Laminated articles for microbial removal and low pressure drop filtration, methods of making, and methods of using same

Patent metadata

Field	Value
Publication number	US-10308669-B2
Application number	US-201415037132-A
Country	US
Kind code	B2
Filing date	Dec 12, 2014
Priority date	Dec 19, 2013
Publication date	Jun 4, 2019
Grant date	Jun 4, 2019

Abstract

Laminated articles are provided including a porous fibrous nonwoven matrix and guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix. The laminated articles further include a first substrate and a second substrate sealed to the first substrate. Methods of making laminated articles and methods of using laminated articles are also provided.

First claim

What is claimed is:

1. A laminated article comprising:
a) a porous fibrous nonwoven matrix;
b) a plurality of guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix, the guanidine-functionalized metal silicate particles comprising:
a metal silicate particle that is modified with at least one silane having the formula
X 3-n R a n Si—Y-G,

wherein:
n is 0, 1, or 2;
each R a , if present, is independently an alkyl, aralkyl, or aryl;
Y is a divalent group comprising an alkylene having 2 to 20 carbons;
G is a guanidine group of the formula —NH—C(═NH)—NH 2 ; and
each X is independently alkoxy or acyloxy;

c) a first substrate; and
d) a second substrate sealed to the first substrate along at least a portion of a perimeter of the first substrate, wherein the porous fibrous nonwoven matrix is disposed between the first substrate and the second substrate.

2. The laminated article of claim 1 , wherein the first substrate and the second substrate are independently selected from a spunbond polypropylene, a spunbond polyamide, a spunbond blend of polyamide and polyester, a spunbond polyethylene, a spunbond polyester, a spunbond polybutylene terephthalate, and a spunbond polypropylene.

3. The laminated article of claim 1 , wherein the first substrate and the second substrate independently comprise a spunbond material comprising a gram per square meter basis weight (gsm) of 10 to 200 gsm, inclusive.

4. The laminated article of claim 1 , wherein the laminated article provides a turbidity of less than 0.2 nephelometric turbidity units (NTU) according to the Turbidity Test.

5. The laminated article of claim 1 , wherein the metal silicate particle is a magnesium silicate particle.

6. The laminated article of claim 1 , wherein each of the first substrate and the second substrate is liquid permeable.

7. A method of making a laminated article, the method comprising:
a) providing a plurality of fibers;
b) providing a plurality of guanidine-functionalized metal silicate particles;
c) mixing the plurality of guanidine-functionalized metal silicate particles and the plurality of fibers together to form a porous fibrous nonwoven matrix having the guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix;
d) providing a first substrate;
e) providing a second substrate;
f) disposing the porous fibrous nonwoven matrix having the guanidine-functionalized metal silicate particles between the first substrate and the second substrate; and
g) sealing the second substrate to the first substrate along at least a portion of a perimeter of the first substrate.

8. The method of claim 7 , wherein the providing a plurality of guanidine-functionalized metal silicate particles comprises:
i) reacting an O-methylisourea salt with a linker comprising the formula
X 3-n R a n Si—Y—NH 2 ,

wherein:
n is 0, 1, or 2;
each R a , if present, is independently an alkyl, aralkyl, or aryl;
Y is a divalent group comprising an alkylene having 2 to 20 carbons; and
each X is independently alkoxy or acyloxy;
to form a guanidine-functionalized linker; and

ii) forming a mixture of the guanidine-functionalized linker and metal silicate particles, such that the guanidine-functionalized linker reacts with hydroxyl groups of the metal silicate particles to form covalent bonds between the guanidine-functionalized linker and the metal silicate particles, thereby forming the guanidine-functionalized metal silicate particles.

9. The method of claim 7 , wherein the sealing is performed using ultrasonic sealing, heat sealing, adhesive sealing, stitching, or a combination thereof.

10. The method of claim 7 , further comprising mixing at least one polymeric binder together with the plurality of guanidine-functionalized metal silicate particles and the plurality of fibers.

11. A method of removing microorganisms from a fluid sample, the method comprising:
a) providing a laminated article, the laminated article comprising:
1) a porous fibrous nonwoven matrix;
2) a plurality of guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix, the guanidine-functionalized metal silicate particles comprising:

a metal silicate particle that is modified with at least one silane having the formula
X 3-n R a n Si—Y-G

wherein:
n is 0, 1, or 2;
each R a , if present, is independently an alkyl, aralkyl, or aryl;
Y is a divalent group comprising an alkylene having 2 to 20 carbons;
G is a guanidine group of the formula —NH—C(═NH)—NH 2 ; and
each X is independently alkoxy or acyloxy;
3) a first substrate; and
4) a second substrate sealed to the first substrate along at least a portion of a perimeter of the first substrate, wherein the porous fibrous nonwoven matrix is disposed between the first substrate and the second substrate;

b) providing a fluid sample containing at least one microorganism strain; and
c) contacting the fluid sample with the laminated article such that at least a portion of the at least one microorganism strain is removed from the fluid sample.

12. The method of claim 11 , wherein the contacting comprises passing the fluid sample at least once through the laminated article.

13. The method of claim 12 , wherein the contacting comprises passing the fluid sample through the laminated article at a pressure of 4.0 pounds per square inch (psi) (27.58 kilopascals (kPa)) or less.

14. The method of claim 11 , wherein the laminated article reduces the amount of microorganism in the fluid sample by at least a factor of 100.

15. A filtration device comprising:
a) a container having inlet and outlet ports for liquid passage; and
b) a laminated article contained within the container, the laminated article comprising:
1) a porous fibrous nonwoven matrix;
2) a plurality of guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix, the guanidine-functionalized metal silicate particles comprising:

a metal silicate particle that is modified with at least one silane having the formula
X 3-n R a n Si—Y-G

wherein:
n is 0, 1, or 2;
each R a , if present, is independently an alkyl, aralkyl, or aryl;
Y is a divalent group comprising an alkylene having 2 to 20 carbons;
G is a guanidine group of the formula —NH—C(═NH)—NH 2 ; and
each X is independently alkoxy or acyloxy;
3) a first substrate; and
4) a second substrate sealed to the first substrate along at least a portion of a perimeter of the first substrate, wherein the porous fibrous nonwoven matrix is disposed between the first substrate and the second substrate.

Assignees

• 3M Innovative Properties Co

Inventors

• Kshirsagar Manjiri T
• Yeom Bong Y
• Rowell Timothy J
• Nayar Satinder K

Classifications

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• B32B27/36

  comprising polyesters · CPC title

• D04H13/00 Primary

  Other non-woven fabrics · CPC title

• C07F7/0838

  Compounds with one or more Si-O-Si sequences (compounds with a ring containing only alternating Si and O atoms, i.e. cyclosilanes C07F7/21) · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title