U.S. patent application number 16/653934 was filed with the patent office on 2020-07-09 for filter media including oriented fibers.
This patent application is currently assigned to Hollingsworth & Vose Company. The applicant listed for this patent is Hollingsworth & Vose Company. Invention is credited to Arash Sahbaee, Bruce Smith.
Application Number | 20200215471 16/653934 |
Document ID | / |
Family ID | 54929474 |
Filed Date | 2020-07-09 |
![](/patent/app/20200215471/US20200215471A1-20200709-D00000.png)
![](/patent/app/20200215471/US20200215471A1-20200709-D00001.png)
![](/patent/app/20200215471/US20200215471A1-20200709-D00002.png)
![](/patent/app/20200215471/US20200215471A1-20200709-D00003.png)
![](/patent/app/20200215471/US20200215471A1-20200709-D00004.png)
![](/patent/app/20200215471/US20200215471A1-20200709-D00005.png)
![](/patent/app/20200215471/US20200215471A1-20200709-D00006.png)
United States Patent
Application |
20200215471 |
Kind Code |
A1 |
Sahbaee; Arash ; et
al. |
July 9, 2020 |
FILTER MEDIA INCLUDING ORIENTED FIBERS
Abstract
Filter media incorporating one or more filtration layers that
include fibers including fiber portions orientated at a non-zero
angle with respect to a surface of the filtration layer are
provided. In some embodiments, at least a part of the fiber
portions are positioned at an angle of at least 20 degrees (e.g.,
between 46 degrees and 90 degrees, or between 61 degrees and 90
degrees) with respect to a surface of the filtration layer or an
outer or cover layer of the media. This orientation of fiber
portions may result in an increased efficiency (e.g., average
efficiency and/or initial efficiency) compared to similar filter
media that do not include such oriented fiber portions.
Inventors: |
Sahbaee; Arash;
(Christiansburg, VA) ; Smith; Bruce; (Copper Hill,
VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hollingsworth & Vose Company |
East Walpole |
MA |
US |
|
|
Assignee: |
Hollingsworth & Vose
Company
East Walpole
MA
|
Family ID: |
54929474 |
Appl. No.: |
16/653934 |
Filed: |
October 15, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14314121 |
Jun 25, 2014 |
10441909 |
|
|
16653934 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 46/0001 20130101;
B01D 39/1623 20130101; B01D 2239/069 20130101; B01D 39/02 20130101;
B01D 2239/1233 20130101; B01D 46/546 20130101; B01D 39/163
20130101; B01D 46/023 20130101; B01D 46/00 20130101; B01D 2239/065
20130101; B01D 46/10 20130101; B01D 46/521 20130101 |
International
Class: |
B01D 46/00 20060101
B01D046/00; B01D 46/54 20060101 B01D046/54; B01D 39/16 20060101
B01D039/16; B01D 39/02 20060101 B01D039/02; B01D 46/02 20060101
B01D046/02; B01D 46/10 20060101 B01D046/10; B01D 46/52 20060101
B01D046/52 |
Claims
1. (canceled)
2. A filter media, comprising: a first filtration layer comprising
a plurality of fibers including fiber portions, the plurality of
fibers having an average fiber diameter of at least 5 microns and
less than or equal to 60 microns, the first filtration layer having
a first surface, a second filtration layer comprising a plurality
of fiber portions having an average fiber diameter of at least 5
microns and less than or equal to 40 microns, wherein the first and
second filtration layers are directly adjacent one another, wherein
each of the first and second filtration layers comprises fiber
portions that are positioned at an angle of between 46 degrees and
90 degrees with respect to the first surface, wherein at least 25%
of the combined fiber portions of the first and second filtration
layers are positioned at an angle of between 46 degrees and 90
degrees with respect to the first surface, wherein the first and
second filtration layers have a combined basis weight of at least
40 gsm, wherein the filter media has an thickness of at least 0.035
inches, wherein the filter media has an average filtration
efficiency of at least 40% for 0.4 micron or greater particles.
3. The filter media of claim 1, wherein the basis weight of the
first and/or second filtration layer is between about 80 gsm and
200 gsm.
4. The filter media of claim 1, wherein the first and/or second
filtration layer has a thickness of between about 80 mil and about
230 mil.
5. The filter media of claim 1, wherein the first and/or second
filtration layer has a mean pore flow size of between about 5
microns and about 80 microns.
6. The filter media of claim 1, wherein the first and/or second
filtration layer has an air permeability of between about 350 cfm
and about 600 cfm.
7. The filter media of claim 1, wherein the first filtration layer
has an average fiber diameter that is different from an average
fiber diameter of the second filtration layer.
8. The filter media of claim 1, wherein the plurality of fibers are
comprised of a synthetic polymer.
9. The filter media of claim 8, wherein the synthetic polymer is
selected from the group consisting of polyesters, acrylics,
polyolefins, nylons, rayons, and polyvinyl derivatives.
10. The filter media of claim 1, wherein the first and/or second
filtration layer comprises staple fibers.
11. The filter media of claim 1, wherein the first and/or second
filtration layer comprises between about 20 wt % and about 70 wt %
of binder fibers.
12. The filter media of claim 1, wherein the first and/or second
filtration layer has a pressure drop across the filtration layer of
between about 7 Pa and about 15 Pa.
13. The filter media of claim 1, wherein the first and/or second
filtration layer has an average efficiency for 0.4 micron or larger
particles of between about 30% and about 80%, as determined
according to standard EN779-2012 using a final pressure drop of 450
Pa.
14. The filter media of claim 1, wherein the filter media has a
mean flow pore size of between about 5 microns and about 80
microns.
15. The filter media of claim 1, wherein the first and/or second
filtration layer has an initial efficiency for 3.0-10.0
micron-sized particles of between about 20% to about 90% as
determined according to the standard ASHRAE 52.2.
16. The filter media of claim 1, wherein the first and/or second
filtration layer has a dust holding capacity of between about 100
g/m2 and about 160 g/m2.
17. The filter media of claim 1, wherein the filter media is
classified as an M5 filter media.
18. The filter media of claim 1, wherein the filter media has an
overall thickness of between about 80 mil and about 230 mil.
19. The filter media of claim 1, wherein at least 10% of the fiber
portions of the first and/or second filtration layer are positioned
at an angle of between 0 degrees and 30 degrees with respect to the
first surface, at least 25% of the fiber portions of the filtration
layer are positioned at an angle of between 31 degrees and 60
degrees with respect to the first surface, and at least 40% of the
fiber portions of the filtration layer are positioned at an angle
of between 61 degrees and 90 degrees with respect to the first
surface.
20. The filter media of claim 1, wherein the plurality of fibers
comprise a waved configuration including a plurality of peaks and
troughs.
21. The filter media of claim 20, wherein the fiber density and/or
fiber mass at the peaks is higher than the fiber density and/or
fiber mass at the troughs.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 14/314,121 filed Jun. 25, 2014, which is incorporated herein by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The embodiments herein relate to filtration, and more
particularly to filter media having particular fiber orientations
within the media.
BACKGROUND
[0003] The removal of air borne particulate contaminants from the
air is a concern to everyone. Gas phase particulate filtration has
traditionally been accomplished by methods that utilize woven or
nonwoven fabrics or webs. The performance of such a system is
characterized by the initial efficiency of removal or capture of
the particulate as a function of particle size, the initial
resistance of the system to air or gas flow as a function of gas
flow rate or face velocity, the average efficiency of removal or
capture of the particulate as a function of particle size, and/or
the way these factors change as the filter element loads with the
particulate contaminant. Although different types of filter media
are available, improvements are needed.
SUMMARY
[0004] Filter media having particular fiber orientations within the
media are provided.
[0005] In one embodiment, a filter media is provided. The filter
media comprises a filtration layer comprising a plurality of fibers
including fiber portions, the plurality of fibers having an average
fiber diameter of at least 10 microns and less than or equal to 60
microns, the filtration layer having a first surface, wherein at
least 25% of the fiber portions of the filtration layer are
positioned at an angle of between 46 degrees and 90 degrees with
respect to the first surface. The filtration layer has a basis
weight of at least 40 gsm, and a cover layer adjacent the
filtration layer, wherein a fine fiber layer having an average
fiber diameter of less than 10 microns is absent from the filter
media. The filter media has a thickness of at least 0.035
inches.
[0006] In another embodiment, a filter media comprises a filtration
layer comprising a plurality of fibers including fiber portions,
the plurality of fibers having an average fiber diameter of at
least 10 microns and less than or equal to 60 microns, the
filtration layer having a first surface, wherein at least 25% of
the fiber portions of the filtration layer are positioned at an
angle of between 46 degrees and 90 degrees with respect to the
first surface. The filtration layer comprises at least 10 wt % of
binder fibers, wherein the filtration layer has a basis weight of
at least 40 gsm. A fine fiber layer having an average fiber
diameter of less than 10 microns is absent from the filter media.
The filter media has an thickness of at least 0.035 inches.
[0007] In another embodiment, a filter media comprises a filtration
layer comprising a plurality of fibers including fiber portions,
the plurality of fibers having an average fiber diameter of at
least 5 microns and less than or equal to 60 microns, the
filtration layer having a first surface, wherein at least 25% of
the fiber portions of the filtration layer are positioned at an
angle of between 46 degrees and 90 degrees with respect to the
first surface. The filtration layer has a basis weight of at least
40 gsm, the filter media has an thickness of at least 0.035 inches,
and the filter media has an overall air permeability of between 310
CFM and 800 CFM.
[0008] In another embodiment, a filter media comprises a first
filtration layer comprising a plurality of fibers including fiber
portions, the plurality of fibers having an average fiber diameter
of at least 5 microns and less than or equal to 60 microns, the
first filtration layer having a first surface. The filter media
also includes a second filtration layer comprising a plurality of
fiber portions having an average fiber diameter of at least 5
microns and less than or equal to 40 microns, wherein the first and
second filtration layers are directly adjacent one another. Each of
the first and second filtration layers comprises fiber portions
that are positioned at an angle of between 46 degrees and 90
degrees with respect to the first surface. At least 25% of the
combined fiber portions of the first and second filtration layers
are positioned at an angle of between 46 degrees and 90 degrees
with respect to the first surface. The first and second filtration
layers have a combined basis weight of at least 40 gsm. The filter
media has an thickness of at least 0.035 inches. The filter media
has an average filtration efficiency of at least 40% for 0.4 micron
or greater particles.
[0009] In another embodiment, a filter media comprises a filtration
layer comprising a plurality of fibers including fiber portions,
the plurality of fibers having an average fiber diameter of at
least 10 microns and less than or equal to 60 microns, the
filtration layer having a first surface. At least 10% of the fiber
portions of the filtration layer are positioned at an angle of
between 0 degrees and 30 degrees with respect to the first surface,
at least 25% of the fiber portions of the filtration layer are
positioned at an angle of between 31 degrees and 60 degrees with
respect to the first surface, and at least 40% of the fiber
portions of the filtration layer are positioned at an angle of
between 61 degrees and 90 degrees with respect to the first
surface. The filtration layer has a basis weight of at least 40
gsm. The filter media also includes a cover layer adjacent the
filtration layer. A fine fiber layer having an average fiber
diameter of less than 10 microns is absent from the filter media.
The filter media has an thickness of at least 0.035 inches.
[0010] Filter elements including the filter media described above
and herein are also provided. Methods of filtering fluids including
such filter media and filter elements are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a side view illustration of one embodiment of a
filter media;
[0012] FIG. 1B is a side view illustration of another embodiment of
a filter media;
[0013] FIG. 1C is a side view illustration of yet another
embodiment of a filter media;
[0014] FIG. 2 is a perspective view of one embodiment of a panel
filter;
[0015] FIG. 3A is a perspective view of one embodiment of a pleated
filter element;
[0016] FIG. 3B is a side cross-sectional view of another embodiment
of a pleated filter element;
[0017] FIG. 3C is a side cross-sectional view of yet another
embodiment of a pleated filter element;
[0018] FIG. 4A is a perspective view of one embodiment of a bag
filter having multiple filter bags disposed therein;
[0019] FIG. 4B is a perspective view of one of the filter bags of
FIG. 4A;
[0020] FIG. 5 is a plot of initial efficiency as a function of
particle size;
[0021] FIG. 6A is a representative SEM cross-sectional image of
fibers oriented substantially between 0 degrees and 45 degrees;
and
[0022] FIG. 6B is a representative SEM cross-sectional image of
fibers oriented substantially between 46 degrees and 90
degrees.
DETAILED DESCRIPTION
[0023] Filter media incorporating one or more filtration layers
that include fiber portions orientated at a non-zero angle with
respect to a surface of the filtration layer are provided. In some
embodiments, at least some of the fiber portions are positioned at
an angle of at least 20 degrees (e.g., between 46 degrees and 90
degrees, or between 61 degrees and 90 degrees) with respect to a
surface (e.g., a planar surface) of the filtration layer. In some
embodiments, the angle may be measured with respect to the
horizontal or an outer or cover layer of the media. This
orientation of fiber portions results in an increased efficiency
(e.g., average efficiency and/or initial efficiency) compared to
filter media that do not include such oriented fiber portions,
thereby enhancing various properties of the filter media. The
fibers of the filtration layer may be relatively coarse; for
instance, they may have an average fiber diameter of at least 5
microns or at least 10 microns. The filtration layer may optionally
include binder fibers that can help to maintain the configuration
of fibers in their orientations. The filter media may also
optionally include a support layer (e.g., a scrim) that is planar
with respect to the surface of the filtration layer. In certain
embodiments described herein, the filter media do not include a
fine fiber layer which would improve filtration efficiency, but
also increase cost of the media. Advantageously, the filter media
described herein can be used to form a variety of filter elements
for use in various applications. Moreover, the filter media may be
cost effective and easy to manufacture.
[0024] FIG. 1A illustrates one exemplary embodiment of a filter
media 10 having a filtration layer that includes fiber portions
orientated at a non-zero angle with respect to a surface of the
filtration layer. The fibers or fiber portions may have a waved
configuration as described in more detail below. In the illustrated
embodiment, the filter media includes a filtration layer 14 having
a surface 15 (e.g., a first planar surface) and a second surface 19
(e.g., a second planar surface) along the horizontal in the
X-direction. The filter media can also optionally include one or
more outer or cover layers 18 located on the upstream-most and/or
downstream-most sides of the filter media.
[0025] FIG. 1B illustrates one exemplary embodiment of a filter
media 10A having at least two filtration layers that include fiber
portions orientated at a non-zero angle with respect to a surface
of the filtration layer. The fibers or fiber portions may have a
waved configuration. In the illustrated embodiment, the filter
media includes a first, downstream filtration layer 14A having a
surface 15A (e.g., a first planar surface) along the horizontal in
the X-direction. The filter media also includes a second, upstream
filtration layer 16A positioned adjacent the first filtration
layer, the second filtration layer having a surface 19A (e.g., a
second planar surface) along the horizontal in the X-direction. The
filter media can also optionally include one or more outer or cover
layers located on the upstream-most and/or downstream-most sides of
the filter media. FIG. 1B illustrates an outer or cover layer 18A
disposed on the upstream side of the filter media, while FIG. 1C
illustrates an outer or cover layer 18B disposed on the downstream
side of the filter media.
[0026] As shown illustratively in FIG. 1B, the first filtration
layer includes a first plurality of fibers 20A, and the second
filtration layer includes a second plurality of fibers 22A. The
fibers of the filtration layer(s) may be relatively coarse (e.g.,
having an average fiber diameter of at least 5 microns or at least
10 microns). The coarseness of the fibers may give the fibers
sufficient strength to help maintain them in their angled
orientations.
[0027] In some embodiments, each of the first and second plurality
of fibers includes a relatively high percentage of fiber portions
oriented at an angle with respect to the horizontal (e.g.,
X-direction in FIGS. 1A-1C), or with respect to a surface of the
filtration layer (e.g., surface 15 or 19) or a surface of an outer
or cover layer. As described in more detail below, a relatively
high percentage of the fiber portions in the first and/or second
filtration layers may be positioned at an angle of at least 20
degrees (e.g., between 61 degrees and 90 degrees, or between 46
degrees and 90 degrees) with respect to a surface of the filtration
layer (e.g., surface 15 or 19), or with respect to a surface of an
outer or cover layer of the media. For instance, as shown
illustratively in FIG. 1B, a fiber portion 20C is positioned
approximately 90 degrees with respect to a surface of the
filtration layer (e.g., surface 15 or 19), or with respect to a
surface of an outer or cover layer of the media. A fiber portion
20D is positioned approximately 0 degrees with respect to a surface
of the filtration layer (e.g., surface 15 or 19), or with respect
to a surface of an outer or cover layer of the media, because it
lies on substantially the same plane as the surface of the
filtration layer and an outer or cover layer of the media. The more
fiber portions in the layer that are oriented towards the
Z-direction, e.g., positioned perpendicular with respect to a
surface of the filtration layer or with respect to a surface of an
outer or cover layer of the media, the higher percentage of the
fiber portions in the layer that are positioned at an angle of
between 46 degrees and 90 degrees, or between 60 degrees and 90
degrees. This orientation of fiber portions results in an increased
efficiency compared to filter media that do not include such
oriented fiber portions, thereby enhancing various properties of
the filter media. For instance, as described in more detail below
in the Examples section, it has been realized that as a media
includes a higher percentage of fiber portions oriented towards the
Z-direction, the media has a higher initial efficiency as a
function of particle size.
[0028] The layer(s) may be arranged so that surface 19 of the
filter media is an upstream side (e.g., air entering side) in a
filter element, and surface 15 is a downstream side (e.g., outflow
side). Alternatively, surface 19 may be a downstream side and
surface 15 may be an upstream side in a filter element.
[0029] The outer or cover layer can alternatively or additionally
be a bottom layer disposed on the downstream side of the filter
media, as shown illustratively in FIG. 1C. FIG. 1C illustrates
another embodiment of a filter media 10C that is similar to filter
media 10 of FIG. 1B. In this embodiment, filter media 10C does not
include a top outer or cover layer, but rather has a first
filtration layer 14B, a second filtration layer 16B disposed
adjacent to and just upstream of the first filtration layer. It
should be noted that although the outer or cover layers shown in
the figures are illustrated with crosshatched lines, these lines do
not denote an orientation of fibers within the layer(s).
[0030] In some embodiments, the outer or cover layer may function
to help support one or more filtration layers. For instance, the
outer cover layer may function as a strengthening component and/or
elongation component that provides structural integrity to the
filter media to help maintain the fibers of the filtration layer(s)
in the desired orientation. In other embodiments, the outer or
cover layer may function as an aesthetic layer. The outer or cover
layer(s) can also function to offer abrasion resistance.
[0031] As shown illustratively in FIGS. 1B-1C, the filtration
layers may have waved configuration including a plurality of peaks
P and troughs T with respect to each surface thereof. A person
skilled in the art may appreciate that a peak P on one side of the
filtration layer may have a corresponding trough T on the opposite
side. Thus, downstream filtration layer 14A,B may extend into a
trough T, and exactly opposite that same trough T is a peak P,
across which upstream filtration layer 16A,B may extend. Peaks and
troughs may also be present in a single filtration layer as shown
illustratively in FIG. 1A. As shown illustratively in FIGS. 1A-1C,
the troughs may be partially or substantially filled with
fibers.
[0032] In certain exemplary embodiments, a filtration layer (e.g.,
a downstream and/or upstream filtration layer) can have a fiber
density and/or fiber mass at the peaks that differs from a fiber
density and/or fiber mass in the troughs. For instance, in some
embodiments one or more filtration layers may have a fiber density
and/or a fiber mass that is greater at the peaks than a fiber
density and/or a fiber mass in the troughs. In other embodiments,
one or more filtration layers may have a fiber density and/or a
fiber mass that is less at the peaks than a fiber density and/or a
fiber mass in the troughs. Other configurations are also
possible.
[0033] It should be appreciated that a variety of other
configurations are possible other than those shown in FIGS. 1A-1C,
and that the filter media can include any number of layers in
various arrangements. For example, in some embodiments, a filter
media includes both an upstream outer or cover layer, and
downstream outer or cover layer. In other embodiments, neither an
upstream nor a downstream outer or cover layer is present in the
filter media. Additionally, while two filtration layers 14A,B,
16A,B are shown in FIGS. 1B-1C, the filter media need not include
both filtration layers. For instance, in some embodiments, only a
single filtration layer is present in a filter media like that
shown in FIG. 1A. In other embodiments more than one filtration
layers (e.g., at least 2, at least 3, at least 4, at least 5, at
least 6, at least 7, at least 8, at least 9, or at least 10
filtration layers) may be present in a filter media. One, more, or
each of the filtration layers may include a relatively high
percentage of oriented fiber portions as described herein.
Additionally, it should be appreciated that the terms "first",
"second", "third" and "fourth" layers, as used herein, refer to
different layers within the media, and are not meant to be limiting
with respect to the particular function of that layer.
[0034] As shown illustratively in FIGS. 1B and 1C, the filter media
includes two filtration layers that are directly adjacent to one
another and not separated by a fine fiber layer (e.g., a fine fiber
layer having an average fiber diameter of less than 10 microns,
less than 5 microns, less than 3 microns, less than 1.5 microns, or
less than 1 micron). FIG. 1A also does not include such a fine
fiber layer. While including a fine fiber layer in the filter media
would likely have increased efficiency of the media, it would
likely have also increased cost of the media and potentially be
more difficult to manufacture. The absence of a fine fiber layer
from the filter media can allow the media to be cost effective and
easy to manufacture, while the oriented fiber portions of the
filtration layer(s) provide sufficient efficiency for various
applications. In several embodiments described herein, a fine fiber
layer formed from meltblown fibers, electrospun fibers or glass
fibers is absent from the media. In several embodiments described
herein, a fine fiber layer formed from a wetlaid process, an
airlaid process, a drylaid process, a carding process, an
electrospinning process, or a spunbonding process is absent from
the media. In some embodiments, a porous membrane is absent from
the filter media. Additionally, in several embodiments described
herein, a fine fiber layer having (as measured in a planar
configuration) a thickness in the range of about 0.5 mils to 30
mils (e.g., 2 mils to 30 mils) and/or an air permeability in the
range of about 5 CFM to 300 CFM (e.g., 10 CFM to 300 CFM), and/or a
basis weight in the range of about 1.8 gsm to 50 gsm (e.g., 3 gsm
to 50 gsm), and/or a DOP filtration efficiency in the range of
about 20% to 99%, is absent from the media.
[0035] As used herein, when a layer is referred to as being
"adjacent" another layer, it can be directly adjacent the layer, or
one or more intervening layers also may be present. A layer that is
"directly adjacent" another layer means that no intervening layer
is present.
[0036] As indicated above, the filter media 10, 10A and 10B can
include at least one filtration layer. The fiber portions in the
filtration layer may be oriented at an angle with respect to the
horizontal, or with respect to a surface (e.g., a planar surface)
of the filtration layer or an outer or cover layer. In some
embodiments, a certain percentage of the fiber portions of the
layer may be within certain ranges of angles, e.g., between about
46 degrees and about 90 degrees, between about 0 degrees and about
45 degrees, between about 61 degrees and about 90 degrees, between
about 31 degrees and about 60 degrees, or between about 0 degrees
and about 30 degrees. Orientation of the fiber portions of a layer
can be determined by obtaining a scanning electron micrograph (SEM)
of a cross-section of the layer. Scanning electron microscopy will
be known to one skilled in the art and generally refers to the use
of a focused electron beam to produce an image (e.g., a greyscale
image) of the surface topography of a sample. The images can be
analyzed using several image analysis and manipulation software
packages (e.g., Mathematica by Wolfram Research). The images
described herein were collected on an Aspex 3025 SEM at a working
distance of 13.6 mm-22.9 mm, with a magnification ranging between
20.times.-30.times., and a resolution of 1024 pixels.times.1024
pixels. Filter media samples were 1.75'' in diameter and were
vacuum sputter coated with gold prior to image acquisition.
Orientation of the fiber portions, as described herein, is
determined by fitting straight line segments (e.g., ranging from 2
to 25 pixels in length) to each portion of the fibers in the image.
The orientation of each line segment is calculated and normalized
by its length to obtain the overall orientation distribution. The
percentage of fiber portions oriented between a range of two angles
is calculated by counting the number of normalized line segments
having an orientation between the range of the two angles of
interest, and dividing by the total number of normalized line
segments. Accordingly, the percentage of fiber portions oriented
between a range of two angles is a representation of the
orientation of all the fibers portions in the cross-section of the
layer oriented between that range. Images can also be acquired by
optical microscopy.
[0037] In some embodiments, a relatively high percentage of the
fiber portions in the filtration layer are positioned at a non-zero
angle with respect to the horizontal, or with respect to a surface
(e.g., a planar surface) of the filtration layer or an outer or
cover layer. For instance, the percentage of fiber portions in the
filtration layer that are positioned at an angle between about 46
degrees and about 90 degrees with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer, may be greater than or
equal to about 10%, greater than or equal to about 15%, greater
than or equal to about 20%, greater than or equal to about 30%, or
greater than or equal to about 40%, greater than or equal to about
50%, or greater than or equal to about 60%, or greater than or
equal to about 70%. In certain embodiments, the percentage of fiber
portions in the filtration layer that are positioned at an angle of
between about 46 degrees and about 90 degrees with respect to the
horizontal, or with respect to a surface (e.g., a planar surface)
of the filtration layer or an outer or cover layer, may be less
than or equal to about 80%, less than or equal to about 70%, less
than or equal to about 60%, less than or equal to about 50%, less
than or equal to about 40%, less than or equal to about 30%, or
less than or equal to about 20%. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to about 40% and less than or equal to about 80%). Other
ranges are also possible. In some embodiments, a combination of
filtration layers may have a percentage of fiber portions in one or
more of the above-referenced ranges.
[0038] In some embodiments, the percentage of fiber portions in the
filtration layer that are positioned at an angle of between about 0
degrees and about 45 degrees with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer may be relatively low.
For instance, the percentage of fiber portions in the filtration
layer that are positioned at an angle between about 0 degrees and
about 45 degrees with respect to the horizontal, or with respect to
a surface (e.g., a planar surface) of the filtration layer or an
outer or cover layer, may be greater than or equal to about 10%,
greater than or equal to about 15%, greater than or equal to about
20%, greater than or equal to about 30%, or greater than or equal
to about 40%. In certain embodiments, the percentage of fiber
portions in the filtration layer that are positioned at an angle of
between about 0 degrees and about 45 degrees with respect to the
horizontal, or with respect to a surface (e.g., a planar surface)
of the filtration layer or an outer or cover layer, may be less
than or equal to about 50%, less than or equal to about 40%, less
than or equal to about 30%, less than or equal to about 20%, less
than or equal to about 15%, or less than or equal to about
10%.Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to about 10% and less than or equal to
about 40%). Other ranges are also possible. In some embodiments, a
combination of filtration layers may have a percentage of fiber
portions in one or more of the above-referenced ranges.
[0039] In certain embodiments, the percentage of fiber portions in
the filtration layer that are positioned at an angle between about
0 degrees and about 30 degrees with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer, may be greater than or
equal to about 10%, greater than or equal to about 15%, greater
than or equal to about 20%, or greater than or equal to about 30%.
In some embodiments, the percentage of fiber portions in the
filtration layer that are positioned at an angle of between about 0
degrees and about 30 degrees with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer may be less than or
equal to about 40%, less than or equal to about 30%, less than or
equal to about 20%, or less than or equal to about 10%.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to about 10% and less than or equal to
about 30%). Other ranges are also possible In some embodiments, a
combination of filtration layers may have a percentage of fiber
portions in one or more of the above-referenced ranges.
[0040] In certain embodiments, the percentage of fiber portions in
the filtration layer that are positioned at an angle between about
31 degrees and about 60 degrees with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer, may be greater than or
equal to about 10%, greater than or equal to about 20%, greater
than or equal to about 25%, greater than or equal to about 30%,
greater than or equal to about 35%, greater than or equal to about
40%, or greater than or equal to about 50%. In some embodiments,
the percentage of fiber portions in the filtration layer that are
positioned at an angle of between about 31 degrees and about 60
degrees with respect to the horizontal, or with respect to a
surface (e.g., a planar surface) of the filtration layer or an
outer or cover layer may be less than or equal to about 60%, less
than or equal to about 50%, less than or equal to about 40%, less
than or equal to about 35%, less than or equal to about 30%, less
than or equal to about 25%, or less than or equal to about 20%.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to about 20% and less than or equal to
about 50%). Other ranges are also possible In some embodiments, a
combination of filtration layers may have a percentage of fiber
portions in one or more of the above-referenced ranges.
[0041] In certain embodiments, the percentage of fiber portions in
the filtration layer that are positioned at an angle between about
61 degrees and about 90 degrees with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer, may be greater than or
equal to about 30%, greater than or equal to about 40%, greater
than or equal to about 50%, greater than or equal to about 60%, or
greater than or equal to about 70%. In some embodiments, the
percentage of fiber portions in the filtration layer that are
positioned at an angle of between about 61 degrees and about 90
degrees with respect to the horizontal, or with respect to a
surface (e.g., a planar surface) of the filtration layer or an
outer or cover layer may be less than or equal to about 80%, less
than or equal to about 70%, less than or equal to about 60%, less
than or equal to about 50%, less than or equal to about 40%, or
less than or equal to about 30%. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to about 30% and less than or equal to about 70%). Other
ranges are also possible. In some embodiments, a combination of
filtration layers may have a percentage of fiber portions in one or
more of the above-referenced ranges.
[0042] A filtration layer described herein can be formed from a
variety of fibers types and sizes. Additionally, in embodiments in
which more than one filtration layers are present, each of the
filtration layers may be formed of different fiber types and/or
sizes. For instance, in an exemplary embodiment, the downstream
filtration layer 14A of FIG. 1B is formed from fibers having an
average fiber diameter that is greater than an average fiber
diameter of upstream filtration layer. Each of the filtration
layers may independently be formed of fibers having average
diameters and/or average lengths in the ranges described below.
Additionally, each of the filtration layers of a filter media may
independently have other physical and/or performance
characteristics in the ranges described below.
[0043] The fibers of the filtration layer may be relatively course.
For instance, in some embodiments, the fibers of the filtration
layer may have an average fiber diameter of between about 5 microns
and about 65 microns (e.g., between about 9 microns and about 50
microns). In some embodiments, the fibers may have an average fiber
diameter of greater than or equal to about 5 microns, greater than
or equal to about 9 microns, greater than or equal to about 10
microns, greater than or equal to about 12 microns, greater than or
equal to about 15 microns, greater than or equal to about 20
microns, greater than or equal to about 30 microns, greater than or
equal to about 40 microns, greater than or equal to about 50
microns, greater than or equal to about 60 microns, or greater than
or equal to about 65 microns. In some embodiments, the fibers of
the filtration layer may have an average fiber diameter of less
than or equal to about 65 microns, less than or equal to about 60
microns, less than or equal to about 50 microns, less than or equal
to about 40 microns, less than or equal to about 30 microns, less
than or equal to about 20 microns, less than or equal to about 10
microns, less than or equal to about 9 microns, or less than or
equal to about 5 microns. Combinations of the above references
ranges are also possible (e.g., an average fiber diameter of
greater than or equal to about 9 microns and less than about 50
microns). Other ranges are also possible. In some embodiments, a
combination of filtration layers may have an average fiber diameter
in one or more of the above-referenced ranges.
[0044] The fibers of the filtration layer may have an average fiber
length of, for example, between about 0.5 inches and about 3.5
inches (e.g., between about 1.5 inches and about 2 inches). In some
embodiments, the fibers of the filtration layer may have an average
fiber length of less than or equal to about 3.5 inches, less than
or equal to about 3 inches, less than or equal to about 2.5 inches,
less than or equal to about 2 inches, less than or equal to about 1
inch, or less than or equal to about 0.5 inches, or less than or
equal to about 0.3 inches. In some embodiments, the fibers of the
filtration layer may have an average fiber length of greater than
or equal to about 0.2 inches, greater than or equal to about 0.5
inches, greater than or equal to about 1 inch, greater than or
equal to about 1.5 inches, greater than or equal to about 2.0
inches, greater than or equal to about 2.5 inches, greater than or
equal to about 3.0 inches, or greater than or equal to about 3.5
inches. Combinations of the above references ranges are also
possible (e.g., fibers having an average fiber length of greater
than or equal to about 1.5 inches and less than about 2 inches).
Other ranges are also possible. In some embodiments, a combination
of filtration layers may have an average fiber length in one or
more of the above-referenced ranges. In some embodiments, the
fibers of the filtration layer are staple fibers.
[0045] Additionally, in embodiments in which more than one
filtration layers are present in a media, each filtration layer may
have an average fiber diameter and/or length having one or more of
the above-referenced ranges.
[0046] Various materials can also be used to form the fibers of the
filtration layers, including synthetic and non-synthetic materials.
Synthetic fibers may include any suitable type of synthetic
polymer. Examples of suitable synthetic fibers include polyesters
(e.g., polyethylene terephthalate, polybutylene terephthalate),
polyamide, polyaramid, para-aramid, meta-aramid, polyaniline,
polyimide, polyethylene, polypropylene, polyether ether ketone,
polyolefin, nylon, acrylics, polyvinyl alcohol, regenerated
cellulose (e.g., lyocell, rayon), cellulose acetate, polyvinylidene
fluoride, poly(vinylidene fluoride-co-hexafluoropropylene),
polyacrylonitriles, polysulfones (e.g., polyether sulfones,
poly(phenylene ether sulfone)), polystyrene, polybutadiene,
polyurethane, polyphenylene oxide, polycarbonate, poly(methyl
methacrylate), polyhydroxyethylmethacrylate, poly(lactic acid) or
polylactide, silk, poly (4-methyl-1-pentene), polypyrrole, and
combinations thereof. In some embodiments, one or more fibers can
include copolymers of the above (e.g., block copolymers of
polystyrene-polybutadiene). In some embodiments, the synthetic
fibers are organic polymer fibers.
[0047] A filtration layer may include a suitable percentage of
synthetic fibers. For example, in some embodiments, the weight
percentage of synthetic fibers in the filtration layer may be
between about 50 wt % and about 100 wt % of all fibers in the
filtration layer. In some embodiments, the weight percentage of
synthetic fibers in the filtration layer may be greater than or
equal to about 50 wt %, greater than or equal to about 60 wt %,
greater than or equal to about 70 wt %, greater than or equal to
about 80 wt %, greater than or equal to about 90 wt %, or greater
than or equal to about 95 wt %. In some embodiments, the weight
percentage of the synthetic fibers in the filtration layer may be
less than or equal to about 100 wt %, less than or equal to about
95 wt %, less than or equal to about 90 wt %, less than or equal to
about 80 wt %, less than or equal to about 70 wt %, or less than or
equal to about 50 wt %. Combinations of the above-referenced ranges
are also possible (e.g., a weight percentage of greater than or
equal to about 90 wt % and less than or equal to about 100 wt %).
Other ranges are also possible. In some embodiments, a filtration
layer includes 100 wt % of synthetic fibers. In some embodiments, a
filtration layer includes the above-noted ranges of synthetic
fibers with respect to the total weight of the filtration layer
(e.g., including any resins). In some embodiments, a combination of
filtration layers may have a percentage of synthetic fibers in one
or more of the above-referenced ranges. Additionally, in
embodiments in which more than one filtration layers are present in
a media, each filtration layer may have a percentage of synthetic
fibers having one or more of the above-referenced ranges. In other
embodiment, the above-referenced ranges of fibers may apply to the
entire filter media (which may include multiple filtration layers).
The remaining fibers of the filtration layer and/or filter media
may be non-synthetic fibers, such as glass fibers, glass wool
fibers, and/or cellulose pulp fibers (e.g., wood pulp fibers).
[0048] In some embodiments, a filtration layer includes binder
fibers. The amount of binder fibers in a filtration layer may vary.
For example, the weight percentage of binder fibers in the
filtration layer may be between about 10 wt % and about 100 wt %
(e.g., between about 20 wt % and about 70 wt %) of all fibers in
the filtration layer. In some embodiments, the weight percentage of
binder fibers in the filtration layer may be greater than or equal
to about 10 wt %, greater than or equal to about 20 wt %, greater
than or equal to about 30 wt %, greater than or equal to about 40
wt %, greater than or equal to about 50 wt %, greater than or equal
to about 60 wt %, greater than or equal to about 70 wt %, greater
than or equal to about 80 wt %, or greater than or equal to about
90 wt %. In some cases, the weight percentage of binder fibers in
the filtration layer may be less than or equal to about 100 wt %,
less than or equal to about 90 wt %, less than or equal to about 80
wt %, less than or equal to about 70 wt %, less than or equal to
about 60 wt %, less than or equal to about 50 wt %, less than or
equal to about 40 wt %, less than or equal to about 30 wt %, less
than or equal to about 20 wt %, or less than or equal to about 10
wt %. Combinations of the above-referenced ranges are also possible
(e.g., a weight percentage of binder fibers of greater than or
equal to about 20 wt % and less than about 70 wt %). In some
embodiments, a filtration layer includes the above-noted ranges of
binder fibers with respect to the total weight of the filtration
layer (e.g., including any resins). Other ranges of binder fibers
are also possible. In some embodiments, a filtration layer can
include 100% binder fibers. In some embodiments, a combination of
filtration layers may have a percentage of binder fibers in one or
more of the above-referenced ranges. Additionally, in embodiments
in which more than one filtration layers are present in a media,
each filtration layer may have a percentage of binder fibers having
one or more of the above-referenced ranges. In other embodiment,
the above-referenced ranges of fibers may apply to the entire
filter media (which may include multiple filtration layers). The
remaining fibers of the filtration layer and/or filter media may be
non-binder fibers.
[0049] A variety of types of binder and non-binder fibers can be
used to form the media described herein. The binder fibers can be
formed from any material that is effective to facilitate thermal
bonding between the fibers, and will thus have an activation
temperature that is lower than the melting temperature of the
non-binder fibers. The binder fibers can be monocomponent fibers or
any one of a number of bicomponent binder fibers. In one
embodiment, the binder fibers can be bicomponent fibers, and each
component can have a different melting temperature. For example,
the binder fibers can include a core and a sheath where the
activation temperature of the sheath is lower than the melting
temperature of the core. This allows the sheath to melt prior to
the core, such that the sheath binds to other fibers in the layer,
while the core maintains its structural integrity. This is
particularly advantageous in that it creates a more cohesive layer
for trapping filtrate. The core/sheath binder fibers can be
concentric or non-concentric, and exemplary core/sheath binder
fibers can include the following: a polyester core/copolyester
sheath, a polyester core/polyethylene sheath, a polyester
core/polypropylene sheath, a polypropylene core/polyethylene
sheath, and combinations thereof. Other exemplary bicomponent
binder fibers can include split fiber fibers, side-by-side fibers,
and/or "island in the sea" fibers. Exemplary bi-component binder
fibers can include Trevira Types 254, 255, and 256; Invista
Cellbond.RTM. Type 255; Fiber Innovations Types 201, 202, 215, and
252; and ES Fibervisions AL-Adhesion-C ESC 806A.
[0050] The non-binder fibers can be synthetic and/or non-synthetic,
and in an exemplary embodiment the non-binder fibers can be about
100 percent synthetic. In general, synthetic fibers are preferred
over non-synthetic fibers for resistance to moisture, heat,
long-term aging, and microbiological degradation. Exemplary
synthetic non-binder fibers can include polyesters, acrylics,
polyolefins, nylons, rayons, polyvinyl derivatives (e.g.,
polyvinylchloride, polyvinyl alcohol, polytetrafluoroethylene,
polyvinylidene chloride), and combinations thereof. Additionally or
alternatively, the non-binder fibers used to form the media can
include non-synthetic fibers such as glass fibers, glass wool
fibers, cellulose pulp fibers, such as wood pulp fibers, and
combinations thereof. Exemplary synthetic non-binder fibers can
include Trevira Type 290 and Wellman Fortrel.RTM. Types 204, 289
and 510.
[0051] The filtration layers can also be formed using various
techniques known in the art, including wet laid techniques and
non-wet laid techniques. Non-wet laid fibers include, for example,
dry laid (carded) fibers, spunbond fibers, and/or air laid fibers.
In an exemplary embodiment, the filtration layers are carded or
airlaid webs.
[0052] The resulting filtration layers can also have a variety of
basis weights, thicknesses, and air permeabilities depending upon
the requirements of a desired application. In one exemplary
embodiment, the filtration layer has a thickness in the range of
about 40 mil to 1000 mil (e.g., about 80 mil to 230 mil), an air
permeability in the range of about 150 CFM to 800 CFM (e.g., about
350 CFM to 600 CFM), and a basis weight in the range of about 40
gsm to 500 gsm (e.g., about 80 gsm to 200 gsm).
[0053] *Other Characteristics of the Filtration Layer
[0054] The basis weight of the filtration layer can typically be
selected as desired. In some embodiments, the basis weight of the
filtration layer may range from between about 40 and about 500
g/m.sup.2. For instance, the basis weight of the filtration layer
may be between about 80 and about 200 g/m.sup.2. In some
embodiments, the basis weight of the filtration layer may be
greater than or equal to about 40 g/m.sup.2 (e.g., greater than or
equal to about 80 g/m.sup.2, greater than or equal to about 100
g/m.sup.2, greater than or equal to about 150 g/m.sup.2, greater
than or equal to about 200 g/m.sup.2, greater than or equal to
about 250 g/m.sup.2, greater than or equal to about 300 g/m.sup.2,
greater than or equal to about 350 g/m.sup.2, or greater than or
equal to about 400 g/m.sup.2). In some cases, the basis weight of
the filtration layer may be less than or equal to about 500
g/m.sup.2 (e.g., less than or equal to about 400 g/m.sup.2, less
than or equal to about 350 g/m.sup.2, less than or equal to about
300 g/m.sup.2, less than or equal to about 250 g/m.sup.2, less than
or equal to about 200 g/m.sup.2, less than or equal to about 150
g/m.sup.2, less than or equal to about 100 g/m.sup.2, less than or
equal to about 80 g/m.sup.2, or less than or equal to about 40
g/m.sup.2). Combinations of the above-referenced ranges are also
possible (e.g., a basis weight of greater than or equal to about 80
g/m.sup.2 and less than or equal to about 200 g/m.sup.2). Other
ranges are also possible. In some embodiments, a combination of
filtration layers may have a combined basis weight in one or more
of the above-referenced ranges. As determined herein, the basis
weight of the filtration layer is measured according to the ASTM
D-846 standard. Additionally, in embodiments in which more than one
filtration layers are present in a media, each filtration layer may
have a basis weight having one or more of the above-referenced
ranges.
[0055] In some embodiments, the oriented fibers of the filtration
layer results in the layer having a relatively high thickness. In
some embodiments, the thickness of the filtration layer may range
from between about 40 milliinches (mil) and about 1000 mil. For
instance, the thickness of the filtration layer may range between
about 80 mil and about 230 mil. In some embodiments, the thickness
may be greater than or equal to about 40 mil (e.g., greater than or
equal to about 80 mil, greater than or equal to about 100 mil,
greater than or equal to about 200 mil, greater than or equal to
about 300 mil, greater than or equal to about 400 mil, greater than
or equal to about 500 mil, greater than or equal to about 750 mil,
or greater than or equal to about 900 mil). In some cases, the
thickness of the filtration layer may be less than or equal to
about 1000 mil (e.g., less than or equal to about 750 mil, less
than or equal to about 500 mil, less than or equal to about 400
mil, less than or equal to about 300 mil, less than or equal to
about 230 mil, less than or equal to about 200 mil, less than or
equal to about 100 mil, less than or equal to about 80 mil, or less
than or equal to about 40 mil). Combinations of the
above-references ranges are also possible (e.g., a thickness of
greater than or equal to about 80 mil and less than or equal to
about 230 mil). Other ranges are also possible. In some
embodiments, a combination of filtration layers may have a combined
thickness in one or more of the above-referenced ranges. Thickness,
as referred to herein, is determined according to the Standard
TAPPI T411. Additionally, in embodiments in which more than one
filtration layers are present in a media, each filtration layer may
have a thickness having one or more of the above-referenced
ranges.
[0056] The filtration layer may exhibit a suitable mean flow pore
size. Mean flow pore size, as determined herein, is measured
according to Standard ASTM F316. In some embodiments, the mean flow
pore size may range between about 0.1 microns and about 100 microns
(e.g., between about 5 microns and about 40 microns, between about
15 microns and about 40 microns, or between about 25 microns and
about 80 microns). In some embodiments, the mean flow pore size of
the filtration layer may be less than or equal to about 100
microns, less than or equal to about 50 microns, less than or equal
to about 40 microns, less than or equal to about 30 microns, less
than or equal to about 20 microns, less than or equal to about 10
microns, or less than or equal to about 5 microns, or less than or
equal to about 2 microns. In other embodiments, the mean flow pore
size may be greater than or equal to about 1 micron, greater than
or equal to about 5 microns, greater than or equal to about 10
microns, greater than or equal to about 20 microns, greater than or
equal to about 25 microns, greater than or equal to about 30
microns, greater than or equal to about 50 microns or greater than
or equal to about 100 microns. Combinations of the above-referenced
ranges are also possible (e.g., a mean flow pore size of greater
than or equal to about 10 microns and less than or equal to about
50 microns). Other values and ranges of mean flow pore size are
also possible. In some embodiments, a combination of filtration
layers may have a mean flow pore size in one or more of the
above-referenced ranges. Additionally, in embodiments in which more
than one filtration layers are present in a media, each filtration
layer may have a mean flow pore size having one or more of the
above-referenced ranges.
[0057] The filtration layer may exhibit suitable air permeability
characteristics. In some embodiments, the air permeability of a
filtration layer may range from between about 150 CFM and about 800
CFM (e.g., between about 350 CFM and about 600 CFM). In some
embodiments, the air permeability may be greater than or equal to
about 150 CFM, greater than or equal to about 200 CFM, greater than
or equal to about 250 CFM, greater than or equal to about 300 CFM,
greater than or equal to about 310 CFM, greater than or equal to
about 350 CFM, greater than or equal to about 500 CFM, greater than
or equal to about 600 CFM, or greater than or equal to about 700
CFM. In certain embodiments, the air permeability may be less than
or equal to about 800 CFM, less than or equal to about 600 CFM,
less than or equal to about 500 CFM, less than or equal to about
350 CFM, less than or equal to about 250 CFM, or less than or equal
to about 150 CFM. Combinations of the above-referenced ranges are
also possible (e.g., an air permeability of greater than or equal
to 310 CFM and less than or equal to about 800 CFM). Other ranges
are also possible. In some embodiments, a combination of filtration
layers may have a combined air permeability in one or more of the
above-referenced ranges. Additionally, in embodiments in which more
than one filtration layers are present in a media, each filtration
layer may have an air permeability having one or more of the
above-referenced ranges.
[0058] As determined herein, the air permeability is measured
according to the Standard TAPPI T-251. The permeability is an
inverse function of flow resistance and can be measured with a
Frazier Permeability Tester (e.g., TexTest Instrument, FX 3300).
The Frazier Permeability Tester measures the volume of air per unit
of time that passes through a unit area of sample at a fixed
differential pressure across the sample. Permeability can be
expressed in cubic feet per minute per square foot at a 0.5 inch
water differential.
[0059] As previously indicated, the filter media can also
optionally include one or more outer or cover layers disposed on a
side (e.g., an upstream side or a downstream side) of the filter
media. In some embodiments, the outer or cover layer can function
as an aesthetic layer. In an exemplary embodiment, the outer cover
layer is a planar layer that is mated to the filter media after
filtration layers are oriented. The outer cover layer may provide a
top surface that is aesthetically pleasing.
[0060] The outer or cover layer can function as a strengthening
component that provides structural integrity to the filter media to
help maintain the orientation of fibers or fiber portions. The
outer or cover layer can, in some instances, also function to offer
abrasion resistance and/or add stiffness to the media. This is
particularly desirable in ASHRAE bag applications where the
outermost layer is subject to abrasion during use. A downstream
outer or cover layer can have a configuration similar to an
upstream outer cover layer, as described herein. In an exemplary
embodiment, however, the downstream outer cover layer 18B is the
coarsest layer, i.e., it is formed from fibers having an average
fiber diameter that is greater than an average fiber diameter of
fibers forming all of the other layers of the filter media. One
exemplary bottom layer is a spunbond layer, however various other
layers can be used having various configurations.
[0061] The outer or cover layer can be formed from a variety of
materials and can have different forms. For example, in one set of
embodiments, the outer or cover layer is a scrim (e.g., a spunbond
nonwoven material or a carded nonwoven material). In another set of
embodiments, the outer or cover layer is in the form of a mesh. In
some embodiments, the outer cover layer is formed from fibers. In
general, in embodiments in which the outer or cover layer includes
fibers, the outer or cover layer may include a variety of different
fiber types and/or sizes. In an exemplary embodiment, an outer or
cover layer is formed from fibers having an average fiber diameter
that is less than an average fiber diameter of a filtration layer
(e.g., an upstream filtration layer, or a downstream filtration
layer). In another embodiment, an outer or cover layer is formed
from fibers having an average fiber diameter that is greater than
an average fiber diameter of a filtration layer (e.g., an upstream
filtration layer, or a downstream filtration layer). A combination
of two or more outer or cover layers is also possible.
[0062] In embodiments in which an outer or cover layer includes
fibers, the average fiber diameter may vary. For instance, in some
embodiments, the fibers of the outer or cover layer may have an
average fiber diameter of between about 15 microns and about 75
microns. In some embodiments, the fibers of the outer or cover
layer may have an average fiber diameter of less than or equal to
about 75 microns, less than or equal to about 65 microns, less than
or equal to about 60 microns, less than or equal to about 50
microns, less than or equal to about 40 microns, less than or equal
to about 30 microns, or less than or equal to about 20 microns. In
some embodiments, the fibers may have an average fiber diameter of
greater than or equal to about 15 microns, greater than or equal to
about 20 microns, greater than or equal to about 30 microns,
greater than or equal to about 40 microns, greater than or equal to
about 50 microns, greater than or equal to about 60 microns, or
greater than or equal to about 65 microns. Combinations of the
above references ranges are also possible (e.g., an average fiber
diameter of greater than or equal to about 20 microns and less than
about 75 microns). Other ranges are also possible. Additionally, in
embodiments in which more than outer or cover layers are present in
a media, each outer or cover layer may have an average fiber
diameter having one or more of the above-referenced ranges.
[0063] Various materials can also be used to form the fibers of the
outer or cover layer, including synthetic and non-synthetic
materials. In one exemplary embodiment, an outer or cover layer
(e.g., an upstream outer or cover layer and/or a downstream outer
or cover layer), is formed from staple fibers, and in particular
from a combination of binder fibers and non-binder fibers. One
suitable fiber composition is a blend of at least about 20% binder
fiber and a balance of non-binder fiber. Other ranges of binder
fibers are also possible, including the ranges of binder fibers
discussed above with respect to the filtration layers. A variety of
types of binder and non-binder fibers can be used to form the outer
or cover layer described herein, including those previously
discussed above with respect to the filtration layers.
[0064] The outer or cover layer can also be formed using various
techniques known in the art, including meltblowing, wet laid
techniques, air laid techniques, carding, electrospinning, and
spunbonding. In an exemplary embodiment, however, an upstream outer
or cover layer (e.g., layer 18) is an airlaid layer and a
downstream outer cover layer (e.g., layer 18B) is a spunbond layer.
The resulting layer can also have a variety of thicknesses, air
permeabilities, and basis weights depending upon the requirements
of a desired application. In one exemplary embodiment, the outer or
cover layer, as measured in a planar configuration, has a thickness
in the range of about 2 mil to about 10 mil (e.g., about 3 mil to
about 6 mil), an air permeability in the range of about 500 CFM to
about 1200 CFM (e.g., about 800 CFM to about 1000 CFM), and a basis
weight in the range of about 10 gsm to about 20 gsm (e.g., about 12
gsm to about 16 gsm).
[0065] The basis weight of the outer or cover layer can typically
be selected as desired. In some embodiments, the basis weight of
the outer or cover layer may range from between about 10 and about
20 g/m.sup.2. For instance, the basis weight of the outer or cover
layer may be between about 12 and about 16 g/m.sup.2. In some
embodiments, the basis weight of the outer or cover layer may be
greater than or equal to about 10 g/m.sup.2 (e.g., greater than or
equal to about 12 g/m.sup.2, greater than or equal to about 16
g/m.sup.2, or greater than or equal to about 18 g/m.sup.2). In some
cases, the basis weight of the outer or cover layer may be less
than or equal to about 20 g/m.sup.2 (e.g., less than or equal to
about 16 g/m.sup.2, less than or equal to about 12 g/m.sup.2, or
less than or equal to about 10 g/m.sup.2). Combinations of the
above-referenced ranges are also possible (e.g., a basis weight of
greater than or equal to about 10 g/m.sup.2 and less than or equal
to about 20 g/m.sup.2). Other ranges are also possible. As
determined herein, the basis weight of the outer or cover layer is
measured according to the ASTM D-846 standard. Additionally, in
embodiments in which more than outer or cover layers are present in
a media, each outer or cover layer may have a basis weight having
one or more of the above-referenced ranges.
[0066] In some embodiments, the thickness of the outer or cover
layer may range from between about 2 milliinches (mil) and about 10
mil. For instance, the thickness of the outer or cover layer may
range between about 3 mil and about 6 mil. In some embodiments, the
thickness may be greater than or equal to about 2 mil (e.g.,
greater than or equal to about 3 mil, greater than or equal to
about 4 mil, greater than or equal to about 6 mil, or greater than
or equal to about 8 mil). In some cases, the thickness of the outer
or cover layer may be less than or equal to about 10 mil (e.g.,
less than or equal to about 8 mil, less than or equal to about 6
mil, less than or equal to about 4 mil, less than or equal to about
3 mil, or less than or equal to about 2 mil). Combinations of the
above-references ranges are also possible (e.g., a thickness of
greater than or equal to about 2 mil and less than or equal to
about 10 mil). Other ranges are also possible. Additionally, in
embodiments in which more than outer or cover layers are present in
a media, each outer or cover layer may have a thickness having one
or more of the above-referenced ranges.
[0067] The outer or cover layer may exhibit suitable air
permeability characteristics. In some embodiments, the air
permeability of an outer or cover layer may range from between
about 500 CFM and about 1200 CFM (e.g., between about 800 CFM and
about 1000 CFM). In some embodiments, the air permeability may be
greater than or equal to about 500 CFM, greater than or equal to
about 600 CFM, greater than or equal to about 700 CFM, greater than
or equal to about 800 CFM, greater than or equal to about 900 CFM,
greater than or equal to about 1000 CFM, or greater than or equal
to about 1100 CFM. In certain embodiments, the air permeability may
be less than or equal to about 1200 CFM, less than or equal to
about 1100 CFM, less than or equal to about 1000 CFM, less than or
equal to about 900 CFM, less than or equal to about 800 CFM, less
than or equal to about 600 CFM, less than or equal to about 700
CFM, less than or equal to about 600 CFM, or less than or equal to
about 500 CFM. Combinations of the above-referenced ranges are also
possible (e.g., an air permeability of greater than or equal 800
CFM and less than or equal to about 1000 CFM). Other ranges are
also possible. Additionally, in embodiments in which more than
outer or cover layers are present in a media, each outer or cover
layer may have an air permeability having one or more of the
above-referenced ranges.
[0068] A person skilled in the art will appreciate that, while FIG.
1A illustrates a single filtration layer and FIGS. 1B-1C show
filter media including two filtration layers, the media can include
any number of layers in various configurations. For instance, in
some embodiments, a filter media including one, two, three, four,
five, six, seven, or eight filtration layers may be possible,
Various layers can be added to enhance filtration, to provide
support, to alter structure, or for various other purposes. In
certain embodiments, a filter media may include one, two, three,
four, five, six, seven, eight, nine, or ten total number of layers,
regardless of type,
[0069] The filtration layers, outer or cover layers, and filter
media described herein may also exhibit advantageous filtration
performance characteristics such as dust holding capacity (DHC) and
efficiency, amongst others.
[0070] The filtration layers described herein can have beneficial
dust holding properties. In some embodiments, the filtration layer
may have a DHC of between about 66 g/m.sup.2 and about 200
g/m.sup.2 (e.g., a DHC between about 100 g/m.sup.2 and about 160
g/m.sup.2). In some embodiments, the DHC may be greater than or
equal to about 66 g/m.sup.2, greater than or equal to about 80
g/m.sup.2, greater than or equal to about 100 g/m.sup.2, greater
than or equal to about 120 g/m.sup.2, greater than or equal to
about 140 g/m.sup.2, greater than or equal to about 160 g/m.sup.2,
greater than or equal to about 180 g/m.sup.2, or greater than or
equal to about 190 g/m.sup.2. In some cases, the DHC may be less
than or equal to about 200 g/m.sup.2, less than or equal to about
180 g/m.sup.2, less than or equal to about 160 g/m.sup.2, less than
or equal to about 140 g/m.sup.2, less than or equal to about 120
g/m.sup.2, less than or equal to about 100 g/m.sup.2, less than or
equal to about 80 g/m.sup.2, or less than or equal to about 66
g/m.sup.2. Combinations of the above-referenced ranges are also
possible (e.g., a DHC of greater than or equal to about 66
g/m.sup.2 and less than or equal to about 200 g/m.sup.2). Other
ranges are also possible. In some embodiments, a combination of
filtration layers may have a combined dust holding capacity in one
or more of the above-referenced ranges. Additionally, in
embodiments in which more than one filtration layers are present in
a media, each filtration layer may have a dust holding capacity
having one or more of the above-referenced ranges.
[0071] The dust holding capacity, as referred to herein, is tested
based on the EN779-2012 standard. The testing uses ASHRAE test dust
at a base upstream gravimetric dust level of 70 mg/m.sup.2. The
test is run at a face velocity of 0.944 m.sup.3/s (3400 m.sup.3/h)
until a terminal pressure of 450 Pa.
[0072] The filtration layers described herein may have a wide range
of average efficiencies. In some embodiments, a filtration layer
has an average efficiency for 0.4 micron or larger particles of
greater than or equal to about 30%, greater than or equal to about
40%, greater than or equal to about 45%, greater than or equal to
about 50%, greater than or equal to about 55%, greater than or
equal to about 60%, greater than or equal to about 65%, greater
than or equal to about 70%, greater than or equal to about 75%, or
greater than or equal to about 80%. Such efficiencies may be
achieved when the filtration layer is uncharged. Charging the
filtration layer may cause the filtration layer to have even higher
average efficiencies, e.g., greater than or equal to about 85%,
greater than or equal to about 90%, greater than or equal to about
95%, greater than or equal to about 98%, or greater than or equal
to about 99% for 0.4 micron or larger particles. Other efficiencies
are also possible. In some embodiments, the filtration layer has an
average efficiency of less than or equal to 99.9%, less than or
equal to 99.8%, less than or equal to 99.7%, less than or equal to
99.5%, less than or equal to 99%, less than or equal to 98%, less
than or equal to 95%, less than or equal to 90%, less than or equal
to 85%, less than or equal to 80%, less than or equal to 70%, less
than or equal to 60%, or less than or equal to 50% for 0.4 micron
or larger particles. In some embodiments, a combination of
filtration layers may have an average efficiency in one or more of
the above-referenced ranges.
[0073] The filter media described herein may also have a wide range
of average efficiencies. In some embodiments, the average
efficiency of the filter media may be greater than the average
efficiency of a filtration layer, because additional layers added
to the media (e.g., an outer or cover layer) may help to trap
particles, thereby increasing the average efficiency of the overall
filter media. In some embodiments, a filter media has an average
efficiency for 0.4 micron or larger particles of greater than or
equal to about 30%, greater than or equal to about 40%, greater
than or equal to about 45%, greater than or equal to about 50%,
greater than or equal to about 55%, greater than or equal to about
60%, greater than or equal to about 65%, greater than or equal to
about 70%, greater than or equal to about 75%, or greater than or
equal to about 80%. Such efficiencies may be achieved when the
filter media is uncharged. Charging the filter media may cause the
filter media to have even higher average efficiencies, e.g.,
greater than or equal to about 85%, greater than or equal to about
90%, greater than or equal to about 95%, greater than or equal to
about 98%, or greater than or equal to about 99%. Other
efficiencies are also possible. In some embodiments, the filter
media has an average efficiency of less than or equal to 99.9%,
less than or equal to 99.8%, less than or equal to 99.7%, less than
or equal to 99.5%, less than or equal to 99%, less than or equal to
98%, less than or equal to 95%, less than or equal to 90%, less
than or equal to 85%, less than or equal to 80%, less than or equal
to 70%, less than or equal to 60%, or less than or equal to
50%.
[0074] The average efficiency of a filtration layer or a filter
media, as referred to herein, is tested following the EN779-2012
standard. The testing uses an air flow of 0.944 m.sup.3/s (3400
m.sup.3/h) and a maximum final test pressure drop of 250 Pa (e.g.,
for Coarse or G filter media) or a maximum final test pressure drop
of 450 Pa (e.g., for Medium, or M, or Fine, or F, filter media). In
some embodiments, the filter media described herein is classified
as a G1, G2, G3, G4, M5, M6, F7, F8, or F9 filter media. The
average efficiency ranges for 0.4 micron or larger particles for
these classifications are listed in Table 1. Unless otherwise
stated, the testing is performed until a maximum final pressure
drop of 450 Pa. The average arrestance of synthetic dust and
minimum efficiency are described in the EN779-2012 standard.
TABLE-US-00001 TABLE 1 Average Average Minimum Final arrestance
efficiency Efficiency * test (A.sub.m) of (E.sub.m) of 0.4 of 0.4
.mu.m pressure synthetic dust .mu.m particles particles Group Class
drop Pa % % % Coarse G1 250 50 .ltoreq. A.sub.m < 65 -- -- G2
250 65 .ltoreq. A.sub.m < 80 -- -- G3 250 80 .ltoreq. A.sub.m
< 90 -- -- G4 250 90 .ltoreq. A.sub.m -- -- Medium M5 450 -- 40
.ltoreq. E.sub.m < 60 -- M6 450 -- 60 .ltoreq. E.sub.m < 80
-- Fine F7 450 -- 80 .ltoreq. E.sub.m < 90 35 F8 450 -- 90
.ltoreq. E.sub.m < 95 55 F9 450 -- 95 .ltoreq. E.sub.m 70
[0075] Additionally, a filtration layer may have a suitable initial
efficiency. In some embodiments, the initial efficiency of a
filtration layer increases as a function of particle size, e.g., as
shown in the Examples in more detail below. In some embodiments,
the initial efficiency may range from about 20% to about 99.999%
(e.g., between about 60% to about 99.9%) for 0.3-1.0 micron-sized
particles, for 1.0-3.0 micron-sized particles, or 3.0-10.0
micron-sized particles. For instance, in certain embodiments, the
initial efficiency of a filtration layer described herein may be at
least about 20%, at least about 30%, at least about 35%, at least
about 40%, at least about 45%, at least about 50%, at least about
60%, at least about 65%, at least about 70%, at least about 75%, at
least about 80%, at least about 85%, at least about 90%, at least
about 95%, at least about 99%, at least about 99.9%, or at least
about 99.99% for 0.3-1.0 micron-sized particles, for 1.0-3.0
micron-sized particles, or 3.0-10.0 micron-sized particles. In some
embodiments, the initial efficiency may be less than or equal to
about 99.999%, less than or equal to about 99.99%, less than or
equal to about 99.9%, less than or equal to about 99%, less than or
equal to about 98%, less than or equal to about 95%, less than or
equal to about 90%, less than or equal to about 85%, less than or
equal to about 80%, less than or equal to about 75%, less than or
equal to about 70%, less than or equal to about 65%, less than or
equal to about 60%, less than or equal to about 50%, less than or
equal to about 45%, less than or equal to about 40%, less than or
equal to about 35%, less than or equal to about 30%, or less than
or equal to about 20% for 0.3-1.0 micron-sized particles, for
1.0-3.0 micron-sized particles, or 3.0-10.0 micron-sized particles.
Other ranges are also possible.
[0076] The filter media described herein may also have a wide range
of initial efficiencies. In some embodiments, the initial
efficiency of the filter media may be greater than the initial
efficiency of a filtration layer, because additional layers added
to the media (e.g., an outer or cover layer) may help to trap
particles, thereby increasing the initial efficiency of the overall
filter media. In some embodiments, the initial efficiency of a
filter media increases as a function of particle size, e.g., as
shown in the Examples in more detail below. In some embodiments,
the initial efficiency of a filter media described herein may range
from about 20% to about 99.999% (e.g., between about 60% to about
99.9%) for 0.3-1.0 micron-sized particles, for 1.0-3.0 micron-sized
particles, or 3.0-10.0 micron-sized particles. For instance, in
certain embodiments, the initial efficiency may be at least about
20%, at least about 30%, at least about 35%, at least about 40%, at
least about 45%, at least about 50%, at least about 60%, at least
about 65%, at least about 70%, at least about 75%, at least about
80%, at least about 85%, at least about 90%, at least about 95%, at
least about 99%, at least about 99.9%, or at least about 99.99% for
0.3-1.0 micron-sized particles, for 1.0-3.0 micron-sized particles,
or 3.0-10.0 micron-sized particles. In some embodiments, the
initial efficiency may be less than or equal to about 99.999%, less
than or equal to about 99.99%, less than or equal to about 99.9%,
less than or equal to about 99%, less than or equal to about 98%,
less than or equal to about 95%, less than or equal to about 90%,
less than or equal to about 85%, less than or equal to about 80%,
less than or equal to about 75%, less than or equal to about 70%,
less than or equal to about 65%, less than or equal to about 60%,
less than or equal to about 50%, less than or equal to about 45%,
less than or equal to about 40%, less than or equal to about 35%,
less than or equal to about 30%, or less than or equal to about 20%
for 0.3-1.0 micron-sized particles, for 1.0-3.0 micron-sized
particles, or 3.0-10.0 micron-sized particles. Other ranges are
also possible.
[0077] The initial efficiency of a filtration layer or filter
media, as referred to herein, is tested following the ASHRAE 52.2
standard. The testing uses a test air flow rate of 25 FPM. The test
is run at an air temperature of 69.degree. F., a relative humidity
of 25%, and a barometric pressure of 29.30 in Hg. The testing also
uses a challenge aerosol of atomized KCl particles having a range
of particle sizes between 0.3-1.0 microns, 1.0-3.0 microns, or
3.0-10.0 microns.
[0078] In certain embodiments, a filtration layer or filter media
described herein may be classified by determining the initial
efficiency of the filtration layer or filter media for a particle
size range such as Range 1 (e.g., 0.30-1.0 micron particles), Range
2 (e.g., 1.0-3.0 micron particles), or Range 3 (e.g., 3.0-10.0
micron particles), as shown in Table 2.
[0079] Additionally or alternatively, the filtration layer or
filter media described herein may be classified by a MERV (Minimum
Efficiency Reporting Value) rating, as shown in Table 2. MERV
ratings are generally used by the HVAC (Heating, Ventilating and
Air Conditioning) industry to describe a filter's ability to remove
particulates from the air. A higher MERV rating means better
filtration and greater performance. In some embodiments, a
filtration layer or filter media described herein has a MERV rating
that is in the range of about 5 to 12 (e.g., between about 8 and
12, between about 6 and 9), however the rating can vary based on
the intended use. In some embodiments, a filtration layer or filter
media described herein has a MERV rating of at least 5, at least 6,
at least 7, at least 8, at least 9, at least 10, at least 11, or at
least 12. The MERV rating may be, for example, less than or equal
to 15, less than or equal to 14, less than or equal to 13, less
than or equal to 12, less than or equal to 11, or less than or
equal to 10. Combinations of the above-referenced ranges are
possible. Other values are also possible.
TABLE-US-00002 TABLE 2 Standard 52.2 Minimum Composite Average
Particle Size Average Minimum Final Efficiency Efficiency, % in
Size Range, .mu.m Arrestance, % Resistance Reporting Value Range 1
Range 2 Range 3 by Standard in. of (MERV) 0.30-1.0 1.0-3.0 3.0-10.0
52.1 Method Pa water 1 n/a n/a E.sub.3 < 20 A.sub.avg < 65 75
0.3 2 n/a n/a E.sub.3 < 20 65 .ltoreq. A.sub.avg < 70 75 0.3
3 n/a n/a E.sub.3 < 20 70 .ltoreq. A.sub.avg < 75 75 0.3 4
n/a n/a E.sub.3 < 20 75 .ltoreq. A.sub.avg 75 0.3 5 n/a n/a 20
.ltoreq. E.sub.3 < 35 n/a 150 0.6 6 n/a n/a 35 .ltoreq. E.sub.3
< 50 n/a 150 0.6 7 n/a n/a 50 .ltoreq. E.sub.3 < 70 n/a 150
0.6 8 n/a n/a 70 .ltoreq. E.sub.3 n/a 150 0.6 9 n/a E.sub.2 < 50
85 .ltoreq. E.sub.3 n/a 250 1.0 10 n/a 50 .ltoreq. E.sub.2 < 65
85 .ltoreq. E.sub.3 n/a 250 1.0 11 n/a 65 .ltoreq. E.sub.2 < 80
85 .ltoreq. E.sub.3 n/a 250 1.0 12 n/a 80 .ltoreq. E.sub.2 90
.ltoreq. E.sub.3 n/a 250 1.0 13 E.sub.1 < 75 90 .ltoreq. E.sub.2
90 .ltoreq. E.sub.3 n/a 350 1.4 14 75 .ltoreq. E.sub.1 < 85 90
.ltoreq. E.sub.2 90 .ltoreq. E.sub.3 n/a 350 1.4 15 85 .ltoreq.
E.sub.1 < 95 90 .ltoreq. E.sub.2 90 .ltoreq. E.sub.3 n/a 350 1.4
16 95 .ltoreq. E.sub.1 95 .ltoreq. E.sub.2 95 .ltoreq. E.sub.3 n/a
350 1.4
[0080] The filter media may exhibit suitable air permeability
characteristics. In some embodiments, the air permeability of a
filter media may range from between about 150 CFM and about 800 CFM
(e.g., between about 350 CFM and about 600 CFM). In some
embodiments, the air permeability may be greater than or equal to
about 150 CFM, greater than or equal to about 200 CFM, greater than
or equal to about 250 CFM, greater than or equal to about 300 CFM,
greater than or equal to about 310 CFM, greater than or equal to
about 350 CFM, greater than or equal to about 500 CFM, greater than
or equal to about 600 CFM, or greater than or equal to about 700
CFM. In certain embodiments, the air permeability may be less than
or equal to about 800 CFM, less than or equal to about 600 CFM,
less than or equal to about 500 CFM, less than or equal to about
350 CFM, less than or equal to about 250 CFM, or less than or equal
to about 150 CFM. Combinations of the above-referenced ranges are
also possible (e.g., an air permeability of greater than or equal
to 310 CFM and less than or equal to about 800 CFM). Other ranges
are also possible. As determined herein, the permeability is
measured according to the Standard TAPPI T-251.
[0081] The pressure drop across the filter media or a filtration
layer may vary depending on the particular application of the
filter media. In some embodiments, for example, the pressure drop
across the filter media or a filtration layer may range from
between about 5 Pa and about 30 Pa, or between about 7 Pa and about
15 Pa. In some embodiments, the pressure drop across the filter
media or filtration layer may be greater than or equal to about 5
Pa, greater than or equal to about 7 Pa, greater than or equal to
about 10 Pa, greater than or equal to about 15 Pa, greater than or
equal to about 20 Pa, or greater than or equal to about 25 Pa. In
certain embodiments, the pressure drop across the filter media or
filtration layer may be less than or equal to about 30 Pa, less
than or equal to about 20 Pa, less than or equal to about 15 Pa,
less than or equal to about 10 Pa, less than or equal to about 7
Pa, or less than or equal to about 5 Pa. Combinations of the
above-referenced ranges are also possible (e.g., a pressure drop of
greater than or equal 7 Pa and less than or equal to about 15 Pa).
Other ranges are also possible.
[0082] The pressure drop is measured as the differential pressure
across the filter media or filtration layer when exposed to clean
air at a face velocity of approximately 12.7 centimeters per
second. As noted above, the face velocity is the velocity of air as
it hits the upstream side of the filter media or filtration layer.
Values of pressure drop are typically recorded as millimeters of
water or Pascals. The values of pressure drop described herein were
determined according to EN779-2012 standard.
[0083] Some or all of the filtration layers can be formed into a
waved configuration using various manufacturing techniques, but in
an exemplary embodiment involving a single filtration layer, the
filtration layer is positioned on a first moving surface adjacent
to a second moving surface, and the filtration layer is conveyed
between the first and second moving surfaces that are traveling at
different speeds. In an example involving two filtration layers,
the filtration layers are positioned adjacent to one another in a
desired arrangement from air entering side to air outflow side, and
the combined layers are conveyed between first and second moving
surfaces that are traveling at different speeds. For instance, the
second surface may be traveling at a speed that is slower than the
speed of the first surface. In either arrangement, a suction force,
such as a vacuum force, can be used to pull the layer(s) toward the
first moving surface, and then toward the second moving surface as
the layer(s) travel from the first to the second moving surfaces.
The speed difference causes the layer(s) to form Z-direction waves
as they pass onto the second moving surface, thus forming peaks and
troughs in the layer(s). The speed of each surface as well as the
ratio of speeds between the two surfaces can be altered to obtain a
percentage of fiber orientations as described herein. Generally, a
higher ratio of speeds results in a higher percentage of fibers
having a more angled orientation with respect to the horizontal, or
with respect to a surface (e.g., a planar surface) of the
filtration layer or an outer or cover layer. In some embodiments,
one or more filtration layers, or a filter media, is formed using a
ratio of speeds of at least 1.5, at least 2.5, at least 3.5, at
least 4.0, at least 4.5, at least 5.0, at least 5.5, or at least
6.0. In certain embodiments, the ratio of speeds is less than or
equal to 10.0, less than or equal to 9.0, less than or equal to
8.0, less than or equal to 7.0, less than or equal to 6.0, less
than or equal to 5.0, or less than or equal to 4.0, less than or
equal to 3.5, less than or equal to 3.0, or less than or equal to
2.5. Combinations of the above-referenced ranges are also possible.
Other ratios are also possible.
[0084] The speed of each surface can be also altered to obtain the
desired number of waves per inch. The distance between the surfaces
can also be altered to determine the amplitude of the peaks and
troughs, and in an exemplary embodiment the distance is adjusted
between 0 to 2''. The properties of the different layers can also
be altered to obtain a desired filter media configuration. In an
exemplary embodiment the filter media has about 2 to 6 waves per
inch, with a height (overall thickness) in the range of about
0.025'' to 2'', however this can vary significantly depending on
the intended application. As shown in FIG. 1A, a single wave W
extends from the middle of one peak to the middle of an adjacent
peak.
[0085] In some embodiments, the periodicity of the filtration layer
(e.g., the number of waves per inch) may range between about 10 and
about 40 waves per 6 inches (e.g., between about 20 and about 30
waves per 6 inches). In some embodiments, the periodicity of the
filtration layer may be greater than or equal to about 10 waves,
greater than or equal to about 15 waves, greater than or equal to
about 20 waves, greater than or equal to about 25 waves, greater
than or equal to about 30 waves, or greater than or equal to about
35 waves per 6 inches. In some embodiments, the periodicity of the
filtration layer may be less than or equal to about 40 waves, less
than or equal to about 30 waves, less than or equal to about 20
waves, or less than or equal to about 10 waves per 6 inches.
Combinations of the above-referenced ranges are also possible
(e.g., a periodicity of the filtration layer of greater than or
equal to about 20 and less than about 30 waves per 6 inches). Other
ranges of periodicities are also possible. Additionally, in
embodiments in which one or more filtration layers are present in a
media, each filtration layer may have a periodicity having one or
more of the above-referenced ranges.
[0086] Once the layers are formed into a waved configuration, the
waved shape can be maintained by activating the binder fibers to
effect bonding of the fibers. A variety of techniques can be used
to activate the binder fibers. For example, if bicomponent binder
fibers having a core and sheath are used, the binder fibers can be
activated upon the application of heat. If monocomponent binder
fibers are used, the binder fibers can be activated upon the
application of heat, steam and/or some other form of warm moisture.
An upstream outer or cover layer 18 (FIG. 1B) and/or a downstream
outer cover layer 18B (FIG. 1C) can also be positioned on top of
the upstream filtration layer 16 (FIG. 1B) or on the bottom of the
downstream filtration layer 14B (FIG. 1C), respectively, and mated,
such as by bonding, to the upstream filtration layer 16 or
downstream filtration layer 14B simultaneously or subsequently. A
person skilled in the art will also appreciate that the layers can
optionally be mated to one another using various techniques other
than using binder fibers. Other suitable mating techniques include
adhesives, needling, hydroentanglement, and chemical binders
(resins). The layers can also be individually bonded layers, and/or
they can be mated, including bonded, to one another prior to being
waved.
[0087] A saturant can also optionally be applied to the material
prior to drying the material. A variety of saturants can be used
with the media described herein to facilitate the forming of the
layers at a temperature that is less than the melting temperature
of the fibers. Exemplary saturants can include phenolic resins,
melamine resins, urea resins, epoxy resins, polyacrylate esters,
polystyrene/acrylates, polyvinyl chlorides, polyethylene/vinyl
chlorides, polyvinyl acetates, polyvinyl alcohols, and combinations
and copolymers thereof that are present in an aqueous or organic
solvent.
[0088] In other embodiments, the resulting media can also have a
gradient in at least one, and optionally all, of the following
properties: binder and non-binder fibers composition, fiber
diameter, mean flow pore size, basis weight, and saturant content.
In some embodiments, such a gradient is formed by the use of more
than one filtration layers having different properties. For
example, in one embodiment, the media can have a lightweight,
lofty, coarse-fibered, lightly bonded and lightly saturated sheet
upstream (e.g., a first filtration layer), and a heavier, denser,
fine-fibered, heavily bonded and heavily saturated sheet downstream
(e.g., a second filtration layer). This allows the coarser
particles to be trapped in the upstream layer, preventing early
saturation of the bottom layer. The first filtration layer may have
a higher dust hold capacity than the second filtration layer, and
the second filtration layer may have a higher efficiency than the
first filtration layer.
[0089] In other embodiments, the upstream-most layer can be lighter
and/or loftier than the downstream-most layer. That is, the
upstream layer can have a solidity (e.g., the solid volume fraction
of fibers in the web), a density of fibers, and/or a basis weight
that is less than that of the downstream layer. Additionally, in
embodiments where the filter media includes a saturant, the media
can have a gradient with respect to the amount of saturant in the
upstream-most and downstream-most layers. One skilled in the art
will appreciate the variety of properties that the layers of the
media can have.
[0090] An electrostatic charge can also optionally be imparted to
the filter media, or to various layers of the media, to form an
electret fiber web. A variety of techniques are well known to
impart a permanent dipole to the polymer web in order to form
electret filter media. Charging can be effected through the use of
AC and/or DC corona discharge units and combinations thereof. The
particular characteristics of the discharge are determined by the
shape of the electrodes, the polarity, the size of the gap, and the
gas or gas mixture. Charging can also be accomplished using other
techniques, including friction-based charging techniques.
[0091] The filter media can also be pleated after it is formed into
the waved configuration, and various exemplary configurations will
be discussed in more detail below. A person skilled in the art will
appreciate that virtually any pleating technique known in the art
can be used to pleat the waved filter media. Typically, a filter
media is pleated by forming a plurality of parallel score lines in
the media and forming folds at each score line.
[0092] As indicated above, the properties of the resulting filter
media can vary depending on the configuration of the media and the
intended use.
[0093] The filter media described herein may have a single layer,
or multiple layers. In some embodiments involving multiple layers,
a clear demarcation of layers may not always be apparent. For
example, the number of layers in the filter media may range between
1 and 10 layers (e.g., between 2 and 4 layers). In some
embodiments, the number of layers in the filter media may be
greater than or equal to 1, greater than or equal to 2, greater
than or equal to 4, greater than or equal to 6, greater than or
equal to 8, or greater than or equal to 10. In certain embodiments,
the number of layers in the filter media may be less than or equal
to 10, less than or equal to 8, less than or equal to 6, less than
or equal to 4, or less than or equal to 2. Combinations of the
above-referenced ranges may also be possible (e.g., a filter media
with a number of layers of greater than or equal to 2 layers and
less than or equal to 4 layers). Other ranges of the number of
layers in a filter media are also possible.
[0094] It should be appreciated that although the parameters and
characteristics noted above are described with respect to a
filtration layer and/or an outer or cover layer, the same
parameters and characteristics (including, in some embodiments, the
values and ranges for such parameters and characteristics) may also
be applied to the entire filter media. For instance, in some
embodiments the basis weight of the filter media may range between
about 40 g/m.sup.2 and about 500 g/m.sup.2 (e.g., between about 80
g/m.sup.2 and about 200 g/m.sup.2). In some embodiments, the basis
weight of the filter media may be greater than or equal to about 40
g/m.sup.2 (e.g., greater than or equal to about 60 g/m.sup.2,
greater than or equal to about 80 g/m.sup.2, greater than or equal
to about 100 g/m.sup.2, greater than or equal to about 200
g/m.sup.2, or greater than or equal to about 400 g/m.sup.2). In
some cases, the basis weight of the filter media may be less than
or equal to about 500 g/m.sup.2 (e.g., less than or equal to 400
g/m.sup.2, less than or equal to about 200 g/m.sup.2, less than or
equal to about 100 g/m.sup.2, less than or equal to about 80
g/m.sup.2, less than or equal to about 60 g/m.sup.2, or less than
or equal to about 40 g/m.sup.2). Combinations of the
above-referenced ranges are also possible (e.g., a basis weight of
greater than or equal to about 80 g/m.sup.2 and less than or equal
to about 200 g/m.sup.2). Other ranges are also possible. As
determined herein, the basis weight of the filter media is measured
according to the ASTM D-846 standard.
[0095] In some embodiments, the thickness of the filter media may
range from between about 40 mil and about 1000 mil. For instance,
the thickness of the filter media may range between about 80 mil
and about 230 mil. In some embodiments, the thickness may be
greater than or equal to about 40 mil (e.g., greater than or equal
to about 80 mil, greater than or equal to about 100 mil, greater
than or equal to about 200 mil, greater than or equal to about 230
mil, greater than or equal to about 500 mil, or greater than or
equal to about 800 mil). In some cases, the thickness of the filter
media may be less than or equal to about 1000 mil (e.g., less than
or equal to about 500 mil, less than or equal to about 230 mil,
less than or equal to about 100 mil, less than or equal to about 80
mil, or less than or equal to about 40 mil). Combinations of the
above-references ranges are also possible (e.g., a thickness of
greater than or equal to about 80 mil and less than or equal to
about 230 mil). Other ranges are also possible.
[0096] The filter media may exhibit a suitable mean flow pore size.
In some embodiments, the mean flow pore size of the filter media
may range between about 0.1 microns and about 100 microns (e.g.,
between about 5 microns and about 40 microns, between about 15
microns and about 40 microns, or between about 25 microns and about
80 microns). In some embodiments, the mean flow pore size of the
filter media may be less than or equal to about 100 microns, less
than or equal to about 50 microns, less than or equal to about 40
microns, less than or equal to about 30 microns, less than or equal
to about 20 microns, less than or equal to about 10 microns, or
less than or equal to about 5 microns, or less than or equal to
about 2 microns. In other embodiments, the mean flow pore size may
be greater than or equal to about 2 microns, greater than or equal
to about 5 microns, greater than or equal to about 10 microns,
greater than or equal to about 20 microns, greater than or equal to
about 25 microns, greater than or equal to about 30 microns,
greater than or equal to about 50 microns or greater than or equal
to about 75 microns. Combinations of the above-referenced ranges
are also possible (e.g., a mean flow pore size of greater than or
equal to about 10 microns and less than or equal to about 50
microns). Other values and ranges of mean flow pore size are also
possible.
[0097] The filter media described herein can have beneficial dust
holding properties. In some embodiments, the filter media may have
a DHC of between about 66 g/m.sup.2 and about 200 g/m.sup.2 (e.g.,
a DHC between about 100 g/m.sup.2 and about 160 g/m.sup.2). In some
embodiments, the DHC may be greater than or equal to about 66
g/m.sup.2, greater than or equal to about 80 g/m.sup.2, greater
than or equal to about 100 g/m.sup.2, greater than or equal to
about 120 g/m.sup.2, greater than or equal to about 140 g/m.sup.2,
greater than or equal to about 160 g/m.sup.2, or greater than or
equal to about 180 g/m.sup.2. In some cases, the DHC may be less
than or equal to about 200 g/m.sup.2, less than or equal to about
180 g/m.sup.2, less than or equal to about 160 g/m.sup.2, less than
or equal to about 140 g/m.sup.2, less than or equal to about 120
g/m.sup.2, less than or equal to about 100 g/m.sup.2, less than or
equal to about 80 g/m.sup.2, or less than or equal to about 66
g/m.sup.2. Combinations of the above-referenced ranges are also
possible (e.g., a DHC of greater than or equal to about 66
g/m.sup.2 and less than or equal to about 200 g/m.sup.2). Other
ranges are also possible.
[0098] As previously indicated, the filter media disclosed herein
can be incorporated into a variety of filter elements for use in
various applications, including both liquid and air filtration
applications. Exemplary uses include ASHRAE bag filters, pleatable
HVAC filters, liquid bag filter media, dust bag house filters,
residential furnace filters, paint spray booth filters, surgical
face masks, industrial face masks, cabin air filters, commercial
ASHRAE filters, respirator filters, automotive air intake filters,
automotive fuel filters, automotive lube filters, room air cleaner
filters and vacuum cleaner exhaust filters. The filter elements can
have various configurations, and certain exemplary filter element
configurations are discussed in more detail below. Other exemplary
filter elements include, by way of non-limiting example, radial
filter elements that include cylindrical filter media disposed
therein, micron-rater vessel bag filters (also referred to as sock
filters) for liquid filtration, face masks, etc.
[0099] In one exemplary embodiment, the filter media can be used in
a panel filter. In particular, a filter media can include a housing
disposed therearound. The housing can have various configurations,
and the particular configuration can vary based on the intended
application. In one embodiment, as shown in FIG. 2, the housing is
in the form of a frame 20 that is disposed around the perimeter of
a filter media described herein (e.g., filter media 10). In one
embodiment, the frame has a generally rectangular configuration
such that it surrounds all four sides of a generally rectangular
filter media, however the particular shape can vary. The frame can
be formed from various materials, including cardboard, metal,
polymers, etc. In certain exemplary embodiments, the frame can have
a thickness t that is about 12'' or less, and more preferably about
2'' or less. In another embodiment, the frame can be formed from
the edges of the filter media. In particular, a perimeter of the
filter media can be thermally sealed to form a frame therearound.
The panel filter can also include a variety of other features known
in the art, such as stabilizing features for stabilizing the filter
media relative to the frame, spacers, etc.
[0100] In use, the panel filter element can be used in a variety of
applications, including commercial and residential HVAC; automotive
passenger cabin air; automotive air intake; and paint spray booth
filters. The particular properties of the filter element can vary
based on the intended use.
[0101] The filter media having oriented fiber portions as described
herein can also be pleated and used in a pleated filter. As
previously discussed, the media, or various layers thereof, can be
pleated by forming score lines at a predetermined distance apart
from one another, and folding the media. A person skilled in the
art will appreciate, however, that other pleating techniques can be
used. Once the media is pleated, the media can be incorporated into
a housing. FIG. 3A illustrates one embodiment of a pleated filter
media 32 that is disposed within a frame 30. The frame can have
various shapes and sizes. The media can have any number of pleats
depending on the size of the frame and the intended use. In certain
exemplary embodiment, the filter media has 1-2 pleats per inch, and
a pleat height in the range of about 0.75'' to 2''. However, some
applications utilize peaks having a height up to 12''.
[0102] In order to facilitate pleating, the filter media can be
self-supporting, i.e., it can have a stiffness that allows
pleating. In certain exemplary embodiments, the minimum stiffness
of the filter media is about 200 mg with Gurley Stiffness tester to
enable pleating. Alternatively, or in addition, the filter media
can include various stiffening elements. By way of non-limiting
example, FIGS. 3B and 3C illustrate a filter media 32a, 32b
including a filtration layer described herein (e.g., a waved
filtration layer) that is pleated, and that includes a stabilizing
strap 34a, 34b that is adhered to (e.g., using an adhesive or other
bonding techniques) an air outflow side of the filter media 32a,
32b. The filter media 32a, 32b are also shown disposed within a
frame 30a, 30b. FIG. 3B further illustrates a screen backing 36a
disposed on the filter media 32a to stiffen the media 32a and help
retain the pleated configuration. The screen backing 36a can be an
expanded metal wire or an extruded plastic mesh.
[0103] In use, the pleated filter element can be used in a variety
of applications, including pleatable HVAC filters, residential
furnace filters, cabin air filters, commercial ASHRAE filters,
automotive air intake filters, automotive fuel filters, automotive
lube filters, room air cleaner filters, and vacuum cleaner exhaust
filters. The particular properties of the filter element can vary
based on the intended use. In some embodiments, the filter media
can also have a thickness before pleating of about 0.5'' or less
(or another thickness range described herein), and a thickness
after pleating of about 2'' or less. However, in certain
application the thickness after pleating can be up to 12''.
[0104] In yet another embodiment, the filter media can be
incorporated into a bag or pocket filter for use in heating, air
conditioning, ventilation, and/or refrigeration; and micron rated
liquid filter bags. The bag or pocket filter can be formed by
placing two filter media together (or folding a single filter media
in half), and mating three sides (or two if folded) to one another
such that only one side remains opens, thereby forming a pocket
inside the filter. As shown in FIG. 4A, multiple filter pockets 42
can be attached to a frame 44 to form a filter element 40. Each
pocket 42 can be positioned such that the open end is located in
the frame, thus allowing air to flow into each pocket 42 in the
direction indicated by line A. The frame can include rectangular
rings that extend into and retain each pocket. A person skilled in
the art will appreciate that the frame can have virtually any
configuration, and various mating techniques known in the art can
be used to couple the pockets to the frame. Moreover, the frame can
include any number of pockets, but bag filters typically include
between 6 and 10 pockets.
[0105] FIG. 4B illustrates one pocket 42 showing three edges 42a,
42b, 42c being closed and one edge 42d being open for receiving
airflow therethrough, as indicated by line A. As further shown in
FIG. 4B, the pocket filter 42 can also include any number of
spacers 43 disposed therein and configured to retain opposed
sidewalls of the filter 42 at a predetermined distance apart from
one another. The spacers can be threads or any other element
extending between both sidewalls. A person skilled in the art will
appreciate that various features known in the art for use with bag
or pocket filters can be incorporated into the filter media
disclosed herein.
[0106] The following non-limiting examples serve to further
illustrate the present invention:
EXAMPLES
Example 1
[0107] This example demonstrates the properties of four filter
media samples comprising a first filtration layer and a second
filtration layer. The first filtration layers and the second
filtration layers are composed of a blend of three fiber types,
polyethylene (PE), polypropylene (PP), and a PE/PP bicomponent
(BICO) blend. Fiber type, average fiber diameter, and percentage of
each fiber type in the respective layers are shown in Table E1.
TABLE-US-00003 TABLE E1 Fiber Type First Filtration Second
Filtration (Average Diameter) Layer Layer 3.0D .times. 2'' (PE/PP
BICO) 40% 40% (12.75 micron average diameter) 2.2D .times. 1.5''
(PP) 40% 30% (9.3 micron average diameter) 6D .times. 1.5'' (PP)
20% 30% (25.5 micron average diameter)
[0108] Four different samples were formed using the two filtration
layer composition described above. Each of the four samples
(Samples 1-4) were formed at different speed ratios of the moving
surfaces carrying each of the first and second filtration layers,
as noted in Table E2. The weight, thickness, and resistance of the
filtration media samples are also shown in Table E2. As shown in
Table E2, the percentage of fiber portions having an orientation
between 46-90 degrees, or between 61-90 degrees, generally
increased from Sample 1 to Sample 4, with Sample 4 having the
highest percentage of fiber portions within this orientation.
TABLE-US-00004 TABLE E2 Sample 1 Sample 2 Sample 3 Sample 4 (Ratio
1.5) (Ratio 2.5) (Ratio 3.5) (Ratio 4.0) Fiber portions 17% 20% 43%
73% orientated between 46-90.degree. Fiber portions 83% 80% 67% 27%
orientated between 0-45.degree. Fiber portions 6% 11% 25% 55%
orientated between 61-90.degree. Fiber portions 36% 30% 35% 30%
orientated between 31-60.degree. Fiber portions 58% 59% 40% 15%
orientated between 0-30.degree. Weight (g/m.sup.2) 104 98 110 140
Thickness (mil) 150 184 225 230 Resistance 0.7 0.7 0.7 0.8 (mm w
g)
[0109] Initial efficiency of samples 1-4 as a function of average
particle size to be filtered for Range 1 (0.30-1.0 microns), Range
2 (1.0-3.0 microns), and Range 3 (3.0-10.0 micron) particle sizes
was measured by the ASHRAE 52.2 standard using aerosolized KCl feed
particles of the different sizes. The MERV rating was also
measured. Results of the initial efficiency and MERV rating is
listed in table E3. The average efficiency for Sample 4 was
40%.
TABLE-US-00005 TABLE E3 Sample 1 Sample 2 Sample 3 Sample 4 Range 1
Initial 1 2 7 6 Efficiency (%) Range 2 Initial 6 5 12 13 Efficiency
(%) Range 3 Initial 27 23 38 43 Efficiency (%) MERV 5 5 6 6
[0110] As shown in Table E3, as the percentage of fiber portions
having an orientation between 46-90 degrees (or between 61-90
degrees) increased (e.g., with Sample 4 having the highest
percentage of fiber portions within this orientation), the initial
efficiency generally increased. For Samples 1-4, initial efficiency
increased as a function of particle size, as shown in FIG. 5.
Representative cross-sectional SEM images of Sample 1 and Sample 4
are shown in FIG. 6A and FIG. 6B, respectively.
[0111] One skilled in the art will appreciate further features and
advantages of the invention based on the above-described
embodiments. Accordingly, the invention is not to be limited by
what has been particularly shown and described, except as indicated
by the appended claims. All publications and references cited
herein are expressly incorporated herein by reference in their
entirety.
* * * * *