Filter media and elements

Patent metadata

Field	Value
Publication number	US-12023613-B2
Application number	US-202217576455-A
Country	US
Kind code	B2
Filing date	Jan 14, 2022
Priority date	Mar 15, 2013
Publication date	Jul 2, 2024
Grant date	Jul 2, 2024

Abstract

Fibrous filter medium that includes a melt-blown filter layer comprising melt-blown fibers and a high-efficiency glass-containing filter layer comprising glass fibers.

First claim

What is claimed:

1. A filter medium comprising:
a melt-blown filter layer comprising melt-blown fibers;
a high-efficiency glass-containing filter layer comprising glass fibers and multi-component binder fibers and having a solidity of 5% to 20%; and
a support layer;
wherein at least one of the layers comprises a hydrophobic material.

2. The filter medium of claim 1 , wherein the hydrophobic material comprises a hydrophobic coating.

3. The filter medium of claim 2 , wherein the hydrophobic coating is on the high-efficiency glass-containing filter layer.

4. The filter medium of claim 1 , wherein the hydrophobic material comprises a polyolefin.

5. The filter medium of claim 1 , wherein the glass fibers have an average diameter of less than 2 μm.

6. The filter medium of claim 1 , wherein the glass-containing filter layer is positioned between the melt-blown filter layer and the support layer, and wherein the melt-blown filter layer is the upstream-most layer of the filter medium.

7. The filter medium of claim 1 , wherein the multi-component binder fibers of the glass-containing filter layer comprises bicomponent fibers having a low melting point polyester sheath and a higher melting point polyester core.

8. The filter medium of claim 1 , wherein the melt-blown filter layer is electrostatically charged.

9. The filter medium of claim 1 , wherein the support layer comprises a spunbond layer.

10. The filter medium of claim 1 , wherein the filter medium is watertight, as measured using the Water Spray Test.

11. The filter medium of claim 10 , wherein the filter medium displays a hydrostatic head of at least 10 inches (25.4 cm) of water.

12. The filter medium of claim 1 , wherein the filter medium exhibits a dust loading capacity of at least 30 grams per square foot (g/ft 2 ) of ASHRAE dust when loaded to 4 inches of water dP in static mode.

13. The filter medium of claim 1 , wherein the filter medium exhibits an efficiency of at least E10.

14. A filter element, wherein the filter element comprises a media pack comprising a filter medium, wherein the filter medium comprises:
a melt-blown filter layer comprising melt-blown fibers;
a high-efficiency glass-containing filter layer comprising glass fibers and multi-component binder fibers and having a solidity of 5% to 20%; and
a support layer;
wherein at least one of the layers comprises a hydrophobic material,
wherein the melt-blown filter layer is the most upstream layer and the glass-containing layer is positioned adjacent to the melt-blown layer, and
wherein the filter element comprises a cylindrical element comprising the media pack.

15. The filter element of claim 14 , wherein the cylindrical element is axially aligned with a second cylindrical element or wherein the cylindrical element is axially aligned with a partially conical element.

16. A method of preparing filter media, the method comprising:
preparing a glass-containing filter layer from a mixture of glass fibers and multi-component binder fibers using a wet-laid process, the glass-containing filter layer having a solidity of 5% to 20%;
laminating the glass-containing filter layer between a melt-blown filter layer comprising melt-blown fibers and a support layer.

17. The method of claim 16 further comprising rendering the glass-containing filter layer hydrophobic by plasma treatment or by applying a hydrophobic coating.

18. A method of filtering air, the method comprising directing the air through a filter medium comprising:
a melt-blown filter layer comprising melt-blown fibers;
a high-efficiency glass-containing filter layer comprising glass fibers and multi-component binder fibers and having a solidity of 5% to 20%; and
a support layer;
wherein at least one of the layers comprises a hydrophobic material.

19. The method of claim 18 , further comprising directing air to be filtered into a hood arrangement, and from the hood arrangement, directing the air into a louver arrangement.

Assignees

• Donaldson Co Inc

Inventors

• Gao Qiong
• Tronnes Gregory S
• Yadav Rakesh Kumar
• Madden Michael A

Classifications

• B01D46/521

  using folded, pleated material · CPC title

• B01D2239/065

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

• B01D2239/0428

  Rendering the filter material hydrophobic · CPC title

• B01D39/2024

  otherwise bonded, e.g. by resins · CPC title

• B01D2239/1233

  Fibre diameter · CPC title