US20030127171A1 - Filter composite embodying glass fiber and synthetic resin fiber - Google Patents

Filter composite embodying glass fiber and synthetic resin fiber Download PDF

Info

Publication number
US20030127171A1
US20030127171A1 US10376026 US37602603A US2003127171A1 US 20030127171 A1 US20030127171 A1 US 20030127171A1 US 10376026 US10376026 US 10376026 US 37602603 A US37602603 A US 37602603A US 2003127171 A1 US2003127171 A1 US 2003127171A1
Authority
US
Grant status
Application
Patent type
Prior art keywords
combination
fibers
composite
layer
filter
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10376026
Inventor
Jack Pfeffer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Consolidated Fiberglass Products Co
Original Assignee
Consolidated Fiberglass Products Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D39/00Filtering material for liquid or gaseous fluids
    • B01D39/14Other self-supporting filtering material ; Other filtering material
    • B01D39/20Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003Glass or glassy material
    • B01D39/2017Glass or glassy material the material being filamentary or fibrous
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D39/00Filtering material for liquid or gaseous fluids
    • B01D39/14Other self-supporting filtering material ; Other filtering material
    • B01D39/16Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/34Layered products comprising a layer of synthetic resin comprising polyamides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2904Staple length fiber
    • Y10T428/2909Nonlinear [e.g., crimped, coiled, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2918Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
    • Y10T428/292In coating or impregnation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2973Particular cross section
    • Y10T428/2975Tubular or cellular
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/603Including strand or fiber material precoated with other than free metal or alloy
    • Y10T442/604Strand or fiber material is glass
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/603Including strand or fiber material precoated with other than free metal or alloy
    • Y10T442/607Strand or fiber material is synthetic polymer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608Including strand or fiber material which is of specific structural definition
    • Y10T442/609Cross-sectional configuration of strand or fiber material is specified
    • Y10T442/612Hollow strand or fiber material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608Including strand or fiber material which is of specific structural definition
    • Y10T442/627Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608Including strand or fiber material which is of specific structural definition
    • Y10T442/627Strand or fiber material is specified as non-linear [e.g., crimped, coiled, etc.]
    • Y10T442/631Glass strand or fiber material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659Including an additional nonwoven fabric
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659Including an additional nonwoven fabric
    • Y10T442/668Separate nonwoven fabric layers comprise chemically different strand or fiber material
    • Y10T442/669At least one layer of inorganic strand or fiber material and at least one layer of synthetic polymeric strand or fiber material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659Including an additional nonwoven fabric
    • Y10T442/67Multiple nonwoven fabric layers composed of the same inorganic strand or fiber material

Abstract

A filter composite comprises a first layer of glass fibers having random orientation, and synthetic resinous fibers extending in close association with the glass fibers, the glass fibers having:
i) diameters between 1 and 16 microns
ii) lengths between about ¼ and 1½ inches the synthetic fibers having denier between 1.6 and 40, and length between ¼ and 2 inches.

Description

    BACKGROUND OF THE INVENTION
  • This invention relates generally to forming of fiber composites, for example as are used in air filtration; and more particularly, the invention concerns provision of a filter composite comprising multiple layers of porous materials, of such characteristics as enable the composite to be self-supporting, i.e., without need for wire backing or other auxiliary support adjacent areal extents of the composite. Such wireless composites are of great advantage, as respects ease of manufacture, use in filtering, and ease of disposal. Wire-supported filters require wire trimming, producing sharp edges which can and do injure hands of workers manufacturing filters. [0001]
  • There is need for longer-life filters capable of efficiently filtering particulate from gas streams, and there is need for efficient, effective methods of producing such filters. There is also need for preventing escape of smaller diameter fibers from filter structures. [0002]
  • The disclosures of U.S. Pat. Nos. 3,690,852 and 5,985,411 are incorporated herein, by reference. [0003]
  • SUMMARY OF THE INVENTION
  • It is a major object of the invention to provide an improvement filter composites meeting the above needs. That composite basically comprises [0004]
  • a) a first layer of glass fibers having random orientation, and [0005]
  • b) synthetic resinous fibers extending in close association with the glass fibers. [0006]
  • As will be seen, the synthetic resinous fibers may be distributed in mixed relation with the glass fibers of the first layer; or the synthetic resinous fibers may extend in a layer separate from but adjacent to the first layer glass fibers. Both such modes of synthetic fiber disposition may be employed in a filter composite employing glass fibers. Typically, the synthetic resinous fibers may comprise between 10% and 60% by volume of the total composite volume of both glass and synthetic resin fibers. The synthetic resinous fibers may typically consist of polyester resin. [0007]
  • Another object is to provide an additional porous layer which blocks escape of fibers, to consist essentially of non-woven, synthetic fiber, examples being CEREX, non-woven NYLON or RAYON. The latter is provided as an air-laid, NYLON, or RAYON non-woven layer. That additional layer is typically bonded to the glass fiber layer during the manufacturing process. [0008]
  • A further object includes provision of bonding resin adherent to the fibers in such layers, the filter composite being porous. The bonding resin typically is applied to saturate the described layer or layers, excess resin being removed, as by vacuum application to the composite, whereby porosity of the composite is maintained or provided. [0009]
  • Yet another object is to provide a composite having synthetic resinous fibers with crimped or hollow shapes, and straight shafts, and wherein the bulk of the glass fibers have: [0010]
  • i) diameters between 1 and 16 microns [0011]
  • ii) lengths between ¼ and 1½ inches. [0012]
  • The filter composite typically has weight between 0.01 and 0.05 lbs, per square foot; and thickness between 0.02 and 0.10 inches. [0013]
  • A yet further object includes: [0014]
  • a) providing a first layer of glass fibers having random orientation, [0015]
  • b) providing an additional layer of non-woven NYLON or RAYON fibers extending adjacent that first layer, [0016]
  • c) and providing and adhering bonding resin to fibers in such layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter. [0017]
  • As will be seen, the bonding resin consists essentially of thermoplastic resin adapted to be heated during reforming of the filter to selected shape. The filter typically assumes selected shape after heating, reforming, and cooling of the resin; and one advantageous shape comprises folds or pleats, as may be chosen by the user following filter material manufacture and sale. [0018]
  • These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: [0019]
  • DRAWING DESCRIPTION
  • FIGS. [0020] 1-4 are sections taken through filter composites embodying the invention, and are preferred.
  • DETAILED DESCRIPTION
  • In FIG. 1 a first porous layer [0021] 10 of glass fibers (of random orientation) is formed or provided. The fibers may be deposited onto a porous conveyor belt 11 traveling lengthwise as indicated by arrow 12. Layer 10 may include a non-woven glass fiber porous, mat 13 transported by the conveyor belt, and the glass fibers may be deposited as a sub-layer 10 b on the mat 13. Mat 13 may alternatively be deposited on top of layer 10, as indicated by broken lines 13′. Synthetic resin fibers are substantially uniformly and homogeneously mixed in, or dispersed into the glass fibers in the sub-layer 10 b, thereby building up its thickness for enhanced collection and partially entrapment during use as a filter. The synthetic fibers may for example consist of polyester resin, or other man-made fibers such as NYLON and/or RAYON and others, and preferably have bulky form, as produced by crimping of the synthetic resin fibers before they are mixed in with the glass fiber. Alternatively, the synthetic fibers may be hollow to increase their bulk. The overall thickness t of layer 10 of glass fibers thereby is substantially enhanced for improved filtering of particulate.
  • The synthetic fibers in the mix may have various diameters, i.e. denier between 1.6 and 40, and they preferably provide volumetrically between about 10% and 60% of the overall volume of the layer [0022] 10. The fibers have at least one of the following shapes
  • i) crimped [0023]
  • ii) hollow [0024]
  • iii) straight shafts [0025]
  • iv) solid shafts [0026]
  • The length of the bulk of the synthetic fiber lie between 0.25 and 2.0 inches. The overall thickness t of a fiber is typically between 0.010 and 0.100 inches. [0027]
  • The bulk of the glass fibers in layer [0028] 10 b typically have filament diameters between 1 and 16 microns, and lengths between 0.25 and 1.50 inches. The filter composite has weight between 0.01 and 0.05 lbs per square foot.
  • FIG. 2 shows a glass fiber layer [0029] 20 like layer 10 of FIG. 1, except that the synthetic resinous fibers extend in a separate porous layer 21 adjacent or attached by adhesive bonding, to one side of layer 20 instead of being mixed in or distributed within layer 20. The objective of increasing the thickness of the overall composite 22 without increasing the filter weight per unit area is still attained. The synthetic resinous and glass fibers themselves have the same physical characteristics as referred to above. The thickness of synthetic fiber layer 21 is such that volumetrically the synthetic fiber constitute between 10% and 60% of the volume of the overall composite of layers 20 and 21, per unit area of the composite.
  • FIG. 3 is like FIG. 1, (synthetic fibers mixed into glass fibers) except that a thin flexible layer [0030] 100 of porous material (as for example NYLON or RAYON, or other man-made fibers) is attached, as by porous adhesive bonding, as at 40 to one side of the composite layer 10, for containing (preventing pass-through escape of) very small diameter fibers in 10. Layer 100 has a surface weight of between 0.4 and 0.5 oz. per square yard, its thickness being between 0.001 and 0.005 inch. The NYLON, and/or RAYON layer 100 may be supported by a porous belt 24 during formation of the composite. Fiber layer 10, containing synthetic fiber as described, is progressively deposited on the layer 100 during endwise travel of belt 24. The layer 100 may be substantially thinner than the layer 10. The FIG. 3 filter composite is a preferred form of the invention.
  • FIG. 4 is like FIG. 2, except that layer [0031] 100 a of porous material (as for example CEREX, or non-woven NYLON or RAYON) is attached, as by porous adhesive bonding, to one side of the composite 22. Layer 100 a functions and has the characteristics of layer 100 as described above, in regards to FIG. 3. Composite 22 includes glass fiber layer 20 and synthetic fiber layer 21.
  • In each of FIGS. 2, 3 and [0032] 4 above bonding resin may be applied, as by fluid curtain coating application to the composite, to saturate and bind the multiple layers together. Excess resin is removed as by vacuum application to the composite, as it progressively moves with a supporting porous belt, through vacuum application apparatus. The composite then passes through an oven, for drying and curing of the product. Subsequently, the composite is removed from the belt, and cut to size and rolled up into jumbo rolls. The bonding resin advantageously consists of a water resistant thermoplastic resin.
  • The filter composite in its variously described forms has sufficient thickness to be resiliently and yieldably bendable during gas flow impingement on said composite, at gas flow velocity between 35 and 2000 ft[0033] 3 per minute.
  • The method of forming a filter media composite typically includes the steps: [0034]
  • a) providing a first layer of glass fibers having random orientation, [0035]
  • b) providing an additional layer of synthetic resinous fibers extending adjacent said first layer, [0036]
  • c) and providing and adhering bonding resin to fibers in said layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter. [0037]
  • The bonding resin typically consists of thermoplastic resin and the method may also include reforming the media composite to selected shape and heating the reformed media composite to cause the composite to maintain said selected shape. [0038]
  • The bonding resin may for certain purposes consist of thermosetting resin, as where resin softening during reforming is not required, or where reforming is not required. [0039]

Claims (33)

    I claim:
  1. 1. In a filter composite the combination comprising
    a) a first layer of glass fibers having random orientation, and
    b) synthetic resinous fibers extending in close association with said glass fibers,
    c) said glass fibers having:
    i) diameters between 1 and 16 microns
    ii) lengths between about ¼ and 1½ inches
    d) said synthetic fibers having denier between 1.6 and 40, and length between ¼ and 2 inches.
  2. 2. The combination of claim 1 wherein said synthetic resinous fibers are distributed in a homogeneous mix with said first layer glass fibers.
  3. 3. The combination of claim 1 wherein said synthetic resinous fibers together comprise between 10 and 60% by volume of the total composite volume.
  4. 4. The combination of claim 2 wherein the composite includes an additional layer of non-woven NYLON or RAYON fiber extending adjacent said first layer.
  5. 5. The combination of claim 4 wherein said non-woven glass fiber layer consists of non-woven NYLON or RAYON laminated onto the layer of glass fibers.
  6. 6. The combination of claim 5 wherein said synthetic resinous fibers together comprise between 10 and 60% by volume of the total composite volume.
  7. 7. The combination of claim 1 wherein said synthetic resinous fibers extend in a second layer adjacent said first layer.
  8. 8. The combination of claim 7 wherein the composite includes an additional layer of non-woven NYLON or RAYON fiber extending adjacent one of said first and second layers.
  9. 9. The combination of claim 8 wherein said non-woven glass fiber layer consists of NYLON or RAYON.
  10. 10. The combination of claim 4 including bonding resin adherent to the fibers in said layers, the filter composite being porous.
  11. 11. The combination of claim 8 including bonding resin adherent to the fibers in said layers, the filter composite being porous.
  12. 12. The combination of claim 10 wherein the bonding resin saturates said layers.
  13. 13. The combination of claim 11 wherein the bonding resin saturates said layers.
  14. 14. The combination of claim 1 wherein said synthetic resinous fibers consist of polyester resin, or other man-made fibers.
  15. 15. The combination of claim 1 wherein said synthetic resinous fibers have one or more of the following shapes:
    i) crimped
    ii) hollow
    iii) straight shafts
    iv) solid shafts
  16. 16. The combination of claim 4 wherein said synthetic resinous fibers consist of one of the following:
    i) polyester resin
    ii) other man-made fibers
  17. 17. The combination of claim 4 wherein said synthetic resinous fibers have one of the following shapes:
    i) crimped
    ii) hollow
    iii) straight shafts
    iv) solid shafts
  18. 18. The combination of claim 1 wherein the bulk of said glass fibers have:
    i) diameters between 1 and 16 microns
    ii) lengths between ¼ and 1½ inches.
  19. 19. The combination of claim 1 wherein the filter composite has weight between 0.01 and 0.05 lbs, per square foot.
  20. 20. The combination of claim 8 wherein the filter composite has weight between 0.01 and 0.05 lbs per square foot.
  21. 21. The combination of claim 1 wherein the filter composite has sufficient thickness to be self supporting during gas flow impingement on said composite, at gas flow velocity between 35 and 2,000 feet per minute.
  22. 22. The combination of claim 8 wherein the filter composite has sufficient thickness to be self supporting gas flow impingement on said composite at gas flow velocity between 35 and 2,000 feet3 per minute.
  23. 23. The combination of claim 1 wherein the composite overall thickness is between 0.010 and 0.100 inches.
  24. 24. The combination of claim 8 wherein the composite overall thickness is between 0.010 and 0.100 inches.
  25. 25. In a filter composite, the combination comprising
    a) a first layer of glass fibers having random orientation,
    b) an additional layer of non-woven glass fiber extending adjacent said first layer,
    c) and including bonding resin adherent to fibers in said layers, the fiber composite being porous,
    d) and wherein the bulk of said glass fibers have:
    i) diameters between 1 and 16 microns
    ii) lengths between ¼ and 1½ inches.
  26. 26. The combination of claim 25 wherein the additional layer faces the first layer, and consists of NYLON or RAYON.
  27. 27. The combination of claim 25 wherein the bonding resin consists essentially of thermoplastic resin adapted to be heated during reforming of the filter to selected shape.
  28. 28. The combination of claim 27 wherein the filter has been reformed to selected shape, said selected shape including pleats.
  29. 29. The combination of claim 25 wherein the resin is thermosetting.
  30. 30. The method of forming a filter media composite which includes the steps:
    a) providing a first layer of glass fibers having random orientation,
    b) providing an additional layer of synthetic resinous or other man-made fibers extending adjacent said first layer,
    c) and providing and adhering bonding resin to fibers in said layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter.
  31. 31. The method of claim 30 wherein the bonding resin consists essentially of thermoplastic resin, and including reforming the media composite to selected shape and heating the reformed media composite to cause the composite to maintain said selected shape.
  32. 32. The method of claim 30 wherein the bonding resin is thermosetting.
  33. 33. The method of claim 30 wherein an additional layer is positioned to face the first layer, and consists of a non-woven fiber backer.
US10376026 2000-06-20 2003-02-28 Filter composite embodying glass fiber and synthetic resin fiber Abandoned US20030127171A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US09597080 US6555489B1 (en) 2000-06-20 2000-06-20 Filter composite embodying glass fiber and synthetic resin fiber
US10376026 US20030127171A1 (en) 2000-06-20 2003-02-28 Filter composite embodying glass fiber and synthetic resin fiber

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10376026 US20030127171A1 (en) 2000-06-20 2003-02-28 Filter composite embodying glass fiber and synthetic resin fiber

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US09597080 Division US6555489B1 (en) 2000-06-20 2000-06-20 Filter composite embodying glass fiber and synthetic resin fiber

Publications (1)

Publication Number Publication Date
US20030127171A1 true true US20030127171A1 (en) 2003-07-10

Family

ID=24390011

Family Applications (2)

Application Number Title Priority Date Filing Date
US09597080 Expired - Fee Related US6555489B1 (en) 2000-06-20 2000-06-20 Filter composite embodying glass fiber and synthetic resin fiber
US10376026 Abandoned US20030127171A1 (en) 2000-06-20 2003-02-28 Filter composite embodying glass fiber and synthetic resin fiber

Family Applications Before (1)

Application Number Title Priority Date Filing Date
US09597080 Expired - Fee Related US6555489B1 (en) 2000-06-20 2000-06-20 Filter composite embodying glass fiber and synthetic resin fiber

Country Status (2)

Country Link
US (2) US6555489B1 (en)
DE (1) DE10128857A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7427575B2 (en) 2004-06-02 2008-09-23 Owens Corning Intellectual Capital, Llc Faced fibrous insulation

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050284065A1 (en) * 2004-06-02 2005-12-29 Shaffer Roy E Faced fibrous insulation
JP4885134B2 (en) * 2004-08-05 2012-02-29 エイカーズ バイオサイエンスィズ インコーポレイテッド Blood separation device, and a method of separating a liquid component fraction from whole blood
US8021457B2 (en) 2004-11-05 2011-09-20 Donaldson Company, Inc. Filter media and structure
CA2586636C (en) * 2004-11-05 2013-10-01 Donaldson Company, Inc. Filter medium and structure
US8057567B2 (en) 2004-11-05 2011-11-15 Donaldson Company, Inc. Filter medium and breather filter structure
JP5308031B2 (en) 2005-02-04 2013-10-09 ドナルドソン カンパニー,インコーポレイティド Ventilation filter and ventilation filtration assembly
US8404014B2 (en) 2005-02-22 2013-03-26 Donaldson Company, Inc. Aerosol separator
JP2010529902A (en) 2007-02-22 2010-09-02 ドナルドソン カンパニー インコーポレイテッド Filter elements and methods
WO2008103821A3 (en) 2007-02-23 2008-10-23 Donaldson Co Inc Formed filter element
US20080233825A1 (en) * 2007-03-21 2008-09-25 Mohamed Walid Gamaleldin Articles Including High Modulus Fibrous Material
US8673040B2 (en) 2008-06-13 2014-03-18 Donaldson Company, Inc. Filter construction for use with air in-take for gas turbine and methods
US9885154B2 (en) 2009-01-28 2018-02-06 Donaldson Company, Inc. Fibrous media
WO2011017457A3 (en) * 2009-08-04 2011-06-03 The Xextex Corporation High efficiency low pressure drop synthetic fiber based air filter made completely from post consumer waste materials
US20150096444A1 (en) * 2013-10-04 2015-04-09 Bha Altair, Llc Nonwoven felt with hollow specialty polymer fibers for air filtration
US20150096443A1 (en) * 2013-10-04 2015-04-09 Bha Altair, Llc Nonwoven felt with hollow commodity polymer fibers for air filtration
US10011528B2 (en) 2014-10-10 2018-07-03 Fpinnovations Compositions, panels and sheets comprising mineral fillers and methods to produce the same

Citations (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2839158A (en) * 1955-12-20 1958-06-17 Metals Disintegrating Co Filter medium for dust filters
US3074834A (en) * 1956-08-13 1963-01-22 Rohm & Haas Non-woven fibrous products and methods for their production
US3663348A (en) * 1968-05-16 1972-05-16 Johnson & Johnson A lofty and soft nonwoven, through bonded fabric
US3690852A (en) * 1969-12-29 1972-09-12 Owens Corning Fiberglass Corp Method of producing graded fibrous filter media
US3772739A (en) * 1971-01-21 1973-11-20 Johnson & Johnson Web forming apparatus
US4018646A (en) * 1973-05-09 1977-04-19 Johnson & Johnson Nonwoven fabric
US4227899A (en) * 1978-09-06 1980-10-14 Meny Allan H Absolute fluid filter
US4418031A (en) * 1981-04-06 1983-11-29 Van Dresser Corporation Moldable fibrous mat and method of making the same
US5389121A (en) * 1993-08-09 1995-02-14 Pfeffer; Jack R. Composite of layers of glass fibers of various filament diameters
US5472467A (en) * 1994-03-14 1995-12-05 Pfeffer; Jack R. Self-supporting filter composite
US5630856A (en) * 1994-03-14 1997-05-20 Upf Corporation Self-supporting filter composite
US5785725A (en) * 1997-04-14 1998-07-28 Johns Manville International, Inc. Polymeric fiber and glass fiber composite filter media
US5872067A (en) * 1997-03-21 1999-02-16 Ppg Industries, Inc. Glass fiber strand mats, thermoplastic composites reinforced with the same and methods for making the same
US5882517A (en) * 1996-09-10 1999-03-16 Cuno Incorporated Porous structures
US5985411A (en) * 1994-03-14 1999-11-16 Upf Corporation Self-supporting pleated filter composite

Patent Citations (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2839158A (en) * 1955-12-20 1958-06-17 Metals Disintegrating Co Filter medium for dust filters
US3074834A (en) * 1956-08-13 1963-01-22 Rohm & Haas Non-woven fibrous products and methods for their production
US3663348A (en) * 1968-05-16 1972-05-16 Johnson & Johnson A lofty and soft nonwoven, through bonded fabric
US3690852A (en) * 1969-12-29 1972-09-12 Owens Corning Fiberglass Corp Method of producing graded fibrous filter media
US3772739A (en) * 1971-01-21 1973-11-20 Johnson & Johnson Web forming apparatus
US4018646A (en) * 1973-05-09 1977-04-19 Johnson & Johnson Nonwoven fabric
US4227899A (en) * 1978-09-06 1980-10-14 Meny Allan H Absolute fluid filter
US4418031A (en) * 1981-04-06 1983-11-29 Van Dresser Corporation Moldable fibrous mat and method of making the same
US5389121A (en) * 1993-08-09 1995-02-14 Pfeffer; Jack R. Composite of layers of glass fibers of various filament diameters
US5472467A (en) * 1994-03-14 1995-12-05 Pfeffer; Jack R. Self-supporting filter composite
US5630856A (en) * 1994-03-14 1997-05-20 Upf Corporation Self-supporting filter composite
US5985411A (en) * 1994-03-14 1999-11-16 Upf Corporation Self-supporting pleated filter composite
US5882517A (en) * 1996-09-10 1999-03-16 Cuno Incorporated Porous structures
US5928588A (en) * 1996-09-10 1999-07-27 Cuno, Incorporated Porous filter structure and process for the manufacture thereof
US5872067A (en) * 1997-03-21 1999-02-16 Ppg Industries, Inc. Glass fiber strand mats, thermoplastic composites reinforced with the same and methods for making the same
US5785725A (en) * 1997-04-14 1998-07-28 Johns Manville International, Inc. Polymeric fiber and glass fiber composite filter media

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7427575B2 (en) 2004-06-02 2008-09-23 Owens Corning Intellectual Capital, Llc Faced fibrous insulation

Also Published As

Publication number Publication date Type
DE10128857A1 (en) 2002-02-28 application
US6555489B1 (en) 2003-04-29 grant

Similar Documents

Publication Publication Date Title
US4755178A (en) Sorbent sheet material
US4011067A (en) Filter medium layered between supporting layers
US5350620A (en) Filtration media comprising non-charged meltblown fibers and electrically charged staple fibers
US4699681A (en) Method of making a gas phase permeable filter
US5721180A (en) Laminate filter media
US6162522A (en) Loop substrate for releasably attachable abrasive sheet material
US6071419A (en) Fluid filter, method of making and using thereof
US7235115B2 (en) Method of forming self-supporting pleated filter media
US2383066A (en) Filter unit and method of making the same
US6966939B2 (en) Multi-layer filter structure and use of a multi-layer filter structure
US5607491A (en) Air filtration media
Hutten Handbook of nonwoven filter media
EP0960645A2 (en) Vacuum cleaner bag or filter, and method of filtering a gas
US20050026527A1 (en) Nonwoven containing acoustical insulation laminate
US20090120048A1 (en) Meltblown Filter Medium
US4687697A (en) Composite having improved transverse structural integrity and flexibility for use in high temperature environments
US4227904A (en) Gas phase permeable filter
EP0156649A2 (en) Sorbent sheet material
US20100282682A1 (en) Fluid filtration articles and methods of making and using the same
US4961974A (en) Laminated filters
US4921645A (en) Process of forming microwebs and nonwoven materials containing microwebs
US5283106A (en) Nonwoven material of two or more layers, in particular with long-term filter properties and manufacture thereof
US4048075A (en) Filter cartridge
US4661132A (en) Themally formed gradient density filter
US2484787A (en) Battery separator