Filtration materials using fiber blends that contain strategically shaped fibers and/or charge control agents

Patent metadata

Field	Value
Publication number	US-9618220-B2
Application number	US-201414582287-A
Country	US
Kind code	B2
Filing date	Dec 24, 2014
Priority date	Oct 25, 2010
Publication date	Apr 11, 2017
Grant date	Apr 11, 2017

Abstract

A filtration material comprising a blend of polypropylene and acrylic fibers of round, flat, dog bone, oval or kidney bean shape in any size from 0.08 to 3.3 Dtex. A preferred blend contains about 50 weight percent polypropylene fibers and about 50 weight percent acrylic fibers. The fibers can be blended ranging from 90:10 to 10:90 polypropylene to acrylic. The shape contains 25 weight percent round, flat, oval, dog bone and kidney bean shapes. The fiber blend contains 25 weight percent of at least one size between 0.08 and 3.3 Dtex. Electret fibers incorporated within these blends have 0.02 to 33 weight percent of a charge control agent. These fibers can be used in producing electret material by corona or triboelectric charging methods.

First claim

The invention claimed is:

1. A method of making a non-woven electret gas filter media, the method comprising:
(a) dry spinning a plurality of acrylic fibers;
(b) three dimensionally crimping the fibers; and
(c) forming a non-woven electret gas filter media from the fibers.

2. The method in accordance with claim 1 , further comprising the step of blending at least some polypropylene fibers with the acrylic fibers.

3. The method in accordance with claim 1 , further comprising the step of blending at least some dog bone shaped polypropylene fibers with the acrylic fibers.

4. A method of making a non-woven electret gas filter media, the method comprising:
(a) dry spinning a plurality of acrylic fibers;
(b) three dimensionally crimping the dry spun acrylic fibers;
(c) wet spinning a plurality of acrylic fibers; and
(d) forming a non-woven electret gas filter media from a combination of the three dimensionally crimped dry spun acrylic fibers and the wet spun acrylic fibers.

5. The method in accordance with claim 4 , further comprising the step of blending at least some polypropylene fibers with the acrylic fibers.

6. The method in accordance with claim 4 , further comprising the step of blending at least some dog bone shaped polypropylene fibers with the acrylic fibers.

Assignees

• Chapman Rick L
• Delstar Tech Inc

Inventors

• Chapman Rick L

Classifications

• D04H3/018 Primary

  characterised by the shape · CPC title

• D01F6/38

  comprising unsaturated nitriles as the major constituent · CPC title

• D01D5/06

  Wet spinning methods {(D01D5/0046 takes precedence)} · CPC title

• B01D46/0032

  using electrostatic forces to remove particles, e.g. electret filters · CPC title

• D06M13/00

  Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds (D06M10/00, D06M14/00 take precedence; treatment with complexes of organic amines with inorganic substances D06M11/59); Such treatment combined with mechanical treatment · CPC title