Filter media including a filtration layer comprising synthetic fibers

Patent metadata

Field	Value
Publication number	US-10252200-B2
Application number	US-201615045538-A
Country	US
Kind code	B2
Filing date	Feb 17, 2016
Priority date	Feb 17, 2016
Publication date	Apr 9, 2019
Grant date	Apr 9, 2019

Abstract

Filter media comprising a filtration layer comprising synthetic fibers (e.g., pleatable backer layer) and related components, systems, and methods associated herewith are provided. In some embodiments, the filtration layer comprising synthetic fibers may be a non-woven web comprising a blend of coarse and fine diameter fibers. The filtration layer comprising synthetic fibers may be designed to have desirable performance properties without compromising certain mechanical properties, such as the pleatability of the media. In some embodiments, a filter media, described herein, may comprise the filtration layer comprising synthetic fibers and an efficiency layer. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.

First claim

What is claimed is:

1. A filter media, comprising:
a non-woven web comprising:
first synthetic fibers having an average fiber diameter of greater than or equal to about 15 microns, wherein the weight percentage of first synthetic fibers of all fibers in the non-woven web is greater than or equal to about 40 wt. %; and
second synthetic fibers having an average fiber diameter of greater than or equal to about 0.5 microns and less than about 15 microns, wherein the weight percentage of second synthetic fibers of all fibers in the non-woven web is less than or equal to about 50 wt. %, and wherein the surface average fiber diameter of the non-woven web is greater than or equal to about 13 microns and less than or equal to about 17 microns and is measured using the formula:

SAFD
⁡

[

in
⁢

⁢
um

]

=

4
/

(

SSA
⁢

⁢

ρ
⁡

[

in
⁢

g

cm
⁢

⁢
3

]

)

wherein SSA is the BET surface of the filtration layer in m 2 /g and ρ is the density of the layer in g/cm 3 ; and
an efficiency layer, wherein the filter media has a dust holding capacity of greater than or equal to about 20 g/m 2 .

2. A filter media, comprising:
a non-woven web comprising:
first synthetic fibers having an average fiber diameter of greater than or equal to about 15 microns, wherein the weight percentage of first synthetic fibers of all fibers in the non-woven web is greater than or equal to about 40 wt. %; and
second synthetic fibers having an average fiber diameter of greater than or equal to about 0.5 microns and less than about 15 microns, wherein the weight percentage of second synthetic fibers of all fibers in the non-woven web is less than or equal to about 50 wt. %,
wherein the surface average fiber diameter of the non-woven web is greater than or equal to about 13 microns and less than or equal to about 17 microns and is measured using the formula:

SAFD
⁡

[

in
⁢

⁢
um

]

=

4
/

(

SSA
⁢

⁢

ρ
⁡

[

in
⁢

g

cm
⁢

⁢
3

]

)

wherein SSA is the BET surface of the filtration layer in m 2 /g and ρ is the density of the layer in g/cm 3 , and wherein the basis weight of the non-woven web is less than or equal to about 110 g/m 2 ; and
an efficiency layer.

3. The filter media of claim 1 , wherein the first synthetic fibers comprises a first population of fibers and a second population of fibers.

4. The filter media of claim 3 , wherein the first population of fibers has an average fiber diameter of greater than or equal to about 15 microns and less than or equal to about 25 microns.

5. The filter media of claim 3 , wherein the second population of fibers has an average fiber diameter of greater than or equal to about 25 microns and less than or equal to about 50 microns.

6. The filter media of claim 1 , wherein the first synthetic fibers having an average fiber diameter of greater than or equal to about 15 microns and less than or equal to about 60 microns.

7. The filter media of claim 1 , wherein the first synthetic fibers having an average fiber diameter of greater than or equal to about 17 microns and less than or equal to about 35 microns.

8. The filter media of claim 1 , wherein second synthetic fibers having an average fiber diameter of greater than or equal to about 2 microns and less than or equal to about 10 microns.

9. The filter media media of claim 1 , wherein the non-woven web comprises greater than or equal to about 10 wt. % and less than or equal to about 30 wt. % of binder resin.

10. The filter media media of claim 1 , wherein the surface average fiber diameter of the non-woven web is greater than or equal to about 14 microns and less than or equal to about 16 microns.

11. The filter media media of claim 1 , wherein the basis weight of the non-woven web is greater than or equal to about 20 g/m 2 and less than or equal to about 110 g/m 2 .

12. The filter media media of claim 1 , wherein the thickness of the non-woven web is greater than or equal to about 0.25 mm and less than or equal to about 2.0 mm.

13. The filter media media of claim 1 , wherein the air permeability of the non-woven web is greater than or equal to about 50 CFM and less than or equal to about 800 CFM.

14. The filter media of claim 13 , wherein the air permeability of the non-woven web is greater than or equal to about 300 CFM.

15. The filter media of claim 1 , wherein the dry tensile strength in the cross direction of the non-woven web is greater than or equal to about 6 lb/in and less than or equal to about 20 lb/in.

16. The filter media of claim 1 , wherein the dry Gurley stiffness in the machine direction of the non-woven web is greater than or equal to about 200 mg and less than or equal to about 3,500 mg.

17. The filter media of claim 1 , wherein the efficiency of the filter media is greater than or equal to about 40% .

Assignees

• Hollingsworth & Vose Co

Inventors

• Anantharamaiah Nagendra
• Jaganathan Sudhakar
• Gadbois Gerald
• Silin Maxim
• Gallimore Mark A

Classifications

• B01D2239/1291

  Other parameters · CPC title

• B01D2239/1233

  Fibre diameter · CPC title

• B01D2239/065

  More than one layer present in the filtering material · CPC title

• B01D39/163

  sintered or bonded · CPC title

• B01D39/1623 Primary

  of synthetic origin · CPC title