
[0089] Using a FTI Multipass Filter Test Stand (Fluid Technologies
Inc., Stillwater, Okla.), an A2 fine dust is fed at a rate of 0.3
liters per minute into Mobil MIL-H-5606 fuel for a total flow rate
of 1.7 liters per minute to contact a filter medium per ISO 16889
until a terminal pressure of 174 KPa above the baseline filter
pressure drop is obtained. Particle counts (particles per
milliliter) are taken at the particle sized selected (in this case
4, 5, 7, 10, 15, 20, 25 and 30 microns). The particle counts are
taken upstream and downstream of the media at ten points equally
divided over the time of the test. The average of upstream and
downstream particle counts are taken at each selected particle
size. From the average particle count upstream (injected -C.sub.0)
and the average particle count downstream (passed thru-C) the
liquid filtration efficiency test value for each particle size
selected is determined by the relationship
[(100-[C/C.sub.0])*100%]. The liquid filtration retention
efficiency as a function of time and particle size can also be
measured by comparing the upstream and downstream particle counts
(and determining efficiency [(100-[C/C0])*100%]) at the sequential
ten points in the test. This test is referred to herein as a
multi-pass flat sheet test.
B. Examples
Example 1
[0090] Single phase and dual phase filter media were prepared on a
trial paper machine (TPM). The single phase filter media were
prepared using a blend of HPZ fibers and Suzano fibers. The weight
ratios of the HPZ fibers and Suzano fibers in the blend were 90/10,
70/30, and 50/50, respectively. The dual phase filter media were
prepared using HPZ fibers to form an open phase and Suzano fibers
to form a tight phase, in which the weight ratios of the HPZ fibers
and Suzano fibers were also 90/10, 70/30, and 50/50, respectively.
To form a dual phase filter medium, a flow separation insert was
used to separate the pulp containing HPZ fibers from the pulp
containing Suzano fibers. The open phase was formed on the bottom
of a dual phase filter medium and the tight phase was formed at the
top. The dual phase filter media thus formed had a density
equivalent to the single phase filter media. Both the single and
dual phase filter media were not saturated with a resin for
improving the strength of the media.
[0091] The filter media were refined by passing the pulps used to
form the filter media twice through a refiner with a load energy of
35 Amps to meet specific air permeability target for each grade.
Each type of filter medium was replicated three times. The filter
media were then tested for their capacity performance using a Palas
air stand according to the Palas flat sheet test described above,
tested for their Mullen Burst strength according to DIN 53113, and
tested for their tensile strength according to ISO 1924-2.
[0092] The results showed that the dual phase filter media
exhibited from 30% to 100% increase in their specific dust holding
capacity (DHC) compared to the single phase filter media. The
results also showed that the dual phase filter media exhibited
about 20% loss in strength compared to the single phase filter
media.
Example 2
[0093] Three types of automotive air filter media (i.e., filter
media 1, 2, and 3) in both single phase and dual phase of a
sufficient size to allow for saturation and element testing were
produced on a fourdrinier in a manner similar to that described in
Example 1.
[0094] The single phase filter media were prepared using a blend of
fibers. Specifically, single phase filter media 1 contained a blend
of about 47 wt % of HPZ fibers and about 53 wt % of Cacia fibers,
single phase filter media 2 contained a blend of about 70 wt % HPZ
fibers and about 30 wt % of Suzano fibers, and single phase filter
media 3 contained a blend of about 81 wt % HPZ fibers, about 9.5 wt
% Leaf River fibers, and about 9.5 wt % Cacia fibers.
[0095] The dual phase filter media were prepared using HPZ fibers
to form an open phase and Suzano, Cacia, or Leaf River fibers to
form a tight phase. Specifically, dual phase filter media 1
contained about 47 wt % of HPZ fibers in the open phase and about
53 wt % of Cacia fibers in the tight phase, dual phase filter media
2 contained about 70 wt % HPZ fibers in the open phase and about 30
wt % of Suzano fibers in the tight phase, and dual phase filter
media 3 contained about 81 wt % HPZ fibers in the open phase, and
about 9.5 wt % Leaf River fibers and about 9.5 wt % Cacia fibers in
the tight phase.
[0096] The above filter media were subsequently saturated with an
epoxy resin by using an impregnation machine. The filter media were
refined in the same manner as described in Example 1 to meet
specific air permeability target for each grade.
[0097] Panel air elements and cylindrical elements containing each
type of filter medium were produced. Specifically, a panel air
element was produced by assembling a pleated filter medium between
a molded silicone elastomer which holds the filter medium around
the edges. A cylindrical element was produced by wrapping a pleated
medium around a center tube, placing the article thus formed into a
can, and sealing the can. The panel air element is generally used
for high CFM automotive air, while the cylindrical element is
generally used for low CFM heavy duty Air.
[0098] The performance of panel air elements was measured according
to a standard method SAE J726. The results showed that elements
containing the dual phase filter media exhibited an average 25%
increase in DHC compared to elements containing the single phase
filter media. Elements containing the dual phase filter media also
exhibited about 3% increase in initial dust capture efficiency.
[0099] The performance of cylindrical elements was also measured
according to the standard method SAE J726. Elements containing the
dual phase filter media exhibited an average of 7% increase in
overall DHC compared to elements containing the single phase filter
media.
[0100] Mullen Burst and tensile strength of the single phase and
dual phase filter media prepared above were measured. The results
showed that the dual phase filter media exhibited a reduction in
strength compared to the single phase filter media. The impact of
the reduction was however less after the filter media was saturated
with the epoxy resin. The Mullen Burst strength of the dual phase
filter media was an average of about 80% of that of the single
phase filter media depending upon the grade. Tensile strength
comparisons between the two types of filter media showed a similar
trend. In all cases, enough strength was present to effectively
process the dual phase filter media.
Example 3
[0101] An interlayer design was used to produce dual phase filter
media 4 using a rotoformer. As used herein, an interlayer design
refers to a design that include a mixture of fibers with different
characteristics in one or both of the open and tight phases.
Specifically, dual phase filter media 4 contained about 45 wt %
bottom phase (a tight phase) that included about 72 wt % Suzano
fibers and about 28 wt % Robur Flash fibers, and about 55 wt % top
phase (an open phase) that included about 15 wt % Suzano fibers and
about 85 wt % Robur Flash fibers. Single phase filter media 4 were
produced using about 40 wt % of Suzano fibers and about 60 wt %
Robur Flash fibers. The performance of the filter media thus
prepared are summarized in Table 1. Each value is an average of
three tests per sample. After the filter media were formed, they
were corrugated by compressing the media between two grooved
corrugator rolls using sufficient pressure to result in machine
directional grooves or corrugations in the filter media.
[0102] As shown in Table 1, dual phase filter media 4 exhibited
significant improvement in DHC (about 26%) and specific DHC (from
about 14-33%) compared to single phase filter media 4 when measured
using the Palas flat sheet test described above. Further, dual
phase filter media 4 showed little strength degradation compared to
single phase filter media 4. It is believed that the interlayer
design effectively addressed the strength loss issue observed in
Examples 1 and 2.
TABLE-US-00001 TABLE 1 Single phase Dual phase filter media 4
filter media 4 Units Basis weight 115 108 g/m.sup.2 (average) Basis
weight 110 102 g/m.sup.2 (min.) Basis weight 120 115 g/m.sup.2
(max.) Basis weight 70.7 66.4 lbs./3000 ft.sup.2 Caliper 0.55 0.62
mm @2N/cm.sup.2 (average) Caliper 0.53 0.5 mm @2N/cm.sup.2 (min.)
Caliper 0.59 0.85 mm @2N/cm.sup.2 (max.) Caliper 21.7 24.4 mils
Corrugation depth 0.21 0.22 mm @ 1.76N/cm.sup.2 Air resistance 7.44
7.92 mbar @ 40 cm/s Air permeability 135 130 l/s m.sup.2 @ 200 Pa
Air permeability 17.0 16.3 cfm @ 1/2''WG max. pore 44.3 39.3 .mu.m
(IPA) many pores 33.7 33.7 .mu.m (IPA) Burst strength 267 235 kPa
Burst strength 38.7 34.1 psi Tensile strength MD 89 78 N/15 mm
Tensile strength CD 60 43.4 N/15 mm CD/MD ratio 1.48 1.80 CD = 1:
MD Tensile strength MD 33.2 29.1 lbs/inch Tensile strength CD 22.4
16.2 lbs/inch Elongation 4.1 3 % Elongation 10 7.3 % Initial
Pressure Drop 390 438 Pa Initial Efficiency 94.7 94.9 % Final
Efficiency 100 100 % Dust Holding Capacity, 0.76 0.96 g DHC
Specific DHC - g/g 0.33 0.44 g dust/g media Specific DHC - g/mm
1.36 1.55 g dust/mm media
Example 4
[0103] An interlayer approach was used to produce unsaturated
single and dual phase filter media 5, 6, and 7 using a rotoformer.
Single phase (SP) filter media 5 contained a blend of about 28 wt %
HPZ fibers, about 48 wt % Cacia fibers, and about 30 wt % Robur
Flash fibers. Dual phase (DP) filter media 5 contained about 50 wt
% of a tight phase and about 50 wt % of an open phase. The tight
phase included about 12 wt % HPZ fibers, about 68 wt % Cacia
fibers, and about 20 wt % Robur Flash fibers. The open phase
included about 40 wt % HPZ fibers, about 30 wt % Cacia fibers, and
about 30 wt % Robur Flash fibers.
[0104] Single phase filter media 6 contained a blend of about 58.2
wt % HPZ fibers and about 41.8 wt % of Suzano fibers. Dual phase
filter media 6 contained 80 wt % of a tight phase and about 20 wt %
of an open phase. The tight phase included about 52 wt % HPZ
fibers, about 48 wt % Suzano fibers. The open phase included about
83 wt % HPZ fibers, about 17 wt % Robur Flash fibers.
[0105] Single phase filter media 7 contained a blend of about 24.5
wt % polyester fibers, about 43.7 wt % HPZ fibers, about 28.9 wt %
Suzano fibers, and about 3 wt % CTMP fibers. Dual phase filter
media 7 contained about 70 wt % of a tight phase and about 30 wt %
of an open phase. The tight phase included about 26 wt % polyester
fibers, about 37 wt % HPZ fibers, and about 37 wt % of Suzano
fibers. The open phase included about 21 wt % polyester fibers,
about 59 wt % HPZ fibers, about 10 wt % Suzano fibers, and about 10
wt % CTMP fibers.
[0106] The performance of the filter media thus prepared are
summarized in Table 2. Each value is an average of three tests per
sample.
TABLE-US-00002 TABLE 2 SP 5 DP 5 SP 6 DP 6 SP 7 DP 7 unit Basis
weight 97 103 119 115 115 127 g/m.sup.2 (average) Basis weight 97
101 118 111 113 125 g/m.sup.2 (min.) Basis weight 98 105 121 122
116 130 g/m.sup.2 (max.) Basis weight 59.6 63.3 73.1 70.7 70.7 78.1
lbs./3000 ft.sup.2 Caliper 0.47 0.66 0.69 0.64 0.75 0.91 mm @2
N/cm.sup.2 (average) Caliper 0.46 0.5 0.67 0.58 0.72 0.61 mm @2
N/cm.sup.2 (min.) Caliper 0.49 0.91 0.72 0.67 0.8 1.27 mm @2
N/cm.sup.2 (max.) Caliper 18.5 26.0 27.2 25.2 29.6 35.9 mils
Corrugation depth 0 0 0 0 0 0 mm @ 1.76 N/cm.sup.2 Air resistance
4.82 6.54 2.28 2.38 1.27 1.52 mbar @ 40 cm/s Air permeability 198
156 400 387 701 605 l/s m.sup.2 @ 200 Pa Air permeability 25.1 19.7
51.4 49.7 91.2 78.4 cfm @ 1/2 ''WG max. pore 46 45.2 62.4 65.2 78.7
67.2 .mu.m (IPA) many pores 40 34.9 54.9 52.9 70.4 61.9 .mu.m (IPA)
Burst strength 77 73 55 57 49 46 kPa Burst strength 11.2 10.6 8.0
8.3 7.1 6.7 psi Tensile strength 22.5 25.6 16.1 16.7 11.5 11.9 N/15
mm MD Tensile strength 18.4 17.3 11.6 11.3 7.6 8.1 N/15 mm CD CD/MD
ratio 1.22 1.48 1.39 1.48 1.51 1.47 CD = 1:MD Tensile strength 8.4
9.6 6.0 6.2 4.3 4.4 lbs/inch MD Tensile strength 6.9 6.5 4.3 4.2
2.8 3.0 lbs/inch CD Elongation 1.2 1.4 1.6 1.2 1.2 1.1 % Elongation
1.6 2.8 2.5 2.8 1.6 1.6 % Initial Pressure 249 333 104 118 Pa Drop
Initial Efficiency 93.3 96.6 78 82.5 % Final Efficiency 100 100 100
99.8 % Dust Holding 1.1 1.37 1.88 2.07 5.51* 5.05* g Capacity, DHC
Specific DHC-g/g 0.56 0.66 0.79 0.9 g dust/g media Specific DHC-
2.34 2.07 2.72 3.23 1.6* g dust/mm g/mm media *These values were
measured by using a multi-pass flat sheet test.
[0107] As shown in Table 2, the dual phase filter media exhibited
significant improvement in DHC when measured using the PALAS flat
sheet test described above.
Example 5
[0108] Dual phase and single phase filter media were produced to
target specifications using a rotoformer. Specifically, the
following filter media were produced in the same manner as that
described in Examples 3 and 4: (1) dual phase filter media 8, 9,
and 10, and (2) single phase filter media 12 and 13 as controls. An
interlayer approach was used to produce dual phase filter media.
The compositions of these dual phase and single phase filter media
are summarized in Table 3 below. In the dual phase filter media,
the bottom phase was a tight phase and the top phase was an open
phase.
TABLE-US-00003 TABLE 3 Single phase (SP) SP 12 SP 11 Robur Flash -
60 wt % Robur Flash - 32.5 wt % Suzano - 40 wt % Suzano - 29 wt %
Westvaco HW - 38.5 wt % Dual phase (DP) DP 8 DP 9 DP 10 Bottom
Phase - 70 wt % Bottom Phase - 70 wt % Bottom Phase - 70 wt % Robur
Flash - 49 wt % Robur Flash - 43 wt % Robur Flash - 10 wt % Suzano
- 51 wt % Suzano - 57 wt % Suzano - 35 wt % Top Phase - 30 wt % Top
Phase - 30 wt % Westvaco HW - 55 wt % Robur Flash - 85 wt % Robur
Flash - 100 wt % Top Phase - 30 wt % Suzano - 15 wt % Suzano - 0 wt
% Robur Flash - 85 wt % Suzano - 15 wt %
[0109] The performance of these filter media were measured using
the Palas flat sheet test described above. The results are
summarized in Table 4 below.
TABLE-US-00004 TABLE 4 Initial Final Initial Specific Efficiency
Efficiency DP Specific DHC Trial # (%) (%) (Pa) DHC (g) DHC (g/g)
(g/mm) DP 8 88.50 99.99 415 1.352 0.60725 4.9746 DP 9 92.13 99.99
438 1.000 0.45514 3.1073 DP 10 91.84 100.00 465 1.064 0.50212
3.4908 SP 11 92.07 100.00 451 0.920 0.42112 2.9376 SP 12 90.11
100.00 421 0.824 0.36320 2.7034
[0110] As shown in Table 4, DP 8 and DP 9 exhibited at least 20%
improvement in DHC and at least 15% improvement in specific DHC
compared to SP 12. DP 10 also exhibited about 10% improvement in
DHC and about 17% improvement in specific DHC compared to SP
11.
[0111] The strength of the filter media above were also tested. The
results showed that the strength of the dual phase filter media was
about 10% lower than that of the single phase filter media, and was
more significant for DP10 as compared to SP11.
Example 6
[0112] Additional testing of DP 8 and SP 12 prepared in Example 5
were carried out as follows.
[0113] High pressure flat sheet testing of DP 8 and SP 12 were
carried out using the Palas flat sheet test described above except
that a higher terminal pressure of 4,500 Pa was applied. The
results are summarized in Table 5 below. As shown in Table 5, DP 8
exhibited at least about 40% improvement in DHC and specific DHC
compared to SP 12.
TABLE-US-00005 TABLE 5 Specific Specific Initial dP Initial Eff.
Final Eff. DHC/mm DHC/g Type Trial # (Pa) (%) (%) DHC (g) (g/mm)
(g/g) Single SP 12 383 89.3 100 2.06 2.75 0.91 phase Dual DP 8 379
84.8 100 2.87 4.33 1.29 phase
[0114] DP 8 and SP 12 were incorporated into radial filter elements
and tested using a radial element test designed to simulate heavy
duty air face velocity of 8 ft/min. Compared to elements containing
SP 12, elements containing DP 8 exhibited about 23% improvement in
DHC and specific DHC calculated based on per square meter of a
filter medium.
Example 7
[0115] A series of short trials were completed using a TPM to
optimize the DHC of dual phase filter media. Filter media 13, 14,
15, 16, and 17 were produced. For each type of filter media, a
single phase version (i.e., SP) and two dual phase versions (i.e.,
DP1 and DP2) were produced. For filter media 14, an addition dual
phase version (i.e., DP2vv) with a tight phase at the bottom was
produced. All of the dual phase filter media were produced by an
interlayer design. The compositions of these filter media are
summarized in Table 6 and the performance of the filter media are
summarized in Tables 7 and 8.
TABLE-US-00006 TABLE 6 Filter media 13 Filter media 14 Filter media
15 Filter media 16 Filter media 17 (wt %) (wt %) (wt %) (wt %) (wt
%) Single phase (SP) HPZ - 28% HPZ - 71% Polyester - 23% HPZ - 64%
HPZ - 19% Cacia - 48% Suzano - 29% HPZ - 49% Brunswick Pine - 26%
Suzano - 63% Robur Flash - 24% Suzano - 22% Cacia - 10% Tarascon -
18% CTMP - 6% Dual phase (DP1) Open Phase - 50% Open Phase - 50%
Open Phase - 50% Open Phase - 50% Open Phase - 50% HPZ - 40% HPZ -
83% HPZ - 60% HPZ - 85% HPZ - 35% Cacia - 20% Suzano - 17%
Polyester - 30% Brunswick Pine - 10% Suzano - 65% Robur Flash - 40%
Tight Phase - 50% Suzano - 10% Cacia - 5% Tight Phase - 50% Tight
Phase - 50% HPZ - 60% Tight Phase - 50% Tight Phase - 50% HPZ - 10%
HPZ - 0% Suzano - 40% HPZ - 32% HPZ - 42.5% Suzano - 54% Cacia -
68% Polyester - 16% Brunswick Pine - 42.5% Tarascan - 36% Robur
Flash - 32% Suzano - 32% Cacia - 15% CTMP - 20% Dual phase (DP2)
Open Phase - 50% Open Phase - 50% Open Phase - 50% Open Phase - 70%
Open Phase - 50% HPZ - 56% HPZ - 83% HPZ - 50% HPZ - 87% HPZ - 40%
Cacia - 30% Suzano - 7% Polyester - 30% Brunswick Pine - 13% Suzano
- 50% Robur Flash - 14% Robur Flash - 10% Robur Flash - 20% Tight
Phase - 30% Robur Flash - 10% Tight Phase - 50% Tight Phase - 50%
Tight Phase - 50% HPZ - 9% Tight Phase - 50% HPZ - 0% HPZ - 40% HPZ
- 32% Brunswick Pine - 55% Suzano - 54% Cacia - 68% Suzano - 35%
Polyester - 16% Cacia - 36% Tarascan - 36% Robur Flash - 32% Robur
Flash - 25% Suzano - 32% Acacia - 10% Robur Flash - 20%
TABLE-US-00007 TABLE 7 test results Palas Multipass g/m.sup.2
l/m.sup.2s @ Burst initial initial DHC efficiency efficiency DHC
Samples [g/m.sup.2] mm @ 2 N/cm.sup.2 200 Pa Strength efficiency
pressure [mg/cm.sup.2] 50% [.mu.m] 90% [.mu.m] [g/200 cm.sup.2]
Filter SP 119 0.60 507 90 63.9 107 8.36 media DP 1 117 0.59 494 83
72.4 83 7.88 14 DP 2 117 0.58 507 72 59.2 84 9.56 DP 109 0.56 514
77 69.6 95 11.96 2vv Filter DP 1 105 0.43 125 138 87.2 319 8.12
media DP2 108 0.47 160 120 89 319 7.88 13 SP 107 0.45 176 132 89.1
319 6.44 Filter DP 1 119 0.64 608 50 18.1 26.6 3.72 media DP 2 121
0.66 627 60 20.3 30.1 4.91 15 SP 124 0.67 662 56 20.6 31.2 4.26
Filter DP 1 162 0.81 396 118 19.2 30 4.28 media DP 2 164 0.80 355
71 18.3 26.4 4.25 16 SP 164 0.79 403 132 20.6 30.2 3.57 Filter DP 1
186 0.45 19 299 media DP 1 187 0.43 16 319 3.7 5.25 0.62 17 DP 2
181 0.45 15 280 4 5.5 0.6 SP 189 0.47 16 288 4 5.5 0.38
TABLE-US-00008 TABLE 8 Single Phase Dual Phase 2 DHC Grade DHC/g
DHC/g increase/% Filter media 14 8.36 11.96 43.06 Filter media 13
6.44 7.88 22.36 Filter media 15 4.26 4.91 15.26 Filter media 16
3.57 4.25 19.05 Filter media 17 0.38 0.60 57.89
[0116] As shown in Tables 7 and 8, interlayer designs in the dual
phase filter media showed positive results (i.e., with
significantly improved DHC and strength properties maintained) as
compared to the single phase filter media. The DP2 version of each
type of filter media yielded the most improvement in DHC compared
to its corresponding single phase control. In filter media 14,
DP2vv, which contained a tight phase on the bottom, showed a 43%
improvement in DHC. This approach appeared to yield the highest DHC
improvement.
Example 8
[0117] Trial production was carried out to optimize dual phase
filter media prepared in Example 7. Specifically, optimized
versions of filter media 13 (for use in a heavy duty air filter
element), 14 (for use in an automotive air filter element), 15 (for
use in lube oil filter element), 16 (for use in a heavy duty lube
oil filter element), and 17 (for use in a fuel filter element) were
produced. For each type of filter media, a single phase version and
a dual phase version of each grade of filter media were produced. A
fourdrinier and an impregnator were used to produce single and dual
phase filter media, which were saturated with a solvent based
phenolic resin. All dual phase filter media were produced with a
tight phase on the bottom using an interlayer design. The
compositions of these filter media are summarized in Table 9 and
the performance of the filter media are summarized in Tables 10 and
11.
TABLE-US-00009 TABLE 9 Filter media 13 Filter media 14 Filter media
15 Filter media 16 Filter media 17 (wt %) (wt %) (wt %) (wt %) (wt
%) Single phase HPZ - 28% HPZ - 71% Polyester - 23% HPZ - 64% HPZ -
19% Cacia - 48% Suzano - 29% HPZ - 49% Brunswick Pine - 26% Suzano
- 63% Robur Flash - 24% Suzano - 22% Cacia - 10% Tarascon - 18%
CTMP - 6% Dual phase Open Phase - 50% Open Phase - 50% Open Phase -
50% Open Phase - 50% Open Phase - 50% HPZ - 56% HPZ - 83% HPZ - 50%
HPZ - 85% HPZ - 40% Cacia - 30% Suzano - 7% Polyester - 30%
Brunswick Pine - 10% Suzano - 40% Robur Flash - 14% Robur Flash -
10% Robur Flash - 20% Cacia - 5% Robur Flash - 20% Tight Phase -
50% Tight Phase - 50% Tight Phase - 50% Tight Phase - 50% Tight
Phase - 50% HPZ - 0% HPZ - 40% HPZ - 32% HPZ - 42.5% HPZ - 6% Cacia
- 68% Suzano - 35% Polyester - 16% Brunswick Pine - 42.5% Suzano -
48% Robur Flash - 32% Robur Flash - 25% Suzano - 32% Cacia - 15%
Tarascan - 36% Robur Flash - 20% Acacia - 10%
TABLE-US-00010 TABLE 10 Palas Flat Sheet Test Results Initial
Specific Specific Efficiency DHC DHC Samples (%) DHC (g) (g/g)
(g/mm) Filter media 13 Single phase 87.5 0.60 0.46 1.36 Dual phase
87.2 0.44 0.62 1.73 Dual phase change (%) -0.3 28.57 33.15 27.32
Filter media 14 Single phase 58.1 0.76 0.54 1.38 Dual phase 59.4
1.04 0.73 1.76 Dual phase change (%) 2.2 36.84 35.77 27.93
TABLE-US-00011 TABLE 11 Multi-pass flat sheet Test Results Initial
Specific Specific Efficiency DHC DHC Samples (%) DHC (g) (g/g)
(g/mm) Filter media 15 Single phase 13.0 4.28 1.43 6.47 Dual phase
18.5 5.24 1.91 8.04 Dual phase change (%) 42.3 22.6 33.6 24.3
Filter media 16 Single phase 22.5 3.60 0.90 4.94 Dual phase 17.0
5.50 1.37 6.59 Dual phase change (%) -24.4 52.8 52.2 33.4 Filter
media 17 Single phase 99.7 0.36 0.09 0.80 Dual phase 99.2 0.55 0.13
1.15 Dual phase change (%) -.05 52.8 50.0 43.8
[0118] The optimized dual phase filter media showed from about 23%
to about 52% increase in DHC and specific DHC compared to the
single phase filter media, while strength loss in the dual phase
filter media averaged about 10% compared to the single phase filter
media.
[0119] Other embodiments are in the claims.
* * * * *