Spun-bonded fabric material, object comprising a spun-bonded fabric material, filter medium, filter element, and use thereof

Patent metadata

Field	Value
Publication number	US-11478735-B2
Application number	US-201916585845-A
Country	US
Kind code	B2
Filing date	Sep 27, 2019
Priority date	Mar 28, 2017
Publication date	Oct 25, 2022
Grant date	Oct 25, 2022

Abstract

A filter medium (10) for filtering a fluid, in particular for use in an interior air filter (32), comprises a spun-bonded nonwoven formed at least in part of multi-component segmented pie fibers (1) having at least a first plastic component (2) and a second plastic component (3). The multi-component fibers (1) are largely non-split and in order to manufacture same, segmented pie filaments are spun in a spun-bonding process (S4) to form a spun-bonded nonwoven (10). The segmented pie filaments then form the multi-component fibers (4), the first plastic component (2) and/or the second plastic component (3) being made in particular of a polypropylene.

First claim

What is claimed is:

1. A spun-bonded nonwoven which is formed at least partially from multi-component segmented fibers formed of segmented pie fibers ( 1 ), the multi-component segmented fibers comprising:
at least a first plastic component ( 2 ) forming one or more first pie segments, and
a second plastic component ( 3 ) forming one or more second pie segments,
wherein the multi-component segmented fibers have a circular cross-section;
wherein the first and second pie segments have a pie-shaped cross-section,
wherein the multi-component segmented fibers have an outer sheath surface ( 7 ),
wherein at least a portion of the first and the second pie segments of the multi-component segmented fibers are joined together at inner segment boundaries ( 4 ) of the pie segments,
wherein the outer sheath surface ( 7 ) has one or more longitudinal grooves ( 6 ′) formed along one or more of the inner segment boundaries ( 6 ) where adjacent pie segments abut side by side and are joined together,
wherein the pie segments of at least 50% of the multi-component segmented fibers are joined together side by side over at least 70% of a respective fiber length of each multi-component segmented fiber, such that the joined pie segments are split apart over no more than 30% the respective fiber length of any individual multi-component segmented fiber,
wherein the spun-bonded nonwoven is thermally solidified such that the multi-component segmented fibers are interconnected to form the spun-bonded nonwoven,
wherein the first plastic component ( 2 ) and the second plastic component ( 3 ) consist of a polypropylene.

2. The spun-bonded nonwoven of claim 1 , wherein
at least 70% of the of multi-component segmented fibers ( 1 ) have adjoining pie segments ( 2 , 3 ) joined together at inner segment boundaries ( 4 ) over at least 70% of the respective fiber length of the multi-component segmented fibers ( 1 ).

3. The spun-bonded nonwoven according to claim 1 , wherein
the outer sheath surface ( 7 ) along a circumference ( 5 ) of the sheath surface has an average roughness depth (R Z ) of less than 2 μm.

4. The spun-bonded nonwoven according to claim 1 , wherein
the multi-component segmented fibers ( 1 ) have an average diameter (D) of at least 10 μm.

5. The spun-bonded nonwoven according to claim 1 , wherein
the multi-component segmented fibers ( 1 ) have at least four pie segments ( 2 , 3 ).

6. The spun-bonded nonwoven according to claim 1 , wherein
the pie segments ( 2 , 3 ) of the multi-component segmented fibers ( 1 ) do not split apart under the influence of a waterjet treatment.

7. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 1 ) has a machine direction (M), and the multi-component segmented fibers ( 1 ) are oriented along the machine direction (M).

8. The spun-bonded nonwoven according to claim 1 , wherein
the multi-component segmented fibers ( 1 ) are thermally interconnected together exclusively by hot-air bonding to form the spun-bonded nonwoven.

9. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 10 ) has a thickness (D) between 1.0 mm and 2.0 mm.

10. The spun-bonded nonwoven according to claim 8 , wherein
the multi-component segmented fibers ( 1 ) are thermally interconnected to form a nonwoven material.

11. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 10 ) has a thickness between 0.5 mm and 1.5 mm.

12. The spun-bonded nonwoven according to claim 1 , wherein
the plastic components ( 2 , 3 ) of the multi-component segmented fibers ( 1 ) are charged as electrets.

13. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 10 ) has a grammage of between 80 g/m2 and 160 g/m2.

14. The spun-bonded nonwoven according to claim 1 , wherein
the first plastic component ( 2 ) has a first melting point (T 2 ) and
the second plastic component ( 3 ) has a second melting point (T 3 ),
wherein the first melting point (T 2 ) is higher than the second melting point (T 3 ) and
there is a difference between the first and the second melting point (T 2 , T 3 ) of at least 8 degrees K.

15. The spun-bonded nonwoven according to claim 14 , wherein
a mass fraction of the first plastic component is between 20% and 80%.

16. The spun-bonded nonwoven according to claim 1 , wherein
the first plastic component ( 2 ) and/or the second plastic component ( 3 ) has a first portion of a first thermoplastic material (MA) having a first melting point (TA) and
a second portion of a second thermoplastic material (MB) having a second melting point (TB),
wherein the first melting point (TA) is higher than the second melting point (TB).

17. The spun-bonded nonwoven of claim 16 , wherein
the second thermoplastic material (MB) of adjacent multi-component fibers ( 1 ) are partially fused together to solidify the spun-bonded nonwoven ( 10 ).

18. The spun-bonded nonwoven according to claim 16 , wherein
the first thermoplastic material (MA) is a polypropylene homopolymer and/or the second thermoplastic material (MB) is a metallocene polypropylene.

19. The spun-bonded nonwoven according to claim 15 , wherein
the mass fraction of the first thermoplastic material (MA) is between 40% and 60%.

20. The spun-bonded nonwoven according to any of claim 18 , wherein
the first thermoplastic material (MA) and/or the second thermoplastic material (MB) have a melt flow index (MFI) between 20 g/10 min and 30 g/10 min.

21. The spun-bonded nonwoven according to claim 20 , wherein
the spun-bonded nonwoven ( 10 ) is thermally solidified in a respective area of 10 cm 2 in such a way that it is self-supporting.

22. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 10 ) has an air permeability of between 1,300 l/m 2 s and 1,700 l/m 2 s.

23. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 10 ) has a NaCl retention capacity at 0.3 μm of greater than 20%.

24. The spun-bonded nonwoven according to claim 1 , wherein
the spun-bonded nonwoven ( 10 ) has a dust storage capacity at 50 Pa of more than 20 g/m 2 .

25. The spun-bonded nonwoven according to claim 7 , wherein
the spun-bonded nonwoven ( 10 ) has a flexural rigidity in the machine direction (M) of more than 170 mN.

26. The spun-bonded nonwoven according to claim 18 , wherein
the spun-bonded nonwoven ( 10 ) comprises pleats ( 21 ) with a plurality of pleat sections ( 23 ) arranged between pleat edges ( 22 ).

27. The spun-bonded nonwoven of claim 26 , wherein
the pleats ( 21 ) extend transversely to a machine direction (M).

28. An insulating material for a building insulation, motor vehicles, household appliances, beverage packaging and/or a packing material comprising
a spun-bonded nonwoven according to claim 1 .

29. A filter medium comprising
the spun-bonded nonwoven of claim 1 .

30. The filter medium of claim 29 , wherein
the filter medium ( 11 ) further comprises a melt-blown material ( 9 ).

31. A filter element comprising
a spun-bonded nonwoven according to claim 29 .

32. The filter element according to claim 31 , wherein
the filter element comprises an adsorbent layer.

33. The filter ele

Assignees

• Mann & Hummel Gmbh

Inventors

• Orendt Stefan
• Pemsel Thomas

Classifications

• B01D46/0005

  Mounting of filtering elements within casings, housings or frames (B01D46/2422 takes precedence) · CPC title

• B01D2239/0618

  Non-woven · CPC title

• D04H3/018 Primary

  characterised by the shape · CPC title

• D04H3/147

  Composite yarns or filaments · CPC title

• D01F8/06

  with at least one polyolefin as constituent · CPC title