CN1608155A - Three-dimensional non-woven media, filter and process - Google Patents
Three-dimensional non-woven media, filter and process Download PDFInfo
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- CN1608155A CN1608155A CN 02825973 CN02825973A CN1608155A CN 1608155 A CN1608155 A CN 1608155A CN 02825973 CN02825973 CN 02825973 CN 02825973 A CN02825973 A CN 02825973A CN 1608155 A CN1608155 A CN 1608155A
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Abstract
A non-woven melt-blown filament medium which can be used in the construction of a depth filter cartridge includes a mass of melt-blown polymer filaments and a traversing melt-blown polymer filament extending through the mass. The mass includes a plurality of layers, each of the plurality of layers being generally oriented in the longitudinal and latitudinal dimensions. The traversing filament is generally oriented in the depth dimension and extends through at least one layer of the mass. A method of producing a melt-blown polymer filament medium includes producing a first set of melt-blown polymeric filaments, collecting the first set of filaments on a rotating collection device to form a tubular filament mass having a plurality of layers, and applying a second set of melt-blown polymeric filaments to the filament mass.
Description
Technical field
The present invention relates generally to the melt blown media field, particularly relate to density and reduce the medium that keeps structural strength simultaneously.This medium is favourable is applied to many aspects, comprises low-density and high-voidage volume at the material property of this expectation, particularly keeps the relative stiffness structure simultaneously under pressure.The purposes of this medium comprises various application examples such as micro particle filtering, the filter medium that the coalescent and white blood cell of oil filters.The purposes of other anticipation comprises insulation, the wicking medium of impact absorption protection and submissive material and evaporimeter.
Background technology
Current, there be many equipment and the processing method that is used to form the melt blown media that comprises a plurality of continuous yarn basically in the prior art.In this field, for example at the United States Patent (USP) 3825379 of authorizing people such as Lohkamp with authorize in people's such as Harding the United States Patent (USP) 3825380 and described fibre forming device or fiberizer, this fibre forming device or fiberizer are used for spraying to gathering-device the filament of synthetic resin material.In this process, the jet action of air or other gas is thin diameter so that this filament is weakened, and is transported to gathering-device on filament.Fiber increases continuously on gathering-device, up to a large amount of fibers that obtain desired size and form.
Develop from this universal and a plurality of particular process methods.In these processing methods one of them described in the United States Patent (USP) 3849241 of authorizing people such as Buntin.It discloses a kind of processing mould or fiberizer, and this processing mould or fiberizer are formed by comprising the die head that is used for filament material and subtracts the independently passage of thin air.During operation, molten resin material is forced through one or more apertures or the spinnerets guiding gathering-device in the die head, and the air flow that is positioned on the side of material outlet hole subtracts carefully.The collecting method that this technology is used comprises rotary drum, to form continuous pad.Another kind of such technology is described in authorizing No. 4021281 United States Patent (USP)s of Pall.It has been described and formed the melt blown media paper web continuously on rotary drum, and with tubulose paper web form deposition, this tubulose paper web can be cut into flat media.Another kind of technology is in No. 4240864 United States Patent (USP) illustrated of authorizing people such as Lin.This patent disclosure a kind of processing mould or nozzle block, it to the rotation gathering-device carry a plurality of filaments.Relevant with filament is to subtract thin air flow, and its effect is to subtract carefully when filament makes filament when gathering-device moves.People such as Lin also disclose a kind of pressure roller, and this pressure roller is used to change the pressure that puts on the fiber of building up on the live spindle, so that the filter that changes fibre density to be provided.Identical with the technology of people such as Buntin and Pall, the diameter of the individual filament in people's such as Lin technology passes through whole media unchangeably.Yet, opposite with people such as Buntin and Pall, in people's such as Lin technology, the medium of generation is subjected to continuously to drive by non-cylinder pressure roller and leaves live spindle, to make centreless depth filter element (or depth-type filtration device).
Another kind of special technology is by No. 4594202 and No. 4726901 United States Patent (USP) exemplary illustration of authorizing people such as Pall.Similar with above-mentioned technology, the technology of Pall comprises fiberizer or the fiberizer mould with a plurality of independent spinneretss, and fusion filament resin is forced through this spinnerets guiding and collects axle.Also similar with above-mentioned other technology, this technology disclose when filament to collecting axle when moving, subtract carefully in order to make filament, and use air or gas to flow.Yet this technology is different with above-mentioned technology, because it discloses a kind of fibre diameter that is used to change on the radial dimension of whole filter element, all keeps the device of the voidage of substantial constant simultaneously for the variation in fiber diameter of every kind of degree.This can be by sequentially changing some parameters so that during collecting filament on the live spindle, influence the diameter of fiber, thereby by people's such as Pall technology realization.
Although each above-mentioned special process is fit to some application usually, this each technology also has some restrictions.For example, a kind of restriction of people such as Pall (4594202 and 4726901) technology is that it is discontinuous or half-continuous process.In other words, subtract the filter element that thin filament forms finite length by on live spindle, piling up to form.When the filament material of collecting reached the thickness of expectation, filtration device structure was removed, and restarts at the technology of next filter element.
Although people's such as Pall patent (4594202 and 4726901) has considered to comprise the depth filter element of the filament that diameter changes, still there are a plurality of restrictions.At first, people's such as Pall technology is not a continuous technology, but it must repeat at the filter of each manufacturing.The second, although the filament that some filter elements of people such as Pall have vary in diameter, there is restriction in the technology of making this filter core.Particularly, change in a plurality of operating conditions of filament maker one of them, change filament diameter by order.Yet, no matter when introducing this change, system takes time and responded this change before reaching balance again.The time limit of response and the degree of change are proportional.Owing to during making each independent filter element, introduce this change, cause technology stability lower, variability increases.And the transformation from a kind of filament of diameter to the filament of another kind of diameter takes place gradually with the transformation form relevant with the time, rather than takes place suddenly, and for example its structure comprises the filament of two or more separation.
The critical nature of dielectric structure is a voidage percentage, i.e. the ratio of the volume of air in the structure and total media structural volume.Voidage percentage in the melt blown media should be high as far as possible, so that obtain many desired characteristics, for example high dirt capacity and low initial drop in filtration application.Usually, obtaining high gap volume causes the density of medium group to reduce.Also expectation is the density that reduces medium group, because low-density medium requires low material utilization rate, and allows material cost to reduce, and output improves, and makes and accelerates.
Another advantage with medium of high gap volume is that they are submissive, so that insert the active particle or the fiber of larger volume percentage, can not produce unacceptable pressure drop simultaneously in filtration application increases.For example, when active carbon particle formed, they can be dispersed in the medium.And, have high gap volume and low-density group also shows advantage usually in other purposes, heat insulation for example, evaporation wicking and impact absorbing material.
Yet, in the melt blown media of prior art, there is a upper limit, surpass this upper limit, the further increase of voidage percentage becomes undesirable.Utilize the instruction of prior art, attempt to make low-density, the dielectric structure of high gap volume can cause fiber to combine reduction with interfibrous, and typical inadequate structural strength.When voidage in prior art constructions increased, the pressure drop that the easier fluid of being flowed through it of the fiber medium that uses in the deep filter produces was compressed.When fluid had viscosity, this bothered especially.If voidage percentage is too high, under too low differential pressure, filter medium begins to subside.When it subsided, the hole diminished, and differential pressure increases, thereby causes further compression.Like this, increasing sharply of final pressure drop reduces rather than prolonged the service life of medium and the capacity of dirt, and for the voidage medium that increases, this may expect.Use extra-low density (high gap volume) also can make filter very soft, therefore, be easy to when normal process underminedly, more may in use compress and subside.
The defective of prior art products is that the low-density filter often utilizes the fine fibre manufacturing, therefore, has tiny micron rating, and this is intrinsic for fine fibre matrix.Use fine fibre to obtain low-density, keep capacity to have the medium of gap structure greatly with manufacturing simultaneously, this expects.For filtration application, this means thicker micron rating, thereby allow to filter the particle of relative broad range, and can not stop up in early days by filter.This requires the fine fibre network to be fixed in some way in the more open structure, thereby avoids the trend of fine fibre natural packaging, and this can form thinner gap structure inherently.
Although prior art exist to be made the method for melt blown media, every kind of method and the restriction that under low Media density, has compression strength by the product of this method manufacturing.Therefore, the melt blown media that needs a kind of improved cost savings in this area.Also need a kind of continuous method and apparatus of making this medium.
Summary of the invention
A kind of leptonema that melts and sprays comprises continuous basically meltblown polymer leptonema and is horizontally through the continuous basically meltblown polymer filament that this group stretches.This group has depth dimensions (or dimension), longitudinal size (or dimension) and latitude size (or dimension).This group comprises a plurality of layers, and every layer in a plurality of layers is oriented in vertically and the latitude size usually.Cross filament and be oriented in depth dimensions usually, and one or more layers stretching, extension of this group of process.In one embodiment, this group is tubular (or column), and each layer comprises concentric regions.In one embodiment, the core area of this group has a kind of filament of diameter; The central region of this group has the diameter bigger than the filament of core area; The perimeter of this group has the diameter bigger than the filament of central region.In one embodiment, crossing fiber is one or more layers binding fiber that combines that will roll into a ball.
Dark filter fly filter cylinder (or deep filter tube) comprises continuous basically meltblown polymer leptonema and is horizontally through the continuous basically meltblown polymer filament that this group stretches.This group has depth dimensions, longitudinal size and latitude size.This group comprises a plurality of layers, and every layer in a plurality of layers is oriented in vertically and the latitude size usually.Cross filament and be oriented in depth dimensions usually, and one or more layers stretching, extension of process group.In one embodiment, this group is tubular, and each layer comprises concentric regions.In one embodiment, the core area of this group has the filament that has a kind of diameter; The central region of this group has the diameter bigger than the filament of core area; The perimeter of this group has the diameter bigger than the filament of central region.In one embodiment, crossing fiber is one or more layers binding fiber that combines that will roll into a ball.
A kind of method of continuous manufacturing meltblown polymer leptonema comprises: make first group of meltblown polymer filament, on gathering-device, collect first group of polymer filaments, have a plurality of layers tubulose leptonema with formation, and on this leptonema, apply second group of meltblown polymer filament.First group usually along the online manufacturing of axis that generally is parallel to gathering-device.Second group is deposited on the leptonema, so that second group of filament is through one or more layers stretching, extension of first group of filament and engage.This method comprises that also to form the tubulose leptonema of indefinite length, it has first first type surface and second first type surface along gathering-device promotion leptonema.In one embodiment, second group of curved motion applies.
Description of drawings
Fig. 1 is the schematic diagram that overall expression is used for making continuously the system of non-woven depth filter element;
Fig. 2 represents to be used for to make continuously the schematic diagram of system's structure of depth filter element of the present invention;
Fig. 2 A is the zoomed-in view of gathering-device of the equipment of Fig. 2;
Fig. 3 is the look elevation view of depth filter element of the present invention of the line 3-3 from Fig. 2 A;
Fig. 4 is the schematic diagram of second embodiment of the ordinary representation system that is used for making continuously non-woven depth filter element;
The schematic diagram of system's structure of the embodiment of Fig. 5 presentation graphs 4; And
Fig. 6 represents the look elevation view of second embodiment of depth filter element of the present invention from the line 6-6 of Fig. 5.
The specific embodiment
Melt blown media of the present invention with improved structural strength can be used for comprising the cartridge filter of progressive forming in the multi-form melt blown media, the paper web of progressive forming, and compound paper web of structure and pre-impregnated fiber are strengthened pad.Melt blown media of the present invention comprises continuous basically polymer filaments group.This medium has length or longitudinal size, width or latitude size, and depth dimensions.The main filament of melt blown media be oriented in usually length (x to or vertically) and width (y to the latitude direction or be circumferencial direction under tubular group situation) dimension.Improved characteristics of the present invention are that this medium also is included in the continuous basically polymer filaments of the degree of depth (z) dimension.Allow to be designed to be shaped simultaneously, and carry out engineering design in the medium specific region for application-specific demand at the main fiber of x and y dimension with at the independently binding fiber of z dimension.The present invention also comprises the method for continuous manufacturing melt blown media.
An important embodiment of melt blown media comprises the tubular group of continuous basically polymer filaments.Tubular group has vertically or the x dimension, circumference or y dimension and radially or the z dimension.The main filament of tubular group is oriented in vertically and circumferential size or x and y dimension usually.Leptonema also is included in radially or the z dimension spreads all over the continuous basically polymer filaments that tubular group stretches.These melt blown media are specially adapted to make leptonema, for use in the structure depth filter element.For example in a kind of tubular filter, medium of the present invention allows to form the self-supporting core area, thereby critical filtration zone is provided simultaneously.If compare with being evenly distributed in the whole medium of same amount in conjunction with filament, by in core area and adjacent core zone, be provided with higher percent in conjunction with filament, filter is designed and manufactured into has higher compressive resistance and than low-density.The present invention also comprises the method for continuous manufacturing leptonema.
Of the present inventionly a kind ofly confirm that useful purposes is a particle filtration, especially for the dark filter fly filter cylinder that comprises the filter element that is made of a plurality of continuous basically filaments, filament is collected to form the dark filter fly filter cylinder of common tubulose.The invention still further relates to the method and system of making this filter cylinder.
In order to obtain low-density and the comprehensive benefit that rigidly fixes the uniqueness of dielectric structure, need lay the melt blown media that two or more form simultaneously.Very thin matrix with the main fiber that has reduced fiber and fiber combining is used to form low density structures.Second-source filament when initial medium is shaped simultaneously and be arranged in wittingly on the initial medium z dimension, so that improved fiber and fiber combining to be provided, and the interlocking of mechanical structure.Therefore, these z filaments form more rigid porous structures, and this structure has the mechanical strength that enlarges markedly.Initial medium typically forms two-dimensional layer basically, and its fiber alignment has only subsidiary combination between layer on x axle and y axle.Have been found that z filament arrangements with combination in the shaping layer of initial medium fiber, and the initial medium layer that runs through two or more formation is favourable, these are oriented in the z axle in conjunction with the z filament basically with respect to initial medium.This allows the very thin melt blown media of simultaneously continuous manufacturing relative stiffness, locks in place on the fibre structure wherein.
Have been found that the z filament that runs through initial medium insertion combination when initial medium is shaped is favourable, the z filament of combination runs through one or more zones stretching, extension of initial medium like this.Also finding to run through in conjunction with the z filament each layer stretching, extension of initial medium, is favourable thereby traverse into another first type surface from a first type surface of final initial medium.In a described embodiment of the present invention, the z filament has the low-density initial medium of improved compression as in conjunction with filament with manufacturing.Can imagine that one or more layers the z filament that inserts combination that runs through initial medium when initial medium is shaped can be used to make the medium with other remarkable advantage.For example, the z polymer can have significantly different physics or chemical characteristics, and this complex media that can cause making improves significantly.The layout of these z filaments of engineering design, the ability of compound and physical attribute and offer an opportunity the probing medium structure of great use, and this is impossible in the prior art.
Another aspect of the present invention is the binding fiber that adopts a thin layer on one or two surface of shaping medium, so that the porous surface that processes to be provided.Binding fiber adheres on the initial medium fiber from the teeth outwards, thereby eliminates the loose fiber on the dielectric surface.Another remarkable advantage of finding is that binding fiber adheres on the initial surface fiber, and consistent with the structure on surface.Then, binding fiber shrinks when cooling, and this has strengthened the roughness that generates the surface.The surface area of the finished surface that wonderful discovery generates is about twice of the surface area on undressed initial medium surface.The surface area that increases brings many benefits, is specially adapted to particle filtration and uses.The double surface area of shell allows shell to have lower voidage, can not cause excessive pressure drop simultaneously.And when using filter, a cake of particles is collected on the case surface, also causes pressure drop to increase.High surface area allows causing prolonging operation before this pressure drop increase.And, in filter cylinder embodiment, form harder shell and avoided after making filter cylinder necessity of enclosed filters in support cages.
A preferred embodiment of the present invention is a kind of improved non-woven leptonema that is used to construct depth filter element, and the system and method for this group of a kind of continuous manufacturing.Yet, will be understood that also and can implement other embodiment.For example, although described a kind of tubular products in a preferred embodiment, instruction of the present invention is fit to flat, sheet, or planar products.For example can be by on big drum, making medium, the tubular medium that generates along its length cutting to obtain sheet material, is made this flat product then.
Fig. 1 ordinary representation be used for making continuously indefinite length leptonema an embodiment of system.Then, the individual filament element of a plurality of desired length can be cut in group.Similarly system is open in No. 5340479 United States Patent (USP)s authorizing people such as Szczepanski, and the full content of this patent proposes as a reference at this.The illustrated embodiment of system 10 comprises that motor drives screw type extruder 12, and it has the thermo-plastic polymeric material from a source (not shown).Special thermo-plastic polymeric material can be any of various synthetic resin materials that can make the filament that is used for making depth filter element of the present invention.Although the polypropylene as known polymeric material kind is preferred, can also use polyester, nylon, polyurethane and other material.
In extruder 12, polymeric material is heated to molten condition, and at this moment, it is in measuring and be transported to heating feed-line 14.Material keeps in pipeline 14 or further heating, and finally guides to the filament building mortion, and in one embodiment, it becomes the form of two filament induction systems 16 and 18.Each feed- line 16 and 18 is made one or more continuous basically polymer filaments, and guides this filament along predefined paths to a gathering-device, and this will be discussed in more detail below.
The heater block 22 that independently heats by the heater (not shown) is provided with the inner passage, this inner passage lead a plurality of nozzles 27,28 and 29.The temperature of the polymeric material in heater and the heater block 22 is by temperature controller 30 controls.Each nozzle 27,28 and 29 comprises an aperture, and the size in aperture can be selected as required, to help to obtain the filament size or the diameter of expectation.The melted material Cheng Liuzhuan that is fed into each nozzle 27,28 and 29 leaves corresponding aperture.
Relevant with 29 with each nozzle 27,28 is subtract thin mechanism 31,32 and 33 this subtract thin mechanism and comprise a plurality of gas nozzles or air nozzle.The function that outflow subtracts the gas of thin mechanism 31,32 and 33 is to make the melted material stream of mass flowing nozzle 27,28 and 29 to subtract carefully, to form the polymer filaments of form known in this field.Therefore, subtracting thin mechanism 31,32 and 33 can be any design well known in the art, and it is described in authorizing No. 4173443 United States Patent (USP)s of Lin, and disclosed this patent proposes as a reference at this.
Subtracting thin mechanism 31 is associated with selectable gas heater 34 and air supply source 36.Air supply source 36 by pipeline 38 and suitable valve and adjuster to heater 34 air feed.By temperature controller 40, the temperature of heater 34 raises or is reduced to desired temperatures.Then, gas is fed into through piping 42 from heater 34 and subtracts thin mechanism 31.Subtract thin mechanism 31,32 and 33 and can comprise from for example with reference to the gas of the described common air supply source of figure 1, perhaps alternatively, the gas source of independent control can be used for each and subtracts thin mechanism 31,32 and 33.
Except filament induction system 18 preferably includes a kind of device, this device with system 16 in the filament of one or more nozzle manufacturings of the using mode of actively mixing carry outside the filament, filament induction system 18 is similar with said system 16 basically.Filament induction system 18 can comprise one or more polymer spinning heads.An embodiment adopts a nozzle 44, this nozzle 44 comprise subtract thin device 54 (as Fig. 2 shown in the back) sweep swinging mechanism.Particularly, system 18 comprises heater block 46, the positive-displacement metering pump 48 of drive and motor 50.Heater block 46 is provided with nozzle 44 and temperature controller 52.System 18 also is provided with the thin mechanism 54 that subtracts that is associated with nozzle 44.Compressed Gas leads to by pipeline 58 from air supply source 56 and subtracts thin mechanism 54.As for induction system 16, each in the system 18 subtracts thin device and is associated with unshowned optional gas heater.The independently filament induction system 16 and 18 that provides is controlled separately, and makes polymer filaments by each system 16 and 18.
During operation, continuous basically polymer filaments flows 66,68 and 70 flue figures guiding live spindle 76, and collects thereon in mode well known in the art.Although axle 76 has illustrated, expectation also can be used other gathering-device, for example the major diameter drum.Simultaneously, back and forth or swing stream 72 be deposited as continuous basically filament or fibre stream, this filament or fibre stream stride across the distal edge 82 of stream 66 and flow distance between 70 the distal edge 84, and cross each layer of filament, each of filament layer laid by flowing 66,68 and 70.Rotation pressure roller 80 engages with filament on accumulating in live spindle 76.When enough filaments were deposited on the axle on 76, pressure roller 80 forced non-woven leptonemas or fibre structure 86 to leave the axial end portion of axle 76 on the direction of arrow 88, so that make the continuous leptonema 86 of indefinite length.Leptonema 86 has radial dimension, longitudinal size, and circumferential size.Whole filament gathering-device 74 can be described similar with No. 4240864 United States Patent (USP)s authorizing Lin, and the full content of this patent proposes as a reference at this.
For the more complete the present invention that understands, referring to Fig. 2, Fig. 2 is the schematic diagram of equipment shown in Figure 1.This equipment is configured to make continuously depth filter element of the present invention.As shown in Figure 2, adopt four filament manufacturing installations, each device comprises that a nozzle and one subtract thin mechanism, and for example nozzle 27,28,29 and 44 and subtract thin mechanism 31,32,33 and 54. Nozzle 27,28 and 29 vertically aligns along common axis 90, and this common axis 90 preferably departs from about 0-15 degree from being parallel to axle 76.In a preferred embodiment, nozzle 27,28 and 29 is positioned to separate about 4 inches.Each nozzle 27,28 and 29 comprises the aperture that defines an axis 92,94 and 96 respectively, promptly preferably perpendicular to axis 90, and from depart from about 0-15 degree perpendicular to axle 76.Axis 93,94 and 96 is usually corresponding to the molten polymer fluid axis that leaves the respective nozzles opening.In a preferred embodiment, nozzle 27,28 and 29 is positioned at apart from axle 76 about 35-40 inches, preferably rotates with the speed of about 400RPM.Should be towards the tubaeform filament figure 66,68 and 70 of the axle 76 that causes leading.
Filament figure (or pattern) 66,68 and 70 comprises the diameter polymeric filament that has less than between about 1 micron to about 100 microns.In a preferred embodiment, filament figure 66 comprises the filament of minimum diameter; Filament figure 68 comprises the filament of mid diameter; Comprise the filament of maximum gauge with filament figure 70.As a non-limiting instance, be about 0.016 inch nozzle with per hour about 11 pounds speed extruded polypropylene by in deep filter, passing a hole dimension, this polypropylene is heated to the temperature between about 325 ℃ to about 400 ℃, simultaneously, the molten polymer flow of leaving spout is in the about 25 ℃ of speed process ambient atmosphere with about 13 standard cubic foots of per minute of temperature, like this, make the polymer filaments of filament figure 66,68 and 70.Be appreciated that those of ordinary skill in the art is easy to determine other suitable parameter combinations.Will be appreciated that operating parameter can change between filament figure 66,68 and 70, to make the zone of different densities and fiber size.
Relative filament figure 66,68 and 70, nozzle 44 and subtract thin mechanism 54 and make filament figures 72.Shown in Fig. 2 A the best, filament figure 72 is included in the figure 72A that moves in the back and forth horizontal figure, preferably covers the distance between initial graphics edge 82 and 84.As an alternative, filament figure 72 covers less than the distance between edge 82 and 84.Filament figure 72 preferably from be positioned on the pressure roller 80 or under one or more nozzles 44 of position so that figure 72 moves to axle from nozzle 44, and need not to be directly injected on the pressure roller 80 and be positioned on the leptonema 86 of shaping.
Subtract thin mechanism 54 and preferably include servo-drive and sweep swinging mechanism 98 (see figure 2)s, it allows to subtract thin mechanism 54 and sweeps angle of pendulum, so that filament figure 72A (seeing Fig. 2 A) is traversing back and forth fiber figure 66,68 and 70 along the longitudinal size of leptonema 86.When figure 72A across-the-grain figure 66,68 and 70 o'clock, it was deposited as continuous basically polymer filaments across whole deposition pattern, and stretched between initial graphics edge 82 and 84.In the leptonema 86 that forms, the fiber of the filament figure 66 of 82 depositions forms first first type surface 97 (shown in Figure 3) along the edge, and the fiber of the filament figure 70 of 84 depositions will form second first type surface 99 (shown in Figure 3) along the edge.In another embodiment, but nozzle 44 reciprocally swingings, so that sweep the filament figure 72 of pendulum combination.
In preferred embodiment shown in Figure 2, to sweep swinging mechanism 98 and comprise servo drive motor, it has cam-and-follower.Other proper device, for example AC/DC driving mechanism crank and transfer bar mechanism, for example, this also is acceptable.In a preferred embodiment, sweep the frequency operation of swinging mechanism 98 with about 950 swings of per minute.As shown, the thin mechanism 54 that subtracts of nozzle 44 is orientated the manufacturing air-flow, and this causes tubaeform filament figure 72 guiding axles 76.
In a preferred embodiment, nozzle 44 is positioned at apart from axle 76 about 18-22 inches.Because nozzle 44 is positioned at than nozzle 27,28 and 29 more close axles 76, the fiber of filament figure 72 with have little time before leptonema 86 contact and cool off, therefore hotter, and have more viscosity than the fiber of filament figure 66,68 and 70.Best, the fiber of filament figure 72 when with filament figure 66,68 one-tenth liquid relatively when 70 fiber contact.Because skin or shell not have to form on the fiber of filament figure 72 fully, its fiber of moment and filament figure 66,68 and 70 when contacting is bonding.Yet, require the pars fibrosa of filament figure 72 to subtract thin or cooling, melt with the fiber of avoiding filament figure 66,68 and 70.
In an alternate embodiment, surpass nozzle 44 be positioned to than nozzle 27,28 and 29 more close axles 76, subtract thin mechanism 54 shells use than subtract thin mechanism 31,32 and 33 still less air or hotter air.The fiber that this layout also causes filament figure 72 is warmmer and have more viscosity than the fiber of filament figure 66,68 and 70.The technology that other substitutes well known in the art can be used to transmit the fiber of filament figure 72.For example, can imagine that the fiber of filament figure 72 is colder than the fiber of filament figure 66,68 and 70, so that the thermal of bringing mechanical advantage rather than being instructed in the above-described embodiments.
Filament figure 72 comprises the diameter polymeric filament that has less than between about 1 micron to about 100 microns.As a non-limiting instance, be about 0.016 inch nozzle with per hour about 8 pounds speed extruded polypropylene by in deep filter of the present invention, passing a hole dimension, this polypropylene is heated to the temperature between about 325 ℃ to about 400 ℃, simultaneously, the molten polymer flow of leaving spout is in the about 25 ℃ of speed process ambient atmosphere with about 7 standard cubic foots of per minute of temperature, like this, make the polymer filaments of filament figure 72.Be appreciated that those of ordinary skill in the art is easy to determine other suitable parameter combinations.
Shown in Fig. 2 A was more complete, Fig. 2 A was the zoomed-in view of the gathering-device of Fig. 2, made the leptonema 86 that gathers on axle 76.Filament figure 72 comprises reciprocal tapered filament figure 72A, and this figure 72A sweeps pendulum between pattern edge 82 and 84, to make overall wideer taper figure 72.In a preferred embodiment, pressure roller 80 is directed at an angle with respect to axle 76, and roller edge 100 contacts with axle 76.As the example of an indefiniteness, the outer surface 102 of pressure roller 80 moves about 3 ° angulately with respect to axle 76.In one embodiment, 100 contacts of roller edge are near the axle 76 at the edge 82 of filament figure 66.Because being in tilted layout of pressure roller 80, the compression of the filament in collecting leptonema 86 is along the length variations of pressure roller 80.This causes having at the radial dimension leptonema density gradient of change, and greater than the filament density of leptonema, this leptonema comprises filament figure 68 and 70 to the filament density of filament figure 66 usually.
Usually form the two dimension pad or the layer of material from the fiber of filament figure 66,68 and 70, the two dimension pad of this material or layer progressive forming on axle 76 are to produce by the fibrous leptonema 86 of many layers.These fibers are described as and are laid in the X-Y plane, or vertically and circumference or latitude size.When forming fiber, be placed on the layer, they make radially or depth dimensions.Filament figure 72A sweeps pendular motion, combines with the rotation of axle 76, causes fiber to leave nozzle 44 and group 86 and forms wholely, and constitutes " z " direction fiber, and its is through filament figure 66,68 and the 70 regional circumferentially extendings that constitute.
Fig. 3 represents the look elevation view of leptonema 86 from the line 3-3 of Fig. 2 A.Leptonema 86 comprises first first type surface, 97, the second first type surfaces 99 and concentric filtration zone 104,106 and 108, and filament 110 is radially providing additional leptonema intensity.Filament 110 is as the fibre structure reinforcing element.Filament 110 stretches through whole leptonema 86, and radially, vertically and circumferential size stretch.
Usually, filament zone 104 is made by filament figure 66; Filament zone 106 is made by filament figure 68; Filament zone 108 is made by filament figure 70; Filament zone 110 is made by filament figure 72.Filament zone 104,106 preferably presents different physical characteristics with 108.For example, filtration zone 104 can comprise the filament than minor diameter; Filtration zone 106 can comprise the filament of mid diameter; Filtration zone 108 can comprise larger-diameter filament.Filament zone 104,106 and 108 preferably have the diameter dimension scope from less than about 1 micron to about 100 microns filament.Filament 110 and 172 can have and equals, and is greater than or less than the diameter of average diameter of the filament of filtration zone 104,106 and 108.In certain embodiments, filtration zone 104 can have the filament of higher density; Filtration zone 106 can have the filament of intermediate density, and filtration zone 108 can have more low-density filament.In another embodiment, filtration zone 104,106 and 108 density can have other variation.
In one embodiment, lacking fiber usually in each group 104,106 and 108 combines with interfibrous.By " z " combination between fiber 110 and zone of fiber 104,106 and 108, realize the initial combination in the leptonema 86.It is very big that rigidity is made in the selected zone of medium, so that the filter course of the mechanical load that also carrying generates to be provided, thereby eliminates in given filter for installation demand to independent structural detail.
For an embodiment, Fig. 3 represents " z " fiber approximate towards, during the once rotation (shown in Fig. 2 A) of axle 76, lay " z " fiber.In this embodiment, sweep in the servo-drive of " z " fiber between the speed of rotation of the rate travel of pendulum and axle 76 relation like " z " fiber 110 is arranged from core area or bottom section 104 to shell or top area 108 in a continuous manner, and during the group of formation 86, during rotation about 120 is spent or is following, the core area 104 of the group of turning back to 86.The path of " z " fiber 110 in the once rotation of axle 76 is described below.When filament figure 72A when the pattern edge 82, " z " fiber 110 is arranged on the leptonema 86 near the core of core area 104.72A sweeps pendulum to pattern edge 84 when the filament figure, and " z " fiber 110 crosses zone 104,106 and 108 to be arranged, arrives 108 outsides, shell zone up to it.Axle 76 rotations, filament figure 72A sweeps pendulum simultaneously, and therefore, " z " fiber 110 also moves around filter group 86 at circumferencial direction.Like this, " z " fiber 110 radially, vertically and circumference through 86 operations of filter group.Under group's 86 situations for the plane on-circular, length, width and thickness dimension stretching, extension that " z " fiber 110 can the group of being described as be at 86.
In one embodiment, the fiber in zone 104,106 and 108 comprises about 75-95% of the fiber of filter group 86, and " z " fiber 110 comprises about 5-25% of the fiber of filter group 86; Be more preferably, the fiber in zone 104,106 and 108 comprises about 80-90% of the fiber of filter group 86, and " z " fiber 110 comprises about 10-20% of the fiber of filter group 86; Best, zone 104,106 and 108 fiber comprises fiber about 85% of filter group 86, " z " fiber 110 comprise filter group 86 fiber about 15%.In a preferred embodiment, sweep swinging mechanism 98 and can regulate, be deposited on the amount of " z " fiber 110 in each zone 104,106 and 108 with control.In one embodiment, " z " fiber 110 of higher percent core area 104 internal ratios in zone 106 and 108, deposit many.This can realize by the pendulum of sweeping of the mechanism 98 in the core area 104 that slows down.For example, " z " fiber 110 can in core area 104, constitute total fiber about 25% and shell zone 108 about 3%.This structure provides added strength to the core area of filter group 86, the anti-flattening when this intensity need be used with the maintenance filter.
Zone 104,106 can comprise different materials with 108 fiber, and it can be a different size, perhaps can have different performances.For example, the diameter of the fiber in each zone can increase to shell zone 108 gradually from core area 104.Each zone also can present the density different with each adjacent areas.For example, Qu Yu density can reduce to shell zone 108 gradually from core area 104.For the person of ordinary skill of the art, other to substitute also be obvious.
By fiber being fixed on the supporting construction of an opening, the unique construction of leptonema 86 allows high gap volume, and can not sacrifice intensity.Like this, leptonema of the present invention 86 shows than remarkable big mechanical strength and the weight ratio of the medium of prior art.Leptonema 86 can form any thickness of expectation.In one embodiment, leptonema 86 has about 1.15 inches internal diameter and about 2.5 inches external diameter.In one embodiment, leptonema 86 has about 95 grams of per ten inches portion's sections or littler group and at least about the crushing strength of 40psi.High gap volume causes leptonema 86 to have bigger foul retaining capacity, long component life and lower pressure drop.And, to compare with traditional fiber, the faster and material therefor that its permission leptonema 86 is made is still less.In a preferred embodiment, ten inches portion's sections of leptonema 86 can be made in about 15 seconds, and had 90% retention rate at 20 microns.
Fig. 4 is the schematic diagram of second embodiment of the ordinary representation system that is used for making continuously non-woven depth filter element.Fig. 4 and Fig. 1 are similar, but also comprise filament induction system 114, and nozzle 116 subtracts thin mechanism 118, tubaeform figure 120 and shell shaping filament induction system 122.Additional nozzle 116 subtracts thin mechanism 118 and tubaeform figure 120 and said nozzle 27,28 and 29; Subtract thin mechanism 31,32 and 33; Similar with tubaeform figure 66,68 and 70.Although illustrate four such nozzles of filament induction system 16, subtract thin mechanism and tubaeform figure, can imagine that they can use more or less.At an embodiment, nozzle 27,28,29 and 116 are positioned at apart from axle 76 about 35 inches to about 40 inches.
Be used to carry the device of filament except filament induction system 114 preferably includes, filament induction system 114 is similar with said system 16 basically, and the device of carrying filament is carried filament in the mode of mixing with the filament of one or more nozzle manufacturings of using in the system 16.Filament induction system 114 can comprise that one or more polymer squeeze the silk head.Adopt among the embodiment and have a nozzle 124 that subtracts thin device 126, it is positioned to acutangulate with respect to axle 76, so that carry into filament figure or filament stream 128 that ellipse figure contacts with leptonema 127, this ellipse figure and filament figure 66,68,70 and 120 and filament induction system 18 mix.
Except the lip-deep level and smooth relatively shell of outside column zone 112 (see figure 6)s of leptonema 127 are preferably constructed and be positioned in to shell shaping filament induction system 122, shell shaping filament induction system 122 was similar with said system 16 basically.The different location that shell shaping filament induction system 122 is preferably used with respect to filament induction system 16, polymer-through-out rate and air subtract thin setting value.Compare with system 16, nozzle 144 preferably is arranged near axle 76, and uses lower polymer-through-out rate; In addition, subtracting thin mechanism 146 seldom uses air to subtract carefully.Similar with system 16, shell shaping filament induction system 122 comprises heater block 148, measuring pump 150, motor 152, temperature controller 154, air supply source 156 and pipeline 158.
As a non-limiting example, be about 0.016 inch nozzle 144 with per hour about 1 pound speed extruded polypropylene by in deep filter, passing a hole dimension, this polypropylene is heated to the temperature between about 270 ℃ to about 325 ℃, simultaneously, the molten polymer flow of leaving spout is in the about 25 ℃ of speed process ambient atmosphere with about 1.5 standard cubic foots of per minute of temperature, like this, make the polymer filaments of filament figure 162.In one embodiment, nozzle 144 is arranged to apart from axle 76 about 3-6 inches.Be appreciated that those of ordinary skill in the art is easy to determine other suitable parameter combinations.
Fig. 5 is the schematic diagram that the system of the embodiment of presentation graphs 4 constructs.Shown in an embodiment among Fig. 5, filament induction system 16 comprises four filament manufacturing installations, and each device comprises that a nozzle and one subtract thin mechanism, and for example nozzle 27,28,29 and 116 and subtract thin mechanism 31,32,33 and 118. Nozzle 27,28,29 and 116 vertically align along common axis 90, and this common axis 90 preferably departs from about 0-15 degree from being parallel to axle 76.In a preferred embodiment, nozzle 27,28,29 and 116 are positioned to separate about 4 inches.Each nozzle 27,28,29 and 116 comprises the aperture that defines an axis 92,94,96 and 160 respectively, promptly preferably perpendicular to axle 90, and from depart from about 0-15 degree perpendicular to axle 76. Axle 93,94,96 and 160 is usually corresponding to the molten polymer fluid axle that leaves the respective nozzles opening.In a preferred embodiment, nozzle 27,28,29 and 116 are positioned at apart from axle 76 about 40 inches, preferably rotate with the speed of about 400RPM.Should be towards the tubaeform filament figure 66,68,70 and 120 of the axle 76 that causes leading.
Filament figure 66,68,70 and 120 comprises the diameter polymeric filament that has less than between about 1 micron to about 100 microns.In a preferred embodiment, filament figure 66 comprises the filament of minimum diameter; Filament figure 68 comprises the filament of mid diameter; Filament figure 70 comprises larger-diameter filament, and filament figure 120 comprises the filament of maximum gauge.As a non-limiting instance, be about 0.016 inch nozzle with per hour about 11 pounds speed extruded polypropylene by in deep filter, passing a hole dimension, this polypropylene is heated to the temperature between about 325 ℃ to about 400 ℃, simultaneously, the molten polymer flow of leaving spout like this, is made filament figure 66 in the about 25 ℃ of speed process ambient atmosphere with about 13 standard cubic foots of per minute of temperature, 68,70 and 120 polymer filaments.Be appreciated that those of ordinary skill in the art is easy to determine other suitable parameter combinations.Will be appreciated that operating parameter can change between filament figure 66,68,70 and 120, to make the zone of different densities and fiber dimension.
Filament figure 72 comprises becoming back and forth horizontal figure to move, and preferably covers the figure 72A of the distance between initial graphics edge 82 and 142.As an alternative, filament figure 72 covers less than the distance between edge 82 and 142.Alternative mechanism 54 preferably includes servo-drive and sweeps swinging mechanism 98, and it allows to subtract thin mechanism 54 and sweeps angle of pendulum, so that filament figure 72 is traversing back and forth in 66,68,70 and 120 in fiber figure along the longitudinal size of leptonema 127.When figure 72A across-the-grain figure 66,68,70 and 120 o'clock, it was deposited as continuous basically polymer filaments across whole deposition pattern, and stretched between initial graphics edge 82 and 142.In the leptonema 127 that forms, the fiber of the filament figure 66 of 82 depositions forms first first type surface 97 (shown in Figure 6) along the edge, and the fiber of the filament figure 70 of 84 depositions will form second first type surface 99 (shown in Figure 6) along the edge.In another embodiment, but nozzle 44 reciprocally swingings, so that sweep the filament figure 72 of pendulum combination.
Usually form the two dimension pad or the layer of material from the fiber of filament figure 66,68,70 and 120, the two dimension pad of this material or layer progressive forming on axle 76 are to produce by the fibrous leptonema 127 of many layers.These fibers are described as and are laid in the X-Y plane, or vertically and circumference or latitude size.When forming fiber, be placed on the layer, they make radially or depth dimensions.Filament figure 72A sweeps pendular motion, combines with the rotation of axle 76, causes fiber to leave nozzle 44 and group 127 and forms wholely, and constitutes " z " direction fiber, and its is through filament figure 66,68,70 and the 120 regional circumferentially extendings that constitute.
In the embodiment shown in fig. 5, filament figure 128 is preferably by nozzle 124 with subtract thin mechanism 126 and make simultaneously, this nozzle and subtract thin mechanism and be positioned to apart from axle 76 about 13 inches, in one embodiment, nozzle 124 and subtract thin mechanism 126 and be preferably static or fixing is not because filament figure 128 is swung or back and forth as filament figure 72A.In an alternative embodiment, figure 128 swings or reciprocal.The best filament with the figure 72 that crosses filament figure 66,68,70 and 120 of the filament of figure 128 mixes.In one embodiment, this is by introducing the filament figures with respect to 76 one-tenth acute angles of axle or flow 128 and realize, thereby causes the suitable non-circular cross-section of filament figure 128 to contact with the leptonema 127 of the formation of rotation.
As shown in Figure 5, sweep pendulum filament stream 72A intercepting filament stream 128, help filament stream 128 is fixed on the leptonema 127 of formation.And, nozzle 144 and subtract the thin mechanism 146 filament figure 162 that preferably shell is shaped and guide on the part of leptonema 127, this leptonema 127 arrives on its final circumference basically.
Fig. 6 illustrates the look elevation view of second embodiment of depth filter element of the present invention from the line 6-6 of Fig. 5.Leptonema 127 comprises first first type surface, 97, the second first type surfaces 99 and concentric filtration zone 164,166,168 and 170, and filament 110 and 172 is radially providing additional leptonema intensity. Filament 110 and 172 reinforcing elements as fibre structure 127. Filament 110 and 172 stretches through leptonemas 127, and radially, vertically and circumferential size stretch.
Usually, filament zone 164 is made by filament figure 66; Filament zone 166 is made by filament figure 68; Filament zone 168 is made by filament figure 70; Filament zone 170 is made by filament figure 120, and filament 110 is made by filament figure 72, and filament 172 is made by filament figure 128.Filament zone 164,166,168 preferably presents different physical characteristics with 170.For example, filtration zone 164 can comprise the filament than minor diameter; Filtration zone 166 and 168 can comprise the filament of mid diameter; Filtration zone 170 can comprise larger-diameter filament.Filament zone 164,166,168 and 170 preferably have the diameter dimension scope from less than about 1 micron to about 100 microns filament.In another embodiment, for example, filtration zone 164 can have the filament of higher density; Filtration zone 166 and 168 filaments that can have intermediate density, filtration zone 170 can have more low-density filament.
In one embodiment, lacking fiber usually in each group 164,166,168 and 170 that is made by filament figure 66,68,70 and 120 respectively combines with interfibrous.By " z " combination between the filament of fiber 110 and 172 and regional 164,166,168 and 170, realize the initial combination in the leptonema 127.It is very big that rigidity is made in the selected zone of medium, so that the filter course of the mechanical load that also carrying generates to be provided, thereby eliminates in given filter for installation demand to independent structural detail.
As described in top Fig. 3, make fiber 110.Fiber 172 following formation: when the filament of filament figure 128 flowed near pattern edge 82, " z " fiber 172 was arranged near on the leptonema 127 in surperficial 97 zones.When the filament of filament figure 128 flowed to pattern edge 142 expansions, " z " fiber 172 was arranged to traverse zone 164,166,168 and 170, reaches the outside of perimeter 170 up to it.Axle 76 rotations, filament figure 128 sprays simultaneously, so that " z " fiber 172 also moves around filter group 127 at circumferencial direction.Like this " z " fiber radially, vertically and circumferencial direction roll into a ball 127 through filter.In group 127 is plane rather than cylindricality, and bonding fiber 17 can be described as the length in group 127, and width and thickness dimension stretch.
In a preferred embodiment, filament figure 128 is located such that the oval cross section that contacts with fibrous mass 127 partly crosses one or more regional 164,166,168 and 170; Yet filament figure 128 does not need to cross all zones 164,166,168 and 170.The oval cross section of filament figure 128 produce towards longitudinal component.The fibrous mass 127 that is provided with the formation of filament stream 128 has taper, this produce towards radial component.Axle 26 rotation, with provide have around filter group 127 towards the filament 172 of circumferential components.Like this, " z " fiber 172 in whole filter group 127 radially, vertically and the circumferencial direction distribution.Although illustrate a nozzle 124 to make filament 172, can imagine the nozzle that also can use varying number with other position and structure.
In one embodiment, the fiber in zone 164,166,168 and 170 comprises about 75-95% of the fiber of filter group 127, and " " fiber 110 and 172 comprises about 5-25% of the fiber of filter group 127 to z; Be more preferably, the fiber in zone 164,166,168 and 170 comprises about 80-90% of the fiber of filter group 127, and " z " fiber 110 and 172 comprises about 10-20% of the fiber of filter group 127; Best, zone 164,166,168 and 170 fiber comprises fiber about 85% of filter group 127, " z " fiber 110 and 172 comprise filter group 127 fiber about 15%.
Performance new and that do not expect of the present invention is significantly not increase the integral filter core that density of medium can be made enhancing.In the melt-blown process process, this realizes by deposition binding fiber 110 and 172 on the inceptive filtering fiber in zone 164,166,168 and 170.Binding fiber 110 and 172 additional heat energy allow height amorphous polypropylene inceptive filtering fiber significantly to increase degree of crystallinity, and this is with amplified medium.
Zone 164,166,168 can comprise different materials with 170 fiber, and it can be a different size, perhaps can have different performances.For example, the diameter of the fiber in each zone can be from core area 164 170 increases gradually to the perimeter.Each zone also can present the density different with each adjacent areas.For example, Qu Yu density can be from core area 164 170 reductions gradually to the perimeter.And, in one embodiment, to compare with 170 initial fiber with regional 162,166,168, one or two " z " fiber 110 has different material properties with 172.For example, fiber 110 and/or 172 can be the absorbent or the absorbing material of catalysts or toxin, virus, protein, organic matter, or heavy metal.In a preferred embodiment, structure reinforcing fibre or absorb 110 and 172 diameter and zone 164,166, the diameter of 168 and 170 inceptive filtering fiber can compare, therefore, fiber 110 and 172 not only helps to absorb the intensity of group 127, also helps its strainability.For the person of ordinary skill of the art, other to substitute also be obvious.
The depth filter element proof that forms in mode described here has splendid particle filtration and fluid handling capacity.For example, compare with similar specified filter (for example 90% validity when removing 20 micron particles), deep filter proof of the present invention has the life-span and the foul storage capacity of about twice.And, the degree minimum that depth filter element of the present invention allows the fluid throughput to reduce under fluid pressure through filter.
Filter capability depends on the combination of many factors, comprise following factor: the size of the dirt that filter can be removed (efficient), stop up amount of contaminants (foul storage capacity) that front filter can hold and whole life period or under variable operating condition the reliability of filter function.
For any given filter, foul storage capacity (DHC) and the common negative correlation of filter clogging effect.Cluster of grains changes with the pipe radius, and therefore, the efficient filtration device of only catching larger particles and allowing granule pass through can obtain bigger weight before obstruction.
For the person of ordinary skill of the art, obviously DHC and filter cylinder weight also are negative correlation usually.By the material in the taking-up filter cylinder, thereby stay more spaces (voidage), can assemble the dirt of catching in the space, like this, can realize that the weight of fixed volume filter cylinder reduces.Obviously take out material from filter cylinder, it is constant that the variable of all other keeps, and this makes filter cylinder more weak (low filter compressive resistance).
The filter compressive resistance is that the typical case who is used for accurately measuring the reliability of Filter cartridge measures.If filter is too soft, in whole useful life period or under the variable operation condition, its function will can be unreliable.For the those of ordinary skill in the field of melting and spraying, obviously by the change fibre diameter, and other processing parameter, can handle the filter compressive resistance under fixing filter weight, usually, bigger fiber is made higher compressive resistance.Filter configuration changed into than major diameter hole dimension is increased to a certain extent, thereby cause the lower efficient that retains.
For the filter contrast, consider that these main filter capabilities and structure change, and propose the Madsen performance than (M).
M
Ratio=(DHC * compressive resistance)/(μ m@90% * filter weight)
● DHC is in gram
● compressive resistance is not for there be square inch poundage (psi)
● μ m@90% refers to the particle size (μ m) that filter is produced under 90% efficient
● filter weight (untapped filter) is in gram
Higher rate value refers to that utilizing of material in the filter is preferable, this means with the filter with low rate value to compare, and filter has strength balance preferably, dirt storage capacity and remove efficient
Although described preferred embodiment and method are very special, be expected under the prerequisite that does not exceed essence of the present invention, the present invention can do different modifications.Therefore, expect that scope of the present invention limits by appended claims rather than by the explanation of illustrated embodiment.For example, expect that instruction of the present invention can be fit to product smooth or chip filter and other structure.In addition, the present invention can also utilize " z " fiber 172 rather than " z " fiber 110 to implement, otherwise still.The system that an advantage utilizing " z " filament induction system 18 and 114 is a plurality of sources provides bigger degree of control to the operator.In addition, although illustrate a kind of in every type the filament induction system 16,18,114 and 122, expection can also be used the multisystem of one or more types.
And expection can be changed from the role of the filament of different induction systems.For example, in one embodiment, the inceptive filtering filament is made by system 16, in conjunction with or structure strengthen filament by system 18 and 14 manufacturings.In another embodiment, the inceptive filtering filament is made by one or two system 18 and 114, in conjunction with or structure strengthen filament by system's 16 manufacturings.Operating parameter and condition are used by those of ordinary skill in the art, with the combination of the filament in the group that obtains expectation.
Example 1
With the filter contrast of filter of the present invention and standard, the filter for 10 micron particles sizes (the thin test dust of A.C.) draws following result
| Product | Compressive resistance (psi) | The weight of 10 inches filter cylinders (g) | Life-span (minute) | Foul storage capacity (g) |
| The present invention | ????93 | ????133 | ????60 | ????60 |
| Standard | ????125 | ????205 | ????29 | ????33 |
| Contrast | ????42 | ????143 |
In whole three examples, standardized product is by the method manufacturing of any prior art of discussing in the background technology part of the present invention.Contrast product is by the method manufacturing identical with the present invention, but do not have z filament 110 and 172.This realizes by the material that cut-out is pumped into nozzle 44 and 124.In addition, allow to form the contrast filter cylinder with the more time, so that the input that compensative material reduces, and it reaches comparable weight to compare permission with 172 product of the present invention with employing z filament 110.Other operating condition that forms the present invention and contrast tubular filter cylinder is described below.
In this example, filter of the present invention is lighter than standard filter, about two double-lengths, and have about twice of the DHC of standard filter.Yet it has lower compressive resistance.Adopt above-mentioned formula, M
Ratio of the present invention=4.2 and M
Standard ratio=2.0.Like this, contrast product of the present invention is implemented better than standardized product.Contrast product is only done experiment to compressive resistance.With the comparable weight of product of the present invention under, contrast product present product of the present invention compressive resistance less than half.
In this example, filter of the present invention utilizes initial fiber filament figure 66,68,70 and 120 make this initial fiber filament figure 66,68,70 and 120 by being about 0.016 inch nozzle 27 through hole dimension with per hour about 9.5 pounds speed, 28,29 and 116 extruded polypropylenes are made, and this polypropylene is heated between about 360 ℃ to about 400 ℃.Filament stream 66 and 68 is heated to about 400 ℃, and filament stream 70 and 120 is heated to about 360 ℃.For subtracting thin mechanism 31,32,33 and 118, leave nozzle 27,28,29 and 116 molten polymer flow temperature about 25 ℃ with per minute about 10.5 to about 15 cubic feet flow velocity through ambient atmosphere.Subtract thin mechanism 31 and be 15 cubic feet of about per minutes, subtract the flow velocity that thin mechanism 32,33 and 118 flow velocitys at nozzle 116 places are reduced to 10.5 cubic feet of about per minutes that subtract thin mechanism 118 gradually at the flow velocity at nozzle 27 places.Nozzle 27,28,29 and 116 are positioned at apart between axle 76 about 35 and about 37 inches.
Make " z " fiber filaments figure 128 by being about 0.016 inch nozzle 124 extruded polypropylenes with per hour about 5.5 pounds speed through via size, this polypropylene is heated to about 370 ℃.For subtracting thin mechanism 126, the polymer flow that leaves spout 124 temperature about 25 ℃ with the about 9 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 124 is positioned at apart from axle 76 about 13 inches.
Make " z " fiber filaments figure 72A by being about 0.016 inch nozzle 44 extruded polypropylenes with per hour about 5.5 pounds speed through via size, this polypropylene is heated to about 370 ℃.For subtracting thin mechanism 54, the polymer flow that leaves spout 44 temperature about 25 ℃ with the about 7 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 44 is positioned at apart from axle 76 about 21 inches.
Make shell shaped fibers filament figure 162 by being about 0.016 inch nozzle 144 extruded polypropylenes with per hour about 1.0 pounds speed through via size, this polypropylene is heated to about 280 ℃.For subtracting thin mechanism 146, the polymer flow that leaves spout 144 temperature about 25 ℃ with the about 1.25 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 144 is positioned at apart from axle 76 about 3.5 inches.
Example 2
With the filter contrast of filter of the present invention and standard, the filter for 20 micron particles sizes (A.C. crude test pulvis) draws following result
| Product | Compressive resistance (psi) | The weight of 10 inches filter cylinders (g) | Life-span (minute) | Foul storage capacity (g) |
| The present invention | ????83 | ????119 | ????85 | ????118 |
| Standard | ????100 | ????160 | ????46 | ????65 |
| Contrast | ????36 | ????129 |
In this example, filter of the present invention is lighter than standard filter, about two double-lengths, and have about twice of the DHC of standard filter.Yet it has lower compressive resistance.Adopt above-mentioned formula, M
Ratio of the present invention=4.1 and M
Standard ratio=2.0.Like this, contrast product of the present invention is implemented better than standardized product.Contrast product is only done experiment to compressive resistance.With the comparable weight of product of the present invention under, contrast product present product of the present invention compressive resistance less than half.
In this example, filter of the present invention utilizes initial fiber filament figure 66,68,70 and 120 make this initial fiber filament figure 66,68,70 and 120 by being about 0.016 inch nozzle 27 with the speed between about 10 to 11 pounds per hour through hole dimension, 28,29 and 116 extruded polypropylenes are made, and this polypropylene is heated to about 370 ℃.Nozzle 27 and 28 has approximately per hour 10 pounds flow velocity, and nozzle 29 and 116 per hour has about 11 pounds bigger flow velocity.For subtracting thin mechanism 31,32,33 and 118, leave nozzle 27,28,29 and 116 molten polymer flow temperature about 25 ℃ with per minute about 10.5 to about 15 cubic feet flow velocity through ambient atmosphere.Subtract thin mechanism 31 and be 15 cubic feet of about per minutes, subtract the flow velocity that thin mechanism 32,33 and 118 flow velocitys at nozzle 116 places are reduced to 10.5 cubic feet of about per minutes that subtract thin mechanism 118 gradually at the flow velocity at nozzle 27 places.Nozzle 27,28,29 and 116 are positioned at apart between axle 76 about 38 and about 40 inches.
Make " z " fiber filaments figure 128 by being about 0.016 inch nozzle 124 extruded polypropylenes with per hour about 6 pounds speed through via size, this polypropylene is heated to about 370 ℃.For subtracting thin mechanism 126, the polymer flow that leaves spout 124 temperature about 25 ℃ with the about 12 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 124 is positioned at apart from axle 76 about 13 inches.
Make " z " fiber filaments figure 72A by being about 0.016 inch nozzle 44 extruded polypropylenes with per hour about 6 pounds speed through via size, this polypropylene is heated to about 370 ℃.For subtracting thin mechanism 54, the polymer flow that leaves spout 44 temperature about 25 ℃ with the about 11 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 44 is positioned at apart from axle 76 about 22 inches.
Make shell shaped fibers filament figure 162 by being about 0.016 inch nozzle 144 extruded polypropylenes with per hour about 1.1 pounds speed through via size, this polypropylene is heated to about 290 ℃.For subtracting thin mechanism 146, the polymer flow that leaves spout 144 temperature about 25 ℃ with the about 1.75 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 144 is positioned at apart from axle 76 about 3.5 inches.
Example 3
With the filter contrast of filter of the present invention and standard, the filter for 30 micron particles sizes (A.C. crude test pulvis) draws following result
| Product | Compressive resistance (psi) | The weight of 10 inches filter cylinders (g) | Life-span (minute) | Foul storage capacity (g) |
| The present invention | ????75 | ????113 | ????105 | ????120 |
| Standard | ????80 | ????152 | ????50 | ????73 |
| Contrast | ????43 | ????106 |
In this example, filter of the present invention is lighter than standard filter, about two double-lengths, and have very big DHC, also have comparable compressive resistance.Adopt above-mentioned formula, M
Ratio of the present invention=2.7 and M
Standard ratio=1.3.Like this, contrast product of the present invention is implemented better than standardized product.Contrast product is only done experiment to compressive resistance.With the comparable weight of product of the present invention under, compare with the compressive resistance of product of the present invention, contrast product presents significantly low compressive resistance.
In this example, filter of the present invention utilizes initial fiber filament figure 66,68,70 and 120 make this initial fiber filament figure 66,68,70 and 120 by being about 0.016 inch nozzle 27 with the speed between about 10 to 11 pounds per hour through hole dimension, 28,29 and 116 extruded polypropylenes are made, and this polypropylene is heated to about 360 ℃.Nozzle 27 and 28 has approximately per hour 10 pounds flow velocity, and nozzle 29 and 116 per hour has about 11 pounds bigger flow velocity.For subtracting thin mechanism 31,32,33 and 118, leave nozzle 27,28,29 and 116 molten polymer flow temperature about 25 ℃ with per minute about 10.5 to about 15 cubic feet flow velocity through ambient atmosphere.Subtract thin mechanism 31 and be 15 cubic feet of about per minutes, subtract the flow velocity that thin mechanism 32,33 and 118 flow velocitys at nozzle 116 places are reduced to 10.5 cubic feet of about per minutes that subtract thin mechanism 118 gradually at the flow velocity at nozzle 27 places.Nozzle 27,28,29 and 116 are positioned at apart between axle 76 about 38 and about 40 inches.
Make " z " fiber filaments figure 128 by being about 0.016 inch nozzle 124 extruded polypropylenes with per hour about 6 pounds speed through via size, this polypropylene is heated to about 360 ℃.For subtracting thin mechanism 126, the polymer flow that leaves spout 124 temperature about 25 ℃ with the about 12 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 124 is positioned at apart from axle 76 about 13 inches.
Make " z " fiber filaments figure 72A by being about 0.016 inch nozzle 44 extruded polypropylenes with per hour about 6 pounds speed through via size, this polypropylene is heated to about 360 ℃.For subtracting thin mechanism 54, the polymer flow that leaves spout 44 temperature about 25 ℃ with the about 11 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 44 is positioned at apart from axle 76 about 22 inches.
Make shell shaped fibers filament figure 162 by being about 0.016 inch nozzle 144 extruded polypropylenes with per hour about 1.1 pounds speed through via size, this polypropylene is heated to about 280 ℃.For subtracting thin mechanism 146, the polymer flow that leaves spout 144 temperature about 25 ℃ with the about 1.75 cubic feet flow velocity of per minute through ambient atmosphere.Nozzle 144 is positioned at apart from axle 76 about 3.5 inches.
Claims (141)
1. non-woven filament medium that melts and sprays, this filament medium comprises:
The meltblown polymer leptonema, this leptonema has depth dimensions, longitudinal size and latitude size; The filament of this group is oriented in vertically and the latitude size usually; With
That pass that this group stretches and be oriented in depth dimensions usually pass through the meltblown polymer filament.
2. filament medium as claimed in claim 1 is characterized in that the filament of this group has average diameter, and the diameter that wherein passes through filament approximates the average diameter of the filament of this group.
3. filament medium as claimed in claim 1 is characterized in that the filament of this group has average diameter, passes through the average diameter of the diameter of filament greater than the filament of this group.
4. filament medium as claimed in claim 1 is characterized in that the filament of this group has average diameter, passes through the average diameter of the diameter of filament less than the filament of this group.
5. filament medium as claimed in claim 1 is characterized in that this group comprises a plurality of zones along depth dimensions, and each zone comprises the filament different with each adjacent area size.
6. filament medium as claimed in claim 1 is characterized in that this group comprises a plurality of zones along depth dimensions, compares with each adjacent area, and the ratio that passes through filament amount and whole filament amounts in a zone in each zone is different.
7. filament medium as claimed in claim 1 is characterized in that this group comprises a plurality of zones along depth dimensions, and each regional density is different with the density of each adjacent area.
8. filament medium as claimed in claim 5 is characterized in that, this group comprises:
The first area of polymer filaments;
The second area of contiguous first area, second area comprises polymer filaments, this polymer filaments has the diameter bigger than the filament of first area usually; With
The 3rd zone in adjacent second zone territory, the 3rd zone comprises polymer filaments, this polymer filaments has the diameter bigger than the filament of second area usually.
9. filament medium as claimed in claim 8 is characterized in that, the ratio of all the filament amounts in the filament amount of passing through in the first area and the zone is than the height in the 3rd zone.
10. filament medium as claimed in claim 1 is characterized in that this group is a tubular, and comprises a plurality of concentric regions, and each zone has the density different with each adjacent area.
11. filament medium as claimed in claim 10 is characterized in that, this tubular group comprises:
The core area of polymer filaments;
Center on the zone line of the polymer filaments of core area, this zone line density than core area usually is low; With
Center on the perimeter of the polymer filaments of zone line, this perimeter density than zone line usually is low.
12. filament medium as claimed in claim 1 is characterized in that, the polymer filaments of each of this group layer presents combining between minimum filament and filament.
13. filament medium as claimed in claim 1 is characterized in that, passes through the filament that filament will roll into a ball and combines, and passes through filament through this group stretching, extension.
14. filament medium as claimed in claim 1 is characterized in that, passes through interlocking on the filament structure that filament makes this group, passes through filament through this group stretching, extension.
15. filament medium as claimed in claim 1 is characterized in that, passes through the filament crystallization that filament makes this group, passes through filament and stretches through this group.
16. filament medium as claimed in claim 1 is characterized in that, passes through filament and is made by the polymer different with the filament of this group.
17. filament medium as claimed in claim 16 is characterized in that, passes through filament and comprises absorbing material.
18. filament medium as claimed in claim 16 is characterized in that, passes through filament and comprises absorbing material.
19. filament medium as claimed in claim 16 is characterized in that, passes through filament and comprises catalyst.
20. filament medium as claimed in claim 1 is characterized in that:
This group comprises continuous basically meltblown polymer leptonema, and the filament of this group comprises a plurality of layers, and every layer in a plurality of layers is oriented in vertically and the latitude size usually; With
Cross element and comprise continuous basically meltblown polymer filament, pass through at least one deck stretching, extension of filament through this group.
21. filament medium as claimed in claim 20 is characterized in that the filament of this group has average diameter, the diameter that passes through filament approximates the average diameter of the filament of this group.
22. filament medium as claimed in claim 20 is characterized in that the filament of this group has average diameter, passes through the average diameter of the diameter of filament greater than the filament of this group.
23. filament medium as claimed in claim 20 is characterized in that the filament of this group has average diameter, passes through the average diameter of the diameter of filament less than the filament of this group.
24. filament medium as claimed in claim 20 is characterized in that this group comprises a plurality of zones along depth dimensions, each zone comprises the filament different with each adjacent area size.
25. filament medium as claimed in claim 20 is characterized in that this group comprises a plurality of zones along depth dimensions, compares with each adjacent area, the ratio that passes through filament amount and whole filament amounts in a zone in each zone is different.
26. filament medium as claimed in claim 20 is characterized in that this group comprises a plurality of zones along depth dimensions, each regional density is different with the density of each adjacent area.
27. filament medium as claimed in claim 24 is characterized in that, this group comprises:
The first area of continuous basically polymer filaments;
The second area of contiguous first area, second area comprises continuous basically polymer filaments, this polymer filaments has the diameter bigger than the filament of first area usually; With
The 3rd zone in adjacent second zone territory, the 3rd zone comprises continuous basically polymer filaments, this polymer filaments has the diameter bigger than the filament of second area usually.
28. filament medium as claimed in claim 27 is characterized in that, the ratio of all the filament amounts in the filament amount of passing through in the first area and the zone is than the height in the 3rd zone.
29. filament medium as claimed in claim 20 is characterized in that this group is a tubular, and comprises a plurality of concentric regions, each zone has the density different with each adjacent area.
30. filament medium as claimed in claim 29 is characterized in that, tubular group comprises:
The core area of continuous basically polymer filaments;
Center on the zone line of the continuous basically polymer filaments of core area, this zone line density than core area usually is low; With
Center on the perimeter of the continuous basically polymer filaments of zone line, this perimeter density than zone line usually is low.
31. filament medium as claimed in claim 20 is characterized in that, the continuous basically polymer filaments of each of this group layer presents combining between minimum filament and filament.
32. filament medium as claimed in claim 20 is characterized in that, passes through filament layer is combined, and passes through filament and stretches through layer.
33. filament medium as claimed in claim 20 is characterized in that, passes through filament and makes interlocking on layer structure, passes through filament and stretches through layer.
34. filament medium as claimed in claim 20 is characterized in that, passes through the filament crystallization that filament makes layer, passes through filament and stretches through layer.
35. filament medium as claimed in claim 20 is characterized in that, passes through filament and is made by the polymer different with the filament of this group.
36. filament medium as claimed in claim 35 is characterized in that, passes through filament and comprises absorbing material.
37. filament medium as claimed in claim 35 is characterized in that, passes through filament and comprises absorbing material.
38. filament medium as claimed in claim 35 is characterized in that, passes through filament and comprises catalyst.
39. filament medium as claimed in claim 1 is characterized in that, this medium comprises that three-dimensional non-woven melts and sprays the polymer fiber structure, and this structure has first and second first type surfaces, and this structure comprises:
The continuous basically melt-blown polymer fiber of a plurality of layers; With
Meltblown fibers structure reinforcing element, this reinforcing element cross a plurality of layers between first first type surface and second first type surface, and engage with the fiber of layer.
40. fibre structure as claimed in claim 39 is characterized in that, a plurality of layers fiber has average diameter, and wherein the diameter of fibre structure reinforcing element approximates the average diameter of a plurality of layers fiber.
41. fibre structure as claimed in claim 39 is characterized in that, a plurality of layers fiber has average diameter, and wherein the diameter of fibre structure reinforcing element greater than the average diameter of a plurality of layers fiber.
42. fibre structure as claimed in claim 39 is characterized in that, a plurality of layers fiber has average diameter, and wherein the diameter of fibre structure reinforcing element less than the average diameter of a plurality of layers fiber.
43. fibre structure as claimed in claim 39 is characterized in that, it also comprises the density gradient of crossing a plurality of layers.
44. fibre structure as claimed in claim 43 is characterized in that, a plurality of layers comprise:
The lower area of the layer of contiguous first first type surface; With
Going up of the layer of contiguous second first type surface is regional, and last zone comprises continuous basically polymer fiber, and this polymer fiber has the diameter bigger than the fiber of lower area usually.
45. fibre structure as claimed in claim 44 is characterized in that it also comprises
Zone line between lower area and last zone, zone line comprises continuous basically polymer fiber, the diameter of this polymer fiber is bigger and littler than the diameter of the fiber in last zone than the diameter of the fiber of lower area usually.
46. fibre structure as claimed in claim 44 is characterized in that, the ratio of all fibres amount in lower area in the zone of fibre structure reinforcing element amount and each layer is than the height in last zone.
47. fibre structure as claimed in claim 39 is characterized in that, the fibre structure reinforcing element is made by the polymer different with a plurality of layers fiber.
48. fibre structure as claimed in claim 47 is characterized in that, the fibre structure reinforcing element comprises absorbing material.
49. leptonema as claimed in claim 47 is characterized in that, passes through filament and comprises absorbing material.
50. leptonema as claimed in claim 47 is characterized in that, passes through filament and comprises catalyst.
51. fibre structure as claimed in claim 39 is characterized in that, this structure is a tubular, and comprises a plurality of concentric regions, and each zone has the density different with each adjacent area.
52. fibre structure as claimed in claim 51 is characterized in that, this tubular structure comprises:
The core area of continuous basically polymer filaments;
Center on the zone line of the continuous basically polymer filaments of core area, this zone line density than core area usually is low; With
Center on the perimeter of the continuous basically polymer filaments of zone line, this perimeter density than zone line usually is low.
53. fibre structure as claimed in claim 39 is characterized in that, this fibre structure reinforcing element traverses into another first type surface from a first type surface.
54. fibre structure as claimed in claim 39 is characterized in that, this fibre structure reinforcing element combines a plurality of layers.
55. fibre structure as claimed in claim 39 is characterized in that, this fibre structure reinforcing element makes a plurality of layers of interlocking.
56. fibre structure as claimed in claim 39 is characterized in that, this fibre structure reinforcing element makes a plurality of layers fiber crystallization.
57. the filament medium that is used to construct dark filter fly filter cylinder as claimed in claim 1 is characterized in that it comprises:
The tubular group of meltblown polymer filament, this group has the radial depth size, longitudinal size, and circumferential size; The filament of this group is oriented in vertically and circumferential size usually; With
That pass that this group stretches and be oriented in depth dimensions usually pass through the meltblown polymer filament.
58. dark filter fly filter cylinder as claimed in claim 57 is characterized in that the filament of this group has average diameter, and the diameter that wherein passes through filament approximates the average diameter of the filament of this group.
59. dark filter fly filter cylinder as claimed in claim 57 is characterized in that the filament of this group has average diameter, and wherein passes through the average diameter of the diameter of filament greater than the filament of this group.
60. dark filter fly filter cylinder as claimed in claim 57 is characterized in that the filament of this group has average diameter, and wherein passes through the average diameter of the diameter of filament less than the filament of this group.
61. dark filter fly filter cylinder as claimed in claim 57 is characterized in that this group comprises a plurality of zones along depth dimensions, each zone comprises the filament different with each adjacent area size.
62. dark filter fly filter cylinder as claimed in claim 57 is characterized in that this group comprises a plurality of zones along depth dimensions, compares with each adjacent area, the ratio that passes through filament amount and whole filament amounts in a zone in each zone is different.
63. dark filter fly filter cylinder as claimed in claim 57 is characterized in that this group comprises a plurality of zones along depth dimensions, each regional density is different with the density of each adjacent area.
64. dark filter fly filter cylinder as claimed in claim 61 is characterized in that this group comprises:
The first area of polymer filaments;
The second area of contiguous first area, second area comprises polymer filaments, this polymer filaments has the diameter bigger than the filament of first area usually; With
The 3rd zone in adjacent second zone territory, the 3rd zone comprises polymer filaments, this polymer filaments has the diameter bigger than the filament of second area usually.
65., it is characterized in that the ratio of all the filament amounts in the filament amount of passing through in the first area and the zone is than the height in the 3rd zone as the described dark filter fly filter cylinder of claim 64.
66. dark filter fly filter cylinder as claimed in claim 57 is characterized in that this group comprises a plurality of concentric regions, each zone has the density different with each adjacent area.
67., it is characterized in that this tubular group comprises as the described dark filter fly filter cylinder of claim 66:
The core area of polymer filaments;
Center on the zone line of the polymer filaments of core area, this zone line density than core area usually is low; With
Center on the perimeter of the polymer filaments of zone line, this perimeter density than zone line usually is low.
68. dark filter fly filter cylinder as claimed in claim 57 is characterized in that, the polymer filaments of each of this group layer presents combining between minimum filament and filament.
69. dark filter fly filter cylinder as claimed in claim 57 is characterized in that, this passes through the filament that filament will roll into a ball and combines, and passes through filament through this group stretching, extension.
70. dark filter fly filter cylinder as claimed in claim 57 is characterized in that, this passes through interlocking on the filament structure that filament makes this group, passes through filament through this group stretching, extension.
71. dark filter fly filter cylinder as claimed in claim 57 is characterized in that this passes through the filament crystallization that filament makes this group, passes through filament and stretches through this group.
72. dark filter fly filter cylinder as claimed in claim 57 is characterized in that this passes through filament and is made by the polymer different with the filament of this group.
73., it is characterized in that this passes through filament and comprises absorbing material as the described dark filter fly filter cylinder of claim 72.
74., it is characterized in that this passes through filament and comprises absorbing material as the described dark filter fly filter cylinder of claim 72.
75., it is characterized in that this passes through filament and comprises catalyst as the described dark filter fly filter cylinder of claim 72.
76. dark filter fly filter cylinder as claimed in claim 57 is characterized in that it has first and second first type surfaces, wherein passes through filament and traverses into another first type surface from a first type surface.
77. dark filter fly filter cylinder as claimed in claim 57 is characterized in that, it also comprises the density gradient of crossing a plurality of layers of tubular group.
78. the filament medium that is used to construct dark filter fly filter cylinder as claimed in claim 57 is characterized in that it comprises:
The tubular group of continuous basically meltblown polymer filament, this group has the radial depth size, longitudinal size, and circumferential size; The filament of this group comprises a plurality of layers, and every layer in a plurality of layers is oriented in vertically and circumferential size usually; With
The continuous basically meltblown polymer filament that passes through that passes that this group stretches passes through filament and is oriented in depth dimensions usually, and the one deck at least that passes this group stretches.
79. as the described dark filter fly filter cylinder of claim 78, it is characterized in that the filament of this group has average diameter, and the diameter that wherein passes through filament approximates the average diameter of the filament of this group.
80. as the described dark filter fly filter cylinder of claim 78, it is characterized in that the filament of this group has average diameter, and wherein pass through the average diameter of the diameter of filament greater than the filament of this group.
81. as the described dark filter fly filter cylinder of claim 78, it is characterized in that the filament of this group has average diameter, and wherein pass through the average diameter of the diameter of filament less than the filament of this group.
82. as the described dark filter fly filter cylinder of claim 78, it is characterized in that this group comprises a plurality of zones along depth dimensions, each zone comprises the filament different with each adjacent area size.
83. as the described dark filter fly filter cylinder of claim 78, it is characterized in that this group comprises a plurality of zones along depth dimensions, and wherein compare that the ratio that passes through filament amount and whole filament amounts in a zone in each zone is different with each adjacent area.
84. as the described dark filter fly filter cylinder of claim 78, it is characterized in that this group comprises a plurality of zones along depth dimensions, each regional density is different with the density of each adjacent area.
85., it is characterized in that this group comprises as the described dark filter fly filter cylinder of claim 82:
The first area of continuous basically polymer filaments;
The second area of contiguous first area, second area comprises continuous basically polymer filaments, this polymer filaments has the diameter bigger than the filament of first area usually; With
The 3rd zone in adjacent second zone territory, the 3rd zone comprises continuous basically polymer filaments, this polymer filaments has the diameter bigger than the filament of second area usually.
86., it is characterized in that the ratio of all the filament amounts in the filament amount of passing through in the first area and the zone is than the height in the 3rd zone as the described dark filter fly filter cylinder of claim 85.
87. as the described dark filter fly filter cylinder of claim 78, it is characterized in that this group comprises a plurality of concentric regions, each zone has the density different with each adjacent area.
88., it is characterized in that this tubular group comprises as the described dark filter fly filter cylinder of claim 87:
The core area of continuous basically polymer filaments;
Center on the zone line of the continuous basically polymer filaments of core area, this zone line density than core area usually is low; With
Center on the perimeter of the continuous basically polymer filaments of zone line, this perimeter density than zone line usually is low.
89., it is characterized in that the polymer filaments of each of this group layer presents combining between minimum filament and filament as the described dark filter fly filter cylinder of claim 78.
90. as the described dark filter fly filter cylinder of claim 78, it is characterized in that this passes through filament each layer combined, pass through filament and stretch through layer.
91. as the described dark filter fly filter cylinder of claim 78, it is characterized in that this passes through filament and makes interlocking on layer structure, pass through filament and stretch through layer.
92., it is characterized in that this passes through the filament crystallization that filament makes layer as the described dark filter fly filter cylinder of claim 78, pass through filament and stretch through layer.
93., it is characterized in that this passes through filament and is made by the polymer different with the filament of this group as the described dark filter fly filter cylinder of claim 78.
94., it is characterized in that this passes through filament and comprises absorbing material as the described dark filter fly filter cylinder of claim 93.
95., it is characterized in that this passes through filament and comprises absorbing material as the described dark filter fly filter cylinder of claim 93.
96., it is characterized in that this passes through filament and comprises catalyst as the described dark filter fly filter cylinder of claim 93.
97. as the described dark filter fly filter cylinder of claim 78, it is characterized in that it has first and second first type surfaces, pass through filament and traverse into another first type surface from a first type surface.
98., it is characterized in that it also comprises the density gradient of crossing a plurality of layers of tubular group as the described dark filter fly filter cylinder of claim 78.
99. a method of making the meltblown polymer leptonema continuously, its step comprises:
Make first group of meltblown polymer filament continuously, first group usually along generally being parallel to the online manufacturing of the axis that rotates gathering-device;
Directly on the rotation gathering-device, collect first group of filament continuously, have a plurality of layers tubulose leptonema with formation;
Apply second group of meltblown polymer filament on this leptonema, second group is deposited on the leptonema, so that second group of polymer filaments stretches and engage through a plurality of layers of first group of polymer filaments;
Promote leptonema along the rotation gathering-device, to form the tubulose leptonema of indefinite length, it has first first type surface and second first type surface, the contiguous gathering-device of first first type surface.
100., it is characterized in that the step that promotes leptonema along the rotation gathering-device comprises the use pressure roller as the described method of claim 99.
101., it is characterized in that the step that applies second group of polymer filaments on leptonema comprises being sweeps pendular motion and apply second group of polymer filaments as the described method of claim 99, this sweeps the longitudinal size swing of pendular motion along leptonema.
102. as the described method of claim 101, it is characterized in that, in each rotary course of gathering-device, sweep pendular motion and swing about 3 times.
103., it is characterized in that when contiguous first first type surface of filament applied, it was slower to sweep pendular motion as the described method of claim 101, and when contiguous second first type surface of filament applied, it was very fast to sweep pendular motion.
104., it is characterized in that the step that applies second group of polymer filaments on leptonema comprises from the source that is the acute angle location with respect to gathering-device and applies second group of polymer filaments as the described method of claim 99.
105., it is characterized in that the step that promotes comprises that also edge rotation gathering-device promotes leptonema simultaneously and compresses filament with pressure roller, crosses the density gradient of tubulose leptonema with formation continuously as the described method of claim 99.
106., it is characterized in that it also comprises as the described method of claim 99
The edge rotates an end of gathering-device and leaves this end and promotes the tubulose leptonema continuously,
Therefore, tubulose group has the inner cylindrical passage that is formed by gathering-device; With
The tubulose leptonema is cut into a plurality of independent filamentary element.
107., it is characterized in that the step of making first group of polymer filaments continuously also comprises as the described method of claim 99:
By the first nozzle extrusion polymerization material, to form first polymer flow, first polymer flow is usually perpendicular to gathering-device; With
First polymer flow is exposed to first to be subtracted in the thin air-flow.
108., it is characterized in that the step of making second group of polymer filaments continuously also comprises as the described method of claim 107:
By the second nozzle extrusion polymerization material, to form second polymer flow, second nozzle is than the more close gathering-device of first nozzle; With
Second polymer flow is exposed to second to be subtracted in the thin air-flow.
109., it is characterized in that the step of making first group of polymer filaments continuously also comprises as the described method of claim 108:
By the 3rd nozzle extrusion polymerization material, to form the trimerization logistics, terpolymer circulates often perpendicular to gathering-device, and is parallel to first polymer flow usually, contiguous first polymer flow of trimerization logistics, the trimerization logistics and first polymer flow overlap; With
The trimerization logistics is exposed to the 3rd to be subtracted in the thin air-flow.
110., it is characterized in that the step of making first group of polymer filaments continuously also comprises as the described method of claim 109:
By the 4th nozzle extrusion polymerization material, forming the 4th polymer flow, the 4th polymer flow is usually perpendicular to gathering-device, and is parallel to first and the trimerization logistics usually,
The contiguous trimerization logistics of the 4th polymer flow, the 4th polymer flow and trimerization logistics overlap; With
The 4th polymer flow is exposed to the 4th to be subtracted in the thin air-flow.
111., it is characterized in that it also comprises as the described method of claim 99:
Apply the 3rd group of polymer filaments on leptonema, the 3rd group is deposited on the leptonema, so that the 3rd group polymer filaments stretches through a plurality of layers of first group of polymer filaments and engages.
112., it is characterized in that the step that applies the 3rd group of polymer filaments on leptonema comprises being sweeps pendular motion and apply the 3rd group of polymer filaments as the described method of claim 111, sweep the longitudinal size swing of pendular motion along leptonema.
113., it is characterized in that when contiguous first first type surface of filament applied, it was slower to sweep pendular motion as the described method of claim 112, and when contiguous second first type surface of filament applied, it was very fast to sweep pendular motion.
114., it is characterized in that the step that applies the 3rd group of polymer filaments on leptonema comprises from the source that is the acute angle location with respect to gathering-device and applies the 3rd group of polymer filaments as the described method of claim 111.
115., it is characterized in that it also comprises as the described method of claim 111:
Apply the 4th group of polymer filaments to leptonema, on second first type surface that the 4th group is deposited on leptonema.
116., it is characterized in that it also comprises as the described method of claim 111:
Under than the high temperature of the temperature of first group of polymer filaments, apply the 3rd group of polymer filaments.
117., it is characterized in that the 3rd group of polymer filaments is stretched over another first type surface from a first type surface as the described method of claim 111.
118., it is characterized in that it also comprises as the described method of claim 99:
Under than the high temperature of the temperature of first group of polymer filaments, apply second group of polymer filaments.
119., it is characterized in that second group of polymer filaments is stretched over another first type surface from a first type surface as the described method of claim 99.
120. a method of making the meltblown polymer leptonema, its step comprises:
Make first group of meltblown polymer filament, first group usually along generally being parallel to the online manufacturing of the axis that rotates gathering-device;
Directly on the rotation gathering-device, collect first group of filament, the tubulose leptonema that has the radial depth size with formation; With
On leptonema, apply second group of meltblown polymer filament, second group is deposited on the leptonema, so that second group of polymer filaments stretches at depth dimensions usually, and engage with first group of polymer filaments, to form the tubulose leptonema, this tubulose leptonema has first first type surface and second first type surface, the contiguous gathering-device of first first type surface.
121., it is characterized in that, promote leptonema along the rotation gathering-device, to form the tubulose leptonema of indefinite length as the described method of claim 120.
122., it is characterized in that the step that promotes leptonema along the rotation gathering-device comprises the use pressure roller as the described method of claim 121.
123., it is characterized in that the step that applies second group of polymer filaments on leptonema comprises being sweeps pendular motion and apply second group of polymer filaments as the described method of claim 120, sweep the longitudinal size swing of pendular motion along leptonema.
124. as the described method of claim 123, it is characterized in that, in each rotary course of gathering-device, sweep pendular motion and swing about 3 times.
125., it is characterized in that when contiguous first first type surface of filament applied, it was slower to sweep pendular motion as the described method of claim 123, and when contiguous second first type surface of filament applied, it was very fast to sweep pendular motion.
126., it is characterized in that the step that applies second group of polymer filaments on leptonema comprises from the source that is the acute angle location with respect to gathering-device and applies second group of polymer filaments as the described method of claim 120.
127., it is characterized in that the step that promotes comprises that also edge rotation gathering-device promotes leptonema simultaneously and compresses filament with pressure roller, crosses the density gradient of tubulose leptonema with formation continuously as the described method of claim 120.
128., it is characterized in that it also comprises as the described method of claim 120:
The edge rotates an end of gathering-device and leaves this end and promotes the tubulose leptonema continuously,
Therefore, tubulose group has the inner cylindrical passage that is formed by gathering-device; With
The tubulose leptonema is cut into a plurality of independent filamentary element.
129., it is characterized in that the step of making first group of polymer filaments continuously also comprises as the described method of claim 120:
By the first nozzle extrusion polymerization material, to form first polymer flow, first polymer flow is usually perpendicular to gathering-device; With
First polymer flow is exposed to first to be subtracted in the thin air-flow.
130., it is characterized in that the step of making second group of polymer filaments continuously also comprises as the described method of claim 129:
By the second nozzle extrusion polymerization material, to form second polymer flow, second nozzle is than the more close gathering-device of first nozzle; With
Second polymer flow is exposed to second to be subtracted in the thin air-flow.
131., it is characterized in that the step of making first group of polymer filaments continuously also comprises as the described method of claim 130:
By the 3rd nozzle extrusion polymerization material, to form the trimerization logistics, terpolymer circulates often perpendicular to gathering-device, and is parallel to first polymer flow usually, contiguous first polymer flow of trimerization logistics, the trimerization logistics and first polymer flow overlap;
With
The trimerization logistics is exposed to the 3rd to be subtracted in the thin air-flow.
132., it is characterized in that the step of making first group of polymer filaments continuously also comprises as the described method of claim 131:
By the 4th nozzle extrusion polymerization material, forming the 4th polymer flow, the 4th polymer flow is usually perpendicular to gathering-device, and is parallel to first and the trimerization logistics usually,
The contiguous trimerization logistics of the 4th polymer flow, the 4th polymer flow and trimerization logistics overlap; With
The 4th polymer flow is exposed to the 4th to be subtracted in the thin air-flow.
133., it is characterized in that it also comprises as the described method of claim 120:
Apply the 3rd group of polymer filaments on leptonema, the 3rd group is deposited on the leptonema, so that the 3rd group polymer filaments stretches through a plurality of layers of first group of polymer filaments and engages.
134., it is characterized in that the step that applies the 3rd group of polymer filaments on leptonema comprises being sweeps pendular motion and apply the 3rd group of polymer filaments as the described method of claim 133, sweep the longitudinal size swing of pendular motion along leptonema.
135., it is characterized in that when contiguous first first type surface of filament applied, it was slower to sweep pendular motion as the described method of claim 134, and when contiguous second first type surface of filament applied, it was very fast to sweep pendular motion.
136., it is characterized in that the step that applies the 3rd group of polymer filaments on leptonema comprises from the source that is the acute angle location with respect to gathering-device and applies the 3rd group of polymer filaments as the described method of claim 133.
137., it is characterized in that it also comprises as the described method of claim 133:
Apply the 4th group of polymer filaments to leptonema, on second first type surface that the 4th group is deposited on leptonema.
138., it is characterized in that it also comprises as the described method of claim 133:
Under than the high temperature of the temperature of first group of polymer filaments, apply the 3rd group of polymer filaments.
139., it is characterized in that the 3rd group of polymer filaments is stretched over another first type surface from a first type surface as the described method of claim 133.
140., it is characterized in that it also comprises as the described method of claim 120:
Under than the high temperature of the temperature of first group of polymer filaments, apply second group of polymer filaments.
141., it is characterized in that second group of polymer filaments is stretched over another first type surface from a first type surface as the described method of claim 120.
Applications Claiming Priority (6)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US34382701P | 2001-10-23 | 2001-10-23 | |
| US60/343,827 | 2001-10-23 | ||
| US10/279,043 | 2002-10-23 | ||
| US10/279,043 US6916395B2 (en) | 2001-10-23 | 2002-10-23 | Process for making three-dimensional non-woven media |
| US10/278,247 | 2002-10-23 | ||
| US10/278,247 US6986427B2 (en) | 2001-10-23 | 2002-10-23 | Three-dimensional non-woven media |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2009102526909A Division CN102002820A (en) | 2001-10-23 | 2002-10-23 | Three-dimensional non-woven media, filter and process |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1608155A true CN1608155A (en) | 2005-04-20 |
| CN100582343C CN100582343C (en) | 2010-01-20 |
Family
ID=34799525
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2009102526909A Pending CN102002820A (en) | 2001-10-23 | 2002-10-23 | Three-dimensional non-woven media, filter and process |
| CN02825973A Expired - Lifetime CN100582343C (en) | 2001-10-23 | 2002-10-23 | Three-dimensional non-woven media, filter and process |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2009102526909A Pending CN102002820A (en) | 2001-10-23 | 2002-10-23 | Three-dimensional non-woven media, filter and process |
Country Status (1)
| Country | Link |
|---|---|
| CN (2) | CN102002820A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101913249A (en) * | 2010-06-30 | 2010-12-15 | 苏州工业园区拓朴环保净化有限公司 | External pressing type extrusion device of meltblown filter core |
| CN102085426A (en) * | 2009-12-02 | 2011-06-08 | 现代自动车株式会社 | Diesel fuel filter |
| CN102345210A (en) * | 2010-07-30 | 2012-02-08 | 财团法人纺织产业综合研究所 | Equipment and method for preparing stereoscopic non-woven fabric structure |
| US9260807B2 (en) | 2010-07-30 | 2016-02-16 | Taiwan Textile Research Institute | Apparatus and method for fabricating three-dimensional nonwoven fabric structure |
| CN105705215A (en) * | 2013-11-06 | 2016-06-22 | 通用电气公司 | Melt-blown depth filter cartridge |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11845019B2 (en) | 2013-11-06 | 2023-12-19 | Bl Technologies, Inc. | Large format melt-blown depth filter cartridge |
| EP3288663A1 (en) | 2015-04-28 | 2018-03-07 | General Electric Company | Melt-blown depth filter element, method and machine of making it |
| CN113174700A (en) * | 2021-04-25 | 2021-07-27 | 深圳汇信昌供应链有限公司 | Processing method of non-woven wall cloth with high air permeability |
-
2002
- 2002-10-23 CN CN2009102526909A patent/CN102002820A/en active Pending
- 2002-10-23 CN CN02825973A patent/CN100582343C/en not_active Expired - Lifetime
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102085426A (en) * | 2009-12-02 | 2011-06-08 | 现代自动车株式会社 | Diesel fuel filter |
| CN101913249A (en) * | 2010-06-30 | 2010-12-15 | 苏州工业园区拓朴环保净化有限公司 | External pressing type extrusion device of meltblown filter core |
| CN102345210A (en) * | 2010-07-30 | 2012-02-08 | 财团法人纺织产业综合研究所 | Equipment and method for preparing stereoscopic non-woven fabric structure |
| CN102345210B (en) * | 2010-07-30 | 2013-07-24 | 财团法人纺织产业综合研究所 | Equipment and method for preparing stereoscopic non-woven fabric structure |
| US9260807B2 (en) | 2010-07-30 | 2016-02-16 | Taiwan Textile Research Institute | Apparatus and method for fabricating three-dimensional nonwoven fabric structure |
| CN105705215A (en) * | 2013-11-06 | 2016-06-22 | 通用电气公司 | Melt-blown depth filter cartridge |
Also Published As
| Publication number | Publication date |
|---|---|
| CN100582343C (en) | 2010-01-20 |
| CN102002820A (en) | 2011-04-06 |
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