Method of making a filter media with an enriched binder

Patent metadata

Field	Value
Publication number	US-9289702-B2
Application number	US-201314090142-A
Country	US
Kind code	B2
Filing date	Nov 26, 2013
Priority date	Feb 26, 2010
Publication date	Mar 22, 2016
Grant date	Mar 22, 2016

Abstract

Water filtration media having a charged material affixed directly to binder material used in the fabrication of the filter media. A microbiological interception enhancing agent is added to the binder directly. The media having a charged material and a microbiological interception enhancing agent both affixed directly on or in a binder material is then combined with core filter media and prepared as a filtration media. A filter is prepared from the treated filter media.

First claim

Thus, having described the invention, what is claimed is:

1. A method of making filter media comprising:
providing a charged material;
providing a binder material;
providing an anchoring agent solution for affixing the charged material directly to the binder material;
combining together the binder material and the anchoring agent solution thereby infusing said anchoring agent with said binder material to form a binder-anchoring agent combination;
heating the binder-anchoring agent combination to dry said binder-anchoring agent combination;
crushing the dried binder-anchoring agent combination to form a binder-anchoring agent powder;
mixing the binder-anchoring agent powder with the charged material;
heating the combined binder-anchoring agent powder and charged material in a second heating step to form a charged binder material, whereby during heating the binder melts to attach the charged material to the binder while the anchoring agent forms insoluble polyelectrolyte complexes with the charged material to enhance the attachment of the charged material to the binder thereby forming said charged binder material;
combining a core filter media with the charged binder material; and
forming a filter media with the combined core filter media and the charged binder material.

2. The method of claim 1 wherein the charged material is a cationic charged polymer.

3. The method of claim 1 wherein the charged material is selected from the group consisting of quaternized amines, quaternized amides, quaternary ammonium salts, quaternized imides, benzalkonium compounds, biguanides, cationic aminosilicon compounds, cationic cellulose derivatives, cationic starches, quaternized polyglycol amine condensates, quaternized collagen polypeptides, cationic chitin derivatives, cationic guar gum, colloids including cationic melamine-formaldehyde acid colloids, inorganic treated silica colloids, polyamide-epichlorohydrin resin, cationic acrylamides, polymers, and copolymers and combinations thereof.

4. The method of claim 1 wherein the charged material is a microbiological interception enhancing agent, said microbiological interception enhancing agent comprises an insoluble biologically active metal salt solution including biologically active metals.

5. The method of claim 1 wherein the charged material comprises a combination of a cationic material and a microbiological interception enhancing agent, such that before melting of the binder said cationic material and said microbiological interception enhancing agent are affixed directly on said binder through electrostatic forces.

6. The method of claim 5 further including the steps:
attaching the microbiological interception enhancing agent to the cationic material to form a microbiologically enhanced cationic material;
combining the microbiologically enhanced cationic material and binder-anchoring agent powder prior to the second heating step; and
in the second heating step, heating the microbiologically enhanced cationic material and binder-anchoring agent powder to form the charged binder material that is affixed to the binder material via the anchoring agent.

7. The method of claim 1 wherein the anchoring agent is polyacrylic acid (PAA).

8. The method of claim 1 wherein the combined charged material and binder-anchoring agent powder are heated to a temperature range of approximately 150° F. to 160° F. to affix the charged material directly to the binder material for forming the charged binder material.

9. The method of claim 8 wherein the anchoring agent is polyacrylic acid (PAA).

10. The method of claim 1 wherein the binder-anchoring agent powder includes both the binder material and the anchoring agent, and during the second heating step, the binder material melts to affix the charged material thereto by being embedded within the binder material while the anchoring agent forms the insoluble polyelectrolyte complexes with the charged material to increase the affixing of the embedded charged materials within the binder material.

11. The method of claim 1 wherein the binder-anchoring agent powder includes both the binder material and the anchoring agent, and during the second heating step, the binder material melts to affix the charged material thereto by being anchored to the binder material while the anchoring agent forms the insoluble polyelectrolyte complexes with the charged material to increase the anchoring of the charged materials to the binder material.

12. The method of claim 1 including:
for charged material in an aqueous solution, preparing said charged material in an amount approximately 1% to 35% by weight of said core filter media in approximately a 40% aqueous solution; or
for charged material in its pure state, preparing said charged material in an amount approximately 0.2% to 15% by weight of said core filter media.

13. The method of claim 12 including:
wherein said aqueous solution includes deionized (DI) water;
mixing and heating said charged material with said binder-anchoring agent powder to form said charged binder material; and
drying said charged binder.

14. The method of claim 13 wherein said charged material includes an insoluble microbiological interception enhancing agent comprising silver bromide.

15. A method of making filter media consisting essentially of:
providing a combination of a charged material, a binder material, and a poly acrylic acid (PAA) solution as an anchoring agent for affixing the charged material directly to the binder material;
mixing together the binder material and the PAA solution to infuse the anchoring agent with the binder material thereby forming a binder-anchoring agent combination;
drying said binder-anchoring agent combination;
providing an insoluble microbiological interception enhancing agent of silver bromide;
forming an enriched binder using said charged material, the dried binder-anchoring agent combination and the microbiological interception enhancing agent of silver bromide, whereby the anchoring agent affixes the charged material to the binder material by forming insoluble polyelectrolyte complexes with said charged material;
combining a core filter media with said enriched binder; and
forming a filter media with said core filter media and said enriched binder.

Assignees

• Kx Technologies Llc
• Kx Technologies Llc

Inventors

• Wang Jinwen
• Kareem Meedia A
• Lombardo Andrew W
• Brigano Frank A
• Kendrick Richard D

Classifications

• C04B14/304

  Magnesia · CPC title

• C04B14/04

  Silica-rich materials; Silicates · CPC title

• C04B14/022

  Carbon · CPC title

• B01D2239/086

  Binders between particles or fibres · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title