Air filter with sorbent particles

Patent metadata

Field	Value
Publication number	US-9539532-B2
Application number	US-201113520693-A
Country	US
Kind code	B2
Filing date	Jan 13, 2011
Priority date	Jan 18, 2010
Publication date	Jan 10, 2017
Grant date	Jan 10, 2017

Abstract

An air filter for use in a residential HVAC system includes filtration media including a base layer and a sorbent layer including adhesive fibers and sorbent particles.

First claim

What is claimed is:

1. An air filter for use in a residential HVAC system, comprising:
(a) filtration media having opposed first and second major surfaces and a perimeter edge region, the filter media including:
(i) a nonwoven base layer; and
(ii) a sorbent layer including adhesive fibers and from about 100 to about 500 g/m 2 of sorbent particles comprising granular activated carbon; wherein the adhesive fibers have a ratio of length to diameter of at least about 10,000 or more and are present in an amount of between about 2 wt % and about 20 wt %; and wherein the adhesive fibers bond and adhere to the sorbent particles and bond and adhere the sorbent layer to the nonwoven base layer; and

(b) a frame arranged around at least a portion of the perimeter edge region of the media.

2. A filter as defined in claim 1 , wherein the filtration media is pleated.

3. A filter as defined in claim 1 , wherein the sorbent layer has a basis weight of about 100 g/m 2 to about 625 g/m 2 .

4. A filter as defined in claim 2 , further comprising a support structure attached to at least one of the first and second major surfaces.

5. A filter as defined in claim 4 , wherein the support structure is a wire mesh.

6. A filter as defined in claim 5 , wherein the wire mesh is planar.

7. A filter as defined in claim 5 , wherein the wire mesh follows a contour of the pleated filtration media.

8. A filter as defined in claim 1 , wherein the nonwoven base layer includes a first plurality of fibers of a first size and a second plurality of fibers of a second size, and further wherein the first size is at least 25% larger than the second size.

9. A filter as defined in claim 1 , wherein the nonwoven base layer comprises electrostatically charged fibers.

10. A filter as defined in claim 9 , wherein the nonwoven base layer has a basis weight of about 20 g/m 2 to about 150 g/m 2 .

11. A filter as defined in claim 1 , wherein the filter has a media butane removal capacity of at least about 0.2 g/m 2 when measured according to the test method described in the specification.

12. The air filter of claim 1 , comprising:
(i) a thickness of no greater than about 1.5 inches,
(ii) an initial pressure drop of no greater than about 0.32 inches of water pressure as measured according to ASHRAE 52.2-2007 at a face velocity of 1.5 meters per second, and
(iii) an initial E1 particle removal efficiency as measured according to ASHRAE 52.2-2007 of at least about 10%.

13. An air filter as defined in claim 12 , having a media butane removal capacity of at least about 0.2 g/m 2 when measured according to the test method described in the specification.

14. An air filter as defined in claim 1 , wherein the adhesive fibers are meltblown.

15. An air filter as defined in claim 1 , wherein the adhesive fibers have greater elasticity than polypropylene fibers having the same caliper.

16. An air filter as defined in claim 1 , wherein the adhesive fibers comprise polyolefin copolymers.

Assignees

• Fox Andrew R
• Lise Jonathan M
• 3M Innovative Properties Co

Inventors

• Fox Andrew R
• Lise Jonathan M

Classifications

• B01J20/28011

  Other properties, e.g. density, crush strength · CPC title

• B01J20/20

  comprising free carbon; comprising carbon obtained by carbonising processes · CPC title

• B01D2239/0435

  Electret · CPC title

• B01D46/0036

  by adsorption or absorption · CPC title

• B01J20/10

  comprising silica or silicate · CPC title