US20120012523A1 - Fabric material composite construction for use as a filter means - Google Patents

Fabric material composite construction for use as a filter means Download PDF

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Publication number
US20120012523A1
US20120012523A1 US13/138,696 US201013138696A US2012012523A1 US 20120012523 A1 US20120012523 A1 US 20120012523A1 US 201013138696 A US201013138696 A US 201013138696A US 2012012523 A1 US2012012523 A1 US 2012012523A1
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United States
Prior art keywords
fabric
composite construction
construction
filtering
nanofiber
Prior art date
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Abandoned
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US13/138,696
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English (en)
Inventor
Paolo Canonico
Liuba Napoli
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SAATI SpA
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SAATI SpA
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Publication date
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Assigned to SAATI S.P.A. reassignment SAATI S.P.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CANONICO, PAOLO, NAPOLI, LIUBA
Publication of US20120012523A1 publication Critical patent/US20120012523A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • B01D46/546—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms using nano- or microfibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
    • B01D39/083—Filter cloth, i.e. woven, knitted or interlaced material of organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/728—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by electro-spinning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • B01D2239/0478—Surface coating material on a layer of the filter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0681—The layers being joined by gluing

Definitions

  • the present invention relates to a fabric material composite construction for use as a filter means or media.
  • particles having a particle size less than 1-2 microns cannot be separated by filtering fabric materials, because of technologic limitations of the weaving process preventing from weaving fabric materials with a mesh opening less than 5 microns.
  • the aim of the present invention is to provide a fabric material composite construction preventing particles having a particle size of 1-2 microns from passing therethrough.
  • a main object of the invention is to provide such a fabric material composite construction having precise and selective filtering properties like those of precision fabrics, together with a powder filtering capability.
  • Yet another object of the present invention is to provide such a fabric material composite construction adapted to increase the life span of filtering media made thereby.
  • Yet another object of the present invention is to provide such fabric material composite construction having an acoustical impedance less than that of fabric materials with a similar mesh size, for use in acoustical applications also providing a protective function, for example in a cellular phone where the fabric also protect phone inner parts from magnetic and powder particles, that is a fabric with a very small mesh size and a low fabric impedance, while allowing sound to pass therethrough.
  • a fabric material composite construction for use as a filter means or media, characterized in that said construction comprises a combination of one or more nanofiber layers and a synthetic single-thread squarely knitted precision fabric.
  • the nanofiber layer in particular, is overlapped or coated on said single-thread fabric by an electro-spinning coating method and being embedded in said supporting fabric thereby forming a single or cohesively bound filtering means or media.
  • a further adhesive material layer for example an aqueous solution acrylic glue material, may also be deposited on the above fabric construction, to increase the fabric material and nanofibers cohesive binding.
  • the above fabric material provides a very high structural strength filtering membrane.
  • nanofiber layer on both the fabric material faces and/or to bind thereto an additional fabric layer thereby forming a sandwich fabric arrangement including therein the nanofiber layer, which is very advantageous in several filtering applications such as acoustic, vehicle, white good, water, diagnostic and medical filtering applications requiring highly micrometric particle filtering efficient and permeable filtering media preserving good flowrate properties.
  • FIG. 1 schematically shows an electro-spinning apparatus
  • FIG. 2 shows a table showing the characterizing parameters of the base PA 120.30 WO fabric material, together with its filtering efficiency;
  • FIG. 3 is another table showing the characterizing parameters of a coupled or laminated filtering material consisting of a fabric material+PA 120.30 WO nanofibers;
  • FIG. 4 is another table showing the characterizing parameters of a base PES AM 120.34 WB fabric material
  • FIG. 5 is another table showing the characterizing parameters of a laminated material consisting of a fabric material+PES AM 120.34 WB nanofibers, the nanofiber layer being deposited on a single side of the fabric;
  • FIG. 6 is another table showing the characterizing parameters of a laminated material consisting of a fabric material+PES AM 120.34 WB nanofibers, the nanofiber layer being deposited both on a single side of the fabric and on the two sides thereof;
  • FIG. 7 is another table showing the characterizing parameters of a coupled or laminated material consisting of a fabric material+PES AM 150.27 nanofibers, the nanofiber layer being deposited on an adhesive coated single side of the fabric;
  • FIGS. 8 , 9 and 10 are photos showing the filtering means or media including a synthetic single-thread precision fabric material with a randomly arranged nanofiber layer;
  • FIGS. 11 and 12 are further photos of the filtering means or media including a synthetic single-thread precision fabric material and a nanofiber layer after a filtering efficiency test.
  • the composite fabric construction according to the present invention comprises a synthetic single-thread plain mesh precision fabric material.
  • the inventive fabric has high strength and good handling characteristics making said composite fabric an ideal base material for filtering applications.
  • said composite fabric has a very even fabric weight, thickness, surface properties, temperature resistance, much improved with respect to those of multi-thread prior fabrics, the above advantageous properties being held constant through the overall length of the fabric roll and from one fabric batch to another fabric batch.
  • the inventive precision fabric is made with very narrow tolerance range, thereby providing a filtering means or media having a consistent filtering efficiency and air flow permeability, and this, as stated, with its constant pore size and constant properties of the single thread or yarn used for weaving it.
  • the precision fabric has a very good resistance against weather agents, water, and moisture, and may be easily made on an industrial scale.
  • the above synthetic single-thread squarely knitted precision fabric may be made of polyester, polyamide, polypropylene, polyphenylsulphide, PEEK, PVDF, PTFE, with a mesh size in a mesh size range from 2000 ⁇ m to 5 ⁇ m, and may be used as a supporting base for supporting the nanofiber layer or membrane.
  • the fabric may also be made of organic polymers comprising: PA 6, PA 6/12, Polyaramides, PUR, PES, PVA, PVAC, PAN, PEO, PS, conductive polymers (polythiophenes), fluorine based polymers and so on.
  • the fabric may also be made of biopolymers comprising kitosan, keratine, collagen, peptides and so on.
  • the base fabric is selected based on its mesh size and materials, the deposited nanofiber amount, the thickness of the deposited layer and nanofiber forming polymer based on the characteristics required for the intended application.
  • nanofibers and substrate have been so designed as to provide a maximum filtering efficiency with an acceptable pressure loss and permeability.
  • filter means herein any tridimensional systems where a geometrical dimension can be considered as a main one with respect to the other two.
  • the diameter is less than 1 micron, and of the order of nanometers (100-900 nm).
  • the properties of said nanofibers and nanofiber fabric material comprise a large specific surface, a high surface/volume ratio, a small pore size, a high porosity, a tridimensional pattern, a high permeability and a low air-flow resistance, a good separation of the particles, a good capability of rejecting powder materials and improved physical-mechanical properties thereby allowing to achieve a self-evident-“gain” with respect to the fiber active area, improved filtering properties and self-evident advantages from a flow standpoint.
  • the fabric and nanofiber construction according to the present invention may be also used in a system for depositing polymeric nanofibers on a fabric substrate by an electrospinning process which may be applied to a broad range of polymeric materials which may be also modified by adding suitable additives thereto, thereby providing improved performance fabric materials to be used in specifically designed application.
  • the electrospinning process allows to “cold spin” nanometric size polymeric fibers starting from a concentrated polymeric solution subjected to a suitable outer electrical field.
  • a very simple electrospinning apparatus for performing the above process comprises essentially the following three main component elements:
  • a voltage source generally indicated by the reference number 2, adapted to generate a high potential difference (5-50 kV);
  • a die arrangement 3 that is a device providing filaments, including a syringe, a capillary and nozzle assembly, a related vessel, and so on, therefrom is ejected a polymeric solution and which operates as a positive electrode;
  • the synthetic single-thread fabric material is arranged on the counter-electrode, at a given suitable distance from the die arrangement.
  • the nanofibers are jet deposited directly on the filtering fabric material, or may also be deposited with a random oriented pattern, to form on the fabric a weft pattern having a high surface/volume ratio and a very small pore size, the deposited nanofibers being bound to the fabric both by chemical and physical forces, thereby providing an integral assembly therewith.
  • a plasma pre-processing of the fabric material may also be used to further improve the adhesion of said nanofibers to the sublayer and their depositing evenness.
  • the process parameters to be adjusted to achieve different property nanofiber layers are the fiber size, pore average size, deposited layer thickness and nanofiber layer weight (g/m 2 ).
  • the electrospinning process may be controlled by adjusting the process parameters, material properties and environmental conditions.
  • nanofiber diameter their characteristics and properties may be easily modulated by further adjusting the process parameters.
  • the starting solution is characterized by its viscosity, polymer concentration, and solvent electric conductivity and volatility.
  • the environmental conditions are characterized by the relative moisture, temperature and pressure, while the process conditions are characterized by the applied potential difference, distance between the die arrangement and depositing surface, distance between the electrodes, the solution flow and depositing speed.
  • Inventive fabric samples have been characterized with respect to their filtering efficiency by using a filtering efficiency test bench and a conventional Saati system to verify the particle rates locked by the filtering means, the flow resistance of the laminated or coupled material, determined by measuring its permeability and the sound passage resistance determined by acoustic impedance measurements.
  • the table of FIG. 2 shows the filtering efficiency characterizing parameters of the inventive base fabric.
  • the table of FIG. 3 shows the characterizing parameters of the fabric+nanofiber coupled or laminated material.
  • a plasma pre-processed nanofiber-covered PES AM 120.34 WB fabric A plasma pre-processed nanofiber-covered PES AM 120.34 WB fabric:
  • the table of FIG. 4 further shows the characterizing parameter of the base fabric.
  • the table of FIG. 5 shows the characterizing parameters of the fabric+nanofiber coupled or laminated material, with the nanofiber layer deposited on a single side or face of the fabric
  • the table of FIG. 6 shows the characterizing parameters of the fabric+nanofiber coupled material with the nanofiber layer deposited both on a single fabric side and on the two fabric sides.
  • the table of FIG. 3 shows the characteristic parameters of the fabric+nanofiber coupled material, with the nanofiber layer deposited on a single face of the fabric.
  • the fabric material composite construction according to the present invention has a permeability larger than that of synthetic single-thread precision fabrics with similar values of the mesh size: in fact, the mesh size being the same, the permeability of the coupled filtering media or means is increased by a 2.5 factor with respect to that of a synthetic single-thread precision fabric.
  • the inventive fabric material composite construction moreover, provides filtering media having a filtering efficiency of 99% up to 2 ⁇ m, and accordingly a high filtering efficiency for particles having a particle size ⁇ 5 ⁇ m (which is the filtering limit of prior filtering precision fabrics).
  • the fabric material composite construction according to the present invention provides a powder rejecting capability, though limited to the filtering fabrics, and has an acoustic impedance less than that of synthetic single thread precision fabrics having similar mesh size values: in fact, the opening mesh size being the same, the sound passage resistance of the inventive coupled filtering means is less by a factor of 1.5 than that of a synthetic single thread precision fabric.
  • inventive fabric material composite construction has a long duration efficient filtering characteristic with a large life span of the nanofiber coating.
  • the morphology and diameter distribution of the electrospun filaments have been characterized by a SEM investigation, showing that the nanofibers have diameters varying from 80 to 850 ⁇ m, depending on the selected sample, and are interconnected to one another to define a thin weft pattern with a very small pore size.
  • FIGS. 8 , 9 and 10 show SEM photos of the filtering media constituted by a synthetic single-thread precision fabric and a nanofiber layer arranged in a random manner.
  • FIGS. 11 and 12 are further SEM photos of the filtering media constituted by a synthetic single-thread precision fabric and a nanofiber layer after a filtering efficiency test.
  • the invention has provided a fabric material composite construction for use as a filter means or media allowing to prevent the passage of particles having particle size of 1-2 microns which, up to now, could not be separated by prior filtering fabrics, because of the above mentioned technological limitations of prior weaving processes not allowing to make fabrics having a mesh size less than 5 microns.
  • the composite fabric construction according to the invention provides a precision and selective filtering like that of a typical precision fabric together with a powder rejecting capability (though limited because of the small thickness of the nanofiber layer).
  • the composite fabric construction according to the invention allows the average useful life of the filtering media to be increased due to the provision of the nanofiber layer trapping the particles in the thickness thereof.
  • the pore size being the same, the permeability is larger, with a consequent less flow/pressure drop between the upstream and downstream portions of the filters.
  • inventive composite fabric construction has an acoustic impedance smaller than that of prior fabrics having similar mesh size values, which feature is very important for acoustical application where the fabric material also provides a protective function for inner parts of apparatus (such as cellular phones) from ferromagnetic and powder particles.
  • the present invention overcomes the use limits of nanofiber membranes due to their poor mechanical strength.
  • the used materials, and the contingent size and shapes can be any, according to requirements.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Textile Engineering (AREA)
  • Nanotechnology (AREA)
  • Filtering Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
US13/138,696 2009-04-29 2010-03-11 Fabric material composite construction for use as a filter means Abandoned US20120012523A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ITMI2009A000730 2009-04-29
ITMI2009A000730A IT1393709B1 (it) 2009-04-29 2009-04-29 Struttura composita tessutale, particolarmente per l'uso quale mezzo filtrante.
PCT/EP2010/053110 WO2010124899A1 (en) 2009-04-29 2010-03-11 Fabric material composite construction for use as a filter means

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2010/053110 A-371-Of-International WO2010124899A1 (en) 2009-04-29 2010-03-11 Fabric material composite construction for use as a filter means

Related Child Applications (1)

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US15/782,715 Division US20180036669A1 (en) 2009-04-29 2017-10-12 Fabric material composite construction for use as a filter means

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US20120012523A1 true US20120012523A1 (en) 2012-01-19

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US13/138,696 Abandoned US20120012523A1 (en) 2009-04-29 2010-03-11 Fabric material composite construction for use as a filter means
US15/782,715 Abandoned US20180036669A1 (en) 2009-04-29 2017-10-12 Fabric material composite construction for use as a filter means
US16/577,684 Active US10744446B2 (en) 2009-04-29 2019-09-20 Fabric material composite construction for use as a filter means

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US15/782,715 Abandoned US20180036669A1 (en) 2009-04-29 2017-10-12 Fabric material composite construction for use as a filter means
US16/577,684 Active US10744446B2 (en) 2009-04-29 2019-09-20 Fabric material composite construction for use as a filter means

Country Status (12)

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US (3) US20120012523A1 (pt)
EP (1) EP2424641B1 (pt)
JP (1) JP6048878B2 (pt)
KR (1) KR101768727B1 (pt)
CN (1) CN102421499B (pt)
DK (1) DK2424641T3 (pt)
ES (1) ES2742183T3 (pt)
HK (1) HK1164207A1 (pt)
HR (1) HRP20191252T1 (pt)
IT (1) IT1393709B1 (pt)
PT (1) PT2424641T (pt)
WO (1) WO2010124899A1 (pt)

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WO2013127890A1 (de) * 2012-03-02 2013-09-06 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Luftfiltervorrichtung, luftfilter und luftaufbereitungsanlage
WO2016190753A1 (en) * 2015-05-25 2016-12-01 Dotterel Technologies Limited A shroud for an aircraft
US20180169550A1 (en) * 2016-12-15 2018-06-21 Hollingsworth & Vose Company Fiter media includiing adhesives
US10543441B2 (en) 2016-12-15 2020-01-28 Hollingsworth & Vose Company Filter media including adhesives and/or oleophobic properties
CN112105434A (zh) * 2018-03-08 2020-12-18 E·菲奥基 空气过滤器
US11097828B2 (en) 2017-07-24 2021-08-24 Dotterel Technologies Limited Shroud
US11110496B2 (en) 2014-03-17 2021-09-07 Korea Institute Of Science And Technology Nano composite structure with nano patterned structure on its surface and method of producing the same
US11965674B2 (en) * 2020-04-21 2024-04-23 Samsung Electronics Co., Ltd. Filter device and air cleaner having the same

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WO2016052401A1 (ja) 2014-09-30 2016-04-07 花王株式会社 衛生マスク
US9769554B2 (en) 2015-03-05 2017-09-19 Stmicroelectronics (Malta) Ltd Semiconductor integrated device for acoustic applications with contamination protection element, and manufacturing method thereof
KR101673236B1 (ko) * 2015-11-10 2016-11-07 한국과학기술연구원 섬유 내부에 발광다이오드가 내장된 웨어러블 발광소자와 그 제조방법
ITUB20160059A1 (it) 2016-02-04 2017-08-04 Saati Spa Struttura composita filtrante multistrato, in particolare per l'uso come subcomponente all'interno di prodotti acustici ed elettronici in generale
EP3231595B1 (de) 2016-04-14 2022-09-28 Sefar AG Komposit und verfahren zum herstellen eines komposits für eine akustische komponente
EP3366362B1 (en) 2017-02-23 2021-05-05 Sefar AG A protective vent and method for producing a protective vent
CN107199693B (zh) * 2017-04-18 2019-03-05 华中科技大学 一种用于增减材制造的一体化喷印装置
KR101994776B1 (ko) * 2017-08-22 2019-09-30 주식회사 대창 나노섬유를 포함하는 필터 및 이를 제조하는 방법과 장치
IT201800002049A1 (it) 2018-01-26 2019-07-26 St Microelectronics Srl Metodo di fabbricazione di una piastrina a semiconduttore provvista di un modulo filtrante sottile, piastrina a semiconduttore includente il modulo filtrante, package alloggiante la piastrina a semiconduttore, e sistema elettronico
JP2022553710A (ja) * 2019-10-24 2022-12-26 サーティ・エッセ・ピ・ア 複合フィルタ材の製造方法、及び該製造方法によって得られた複合フィルタ材
CN113272039A (zh) * 2019-10-24 2021-08-17 纱帝股份公司 制备复合过滤介质的方法和用该方法获得的复合过滤介质
ES2765374B2 (es) * 2020-04-20 2021-03-30 Bioinicia S L Filtro multicapa con propiedades antimicrobianas y su uso en aplicaciones de respiradores y mascarillas protectoras
IT202100002891A1 (it) 2021-02-10 2022-08-10 Saati Spa Composizioni polimeriche per la realizzazione di membrane nanofibrose per applicazioni cosmetico-medicali e procedimento per la loro realizzazione
CN114452841A (zh) * 2021-12-08 2022-05-10 中国石油大学(华东) 一种PVDF/PDMS@TiO2自清洁微纳米滤膜的制备方法
KR102424742B1 (ko) * 2022-06-23 2022-07-26 주식회사 휴먼텍스 친환경 원단 염색방법
WO2024009174A1 (en) 2022-07-06 2024-01-11 Saati S.P.A. Improved textile protective element for use in acoustic components of electronic devices and acoustic component provided with this element inside

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