US20180044230A1 - Preparation For Fiberglass Air Filtration Media - Google Patents
Preparation For Fiberglass Air Filtration Media Download PDFInfo
- Publication number
- US20180044230A1 US20180044230A1 US15/640,503 US201715640503A US2018044230A1 US 20180044230 A1 US20180044230 A1 US 20180044230A1 US 201715640503 A US201715640503 A US 201715640503A US 2018044230 A1 US2018044230 A1 US 2018044230A1
- Authority
- US
- United States
- Prior art keywords
- fiberglass
- media
- percent
- filaments
- accordance
- 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
Links
- 239000011152 fibreglass Substances 0.000 title claims abstract description 72
- 238000001914 filtration Methods 0.000 title claims abstract description 28
- 238000002360 preparation method Methods 0.000 title 1
- 239000000203 mixture Substances 0.000 claims abstract description 30
- 238000000034 method Methods 0.000 claims abstract description 26
- 239000011230 binding agent Substances 0.000 claims abstract description 23
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 16
- 229920005989 resin Polymers 0.000 claims abstract description 16
- 239000011347 resin Substances 0.000 claims abstract description 16
- 229920001083 polybutene Polymers 0.000 claims description 17
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 15
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 claims description 13
- 230000000750 progressive effect Effects 0.000 claims description 9
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 7
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 238000005507 spraying Methods 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 abstract description 26
- 239000000835 fiber Substances 0.000 abstract description 19
- 239000000428 dust Substances 0.000 abstract description 13
- 239000000654 additive Substances 0.000 abstract description 6
- 239000000356 contaminant Substances 0.000 abstract description 2
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 11
- IAQRGUVFOMOMEM-UHFFFAOYSA-N but-2-ene Chemical compound CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 11
- 239000007921 spray Substances 0.000 description 9
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical compound CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 description 8
- 229920000058 polyacrylate Polymers 0.000 description 8
- 239000002245 particle Substances 0.000 description 7
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 6
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical class CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 6
- XNMQEEKYCVKGBD-UHFFFAOYSA-N dimethylacetylene Natural products CC#CC XNMQEEKYCVKGBD-UHFFFAOYSA-N 0.000 description 5
- 238000009472 formulation Methods 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 4
- 239000000839 emulsion Substances 0.000 description 4
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
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- 238000000635 electron micrograph Methods 0.000 description 3
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- QQONPFPTGQHPMA-UHFFFAOYSA-N Propene Chemical compound CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 238000004378 air conditioning Methods 0.000 description 2
- GZCGUPFRVQAUEE-SLPGGIOYSA-N aldehydo-D-glucose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O GZCGUPFRVQAUEE-SLPGGIOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
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- 238000012986 modification Methods 0.000 description 2
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- 239000000178 monomer Substances 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000013566 allergen Substances 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
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- 239000003292 glue Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
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- 229940063559 methacrylic acid Drugs 0.000 description 1
- 230000000414 obstructive effect Effects 0.000 description 1
- 229910052760 oxygen Chemical group 0.000 description 1
- 239000001301 oxygen Chemical group 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 239000000375 suspending agent Substances 0.000 description 1
- GQIUQDDJKHLHTB-UHFFFAOYSA-N trichloro(ethenyl)silane Chemical compound Cl[Si](Cl)(Cl)C=C GQIUQDDJKHLHTB-UHFFFAOYSA-N 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 239000005050 vinyl trichlorosilane Substances 0.000 description 1
Images
Classifications
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- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/34—Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions
- C03C17/3405—Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions with at least two coatings of organic materials
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- 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
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
- B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
- B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
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- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2003—Glass or glassy material
- B01D39/2017—Glass or glassy material the material being filamentary or fibrous
- B01D39/2024—Glass or glassy material the material being filamentary or fibrous otherwise bonded, e.g. by resins
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- B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
- B01D46/0035—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions by wetting, e.g. using surfaces covered with oil
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/56—Winding and joining, e.g. winding spirally
- B29C53/58—Winding and joining, e.g. winding spirally helically
- B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
- B29C53/62—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels rotatable about the winding axis
- B29C53/66—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels rotatable about the winding axis with axially movable winding feed member, e.g. lathe type winding
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- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
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- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
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- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J133/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
- C09J133/02—Homopolymers or copolymers of acids; Metal or ammonium salts thereof
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J133/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
- C09J133/04—Homopolymers or copolymers of esters
- C09J133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
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-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J161/00—Adhesives based on condensation polymers of aldehydes or ketones; Adhesives based on derivatives of such polymers
- C09J161/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C09J161/22—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with acyclic or carbocyclic compounds
- C09J161/24—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with acyclic or carbocyclic compounds with urea or thiourea
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- 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
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- D04H3/002—Inorganic yarns or filaments
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- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
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- B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
- B01D2239/0604—Arrangement of the fibres in the filtering material
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- B01D2239/1258—Permeability
Definitions
- the present disclosure relates to air filtration media and, more particularly, to air filtration media manufactured to a Minimum Efficiency Reporting Value (MERV) 8 rating and above with an initial pressure drop of less than or equal to 0.20 inches water gravity (WG).
- MEV Minimum Efficiency Reporting Value
- WG water gravity
- Binders are applied to the fibers as they are wound on the drum. Binder mixtures often are comprised of 65% urea formaldehyde and 35% water. In other methods, 1 butyl tackifiers may be mixed into a water emulsion and then mixed with a urea formaldehyde emulsion binder. Urea formaldehyde emulsion is typically used as a binder of glass fibers in the fiberglass filtration industry.
- MERV Minimum Efficiency Reporting Value
- ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers
- the scale “represents a quantum leap in the precision and accuracy of air-cleaner” and allows for improved health, reduced cost and energy efficiency in heating, ventilation and air conditioning (HVAC) design as well as increased efficiency.
- HVAC heating, ventilation and air conditioning
- a HEPA filter is often impractical in central HVAC systems due to the large initial pressure drop the dense filter material causes.
- less obstructive, medium-efficiency filters of MERV 7 to 13 are almost as effective as true HEPA filters at removing allergens, with much lower associated system and operating costs.
- the addition of a polymer compounded with a dry adherent and a resin binder provides for a filter media without a high initial pressure drop.
- the scale is designed to represent the worst-case performance of a filter when dealing with particles in the range of 0.3 to 10 micrometers.
- the MERV rating is from 1 to 16. Higher MERV ratings correspond to a greater percentage of particles captured on each pass, with a MERV 16 filter capturing more than 95% of particles over the full range.
- FIG. 1 Shown in FIG. 1 is a table grouping MERV ratings by particle size:
- the fiber should be capable of progressive density with a soft springy texture.
- a polymer wherein the polymer is one of a group of polymers consisting of acrylates and methyl acrylic acids, is added to a dry adhering agent consisting essentially of a group of polybutene during the fiberglass air filtration media formation.
- Both the polymer and the dry adhering agent mix in varying percentages with a resin binder (urea formaldehyde) and are applied to the fiberglass as it is spun onto a drum.
- a resin binder urea formaldehyde
- a dry adhering agent e.g. polybutene in a specific formulation
- FIG. 1 shows a table grouping MERV ratings by particle size.
- FIG. 2 depicts a chemical structure indicative of a selected group of acrylate polymers, consisting of a 1-butyl, a methyl, an n-butyl acrylate and others in a polymeric structure.
- FIG. 3 depicts a chemical structure representative of the structures of acrylic and methyl-acrylic acid which are the basis of the methyl-acrylic polymers discussed herein.
- FIG. 4A shows an electron micrograph of a polymer discussed herein.
- FIG. 4B shows information presented by an analysis of the polymer by electron micrograph.
- FIG. 5 is a chemical formula for the most common form of an acrylate polymer 10 utilized in one embodiment of this disclosure.
- the chemical structure shown in FIG. 2 is the general structure that is indicative of a selected group of acrylate polymers, consisting of a 1-butyl, a methyl, an n-butyl acrylate and others in a polymeric structure.
- the IUPAC lists this selection of acrylates as -prop-2-enoate (either butyl or methyl).
- the chemical reaction of a selected polymer with a dry adherent and a resin binder (which also acts as an additional adherent) creates a polymeric-based tackifying agent with substantial dust holding capabilities.
- Ingredients in the acrylates copolymer group all contain the monomers acrylic acid and methyl-acrylic acid or one of their salts or esters.
- the drawing shown in FIG. 3 is more closely representative of the structures of acrylic and methyl-acrylic acid which are the basis of the methyl-acrylic polymers discussed.
- ingredients are considered similar in that they are uniformly produced in chemical reactions that leave very little residual monomer.
- residual acrylic acid may be as high as 1500 ppm, typical levels are 10 to 1000 ppm.
- Concentrations may be as high as 25% if used as a binder, film former, or fixative; or as low as 0.5% if used as a viscosity-increasing agent, suspending agent, or emulsion stabilizer.
- the structure presented provides a desirable basis for binding and adhesive properties with the carbon and oxygen bonds being of the most significance with the sulfur presenting minimally in the base formulation.
- the sodium presents as a salt of the acrylic or meth-acrylic acid.
- the dry adhering agent is a polymer of the group consisting essentially of 1-butene and 2-butene and isobutene.
- the structure of the 1-butene and the 2-butene is seen in the repeat units, where, in the case of 1-butene, the structure is:
- the C4 polymer typically includes various forms of butene, for example isobutene, 1-butene, 2-butene, and others, and can contain a small amount of propene and minor amounts of polymerization byproducts.
- the polymer is referred to herein as polybutene polymer.
- isobutene constitutes from about 80% to about 95% of the total polybutene polymer.
- the polybutene polymer has at least one double bond per molecule.
- the thickness of the skinning of the fiberglass on the air outflow surface and the air inflow surface are controlled such that the skinning process on the air outflow can be densified while still maintaining an initial pressure drop of less than 0.20 WG for the finished fiberglass air filtration media. Furthermore, the skinning on the air inflow surface can be maintained as thin as varying needs require preventing stray fibers from projecting randomly from the surface.
- the fiber media between the two skins progressively increases in density such that the fiber on the air inflow is less dense than the fiber on the air outflow of the fiberglass filtration media. Progressive density is achieved by varying the speed of the traverses of the furnace over the drum. This density control is achieved in a substantially linear fashion.
- the finished media feels and looks different from normal fiberglass. It is relatively soft, springy and dry to the touch.
- the fibers look more like plastic than fiberglass, due in part to the polymeric spray mixture bound to the fiberglass media.
- the progressive density of the skin of the fiberglass filtration media along with the polymer, resin binder and the dry adhering agent mixture provide for increased dust holding capability by allowing for proper airflow and help to hold the initial pressure drop to 0.20 WG.
- a polymer 10 combined with a dry adhering agent and resin binder increases the ability of the fibers to attract and hold dust such that a MERV 8 rating and above can be achieved with a sustainably low initial pressure drop of 0.20 WG.
- This is achieved with a fiberglass based media without the addition of an undesirable oil coating.
- the low initial pressure drop is due in part to the substantially linear progressive density of the fiberglass media coupled with the high dust holding capability. This prevents face loading of the skin surface by large particles.
- the polymer 10 is an isotactic polymeric acrylate, which is sticky and typically used in formulations to aid in viscosity and ability to emulsify.
- a spray composition is formed by combining an acrylate polymer 10 (consisting essentially of the group of polymers such as -prop-2-enoate), a dry adhering agent (a polybutene consisting essentially of a group of 1-butene, 2-butene, and isobutene), and a resin binder.
- the spray composition is applied during the fiberglass air filtration media formation, as the fiberglass is wound onto the rotating drum.
- the addition of a polymer 10 and varying percentages of the dry adhering agent with the resin binder mixture increases the dust holding capacity of the resulting fiberglass filtration media.
- the progressive density of the fiberglass media progresses from a lower density of fiberglass media at the air inflow surface to higher density of the fiberglass media at the air outflow surface.
- the fibers are 21-25 microns with a median size of 23 microns.
- the progressive density of the fiberglass media acts to impede large particulate movement within the fiberglass media bulk. This increased impedance occurs between the two faces of the skin surfaces from the air inflow skin surface to the air outflow skin surface. These large particulates move less freely through the progressively denser fiberglass bulk and are trapped by the lower density in the region of the air inflow surface of the fiberglass media. This allows finer particles to be trapped in the higher density region of the air outflow surface and outflow side skin.
- the spray composition (acrylates, polybutene, and urea formaldehyde) is applied without clogging and is applied to the fiberglass as it is spun onto a drum.
- the spray composition may comprise 55-79% urea formaldehyde, 20-40% polymer compound, and 1-5% polybutene.
- the spray composition comprises 67% urea formaldehyde resin, 30% polymer compound, and 3% polybutene.
- the spray composition along with the progressive density of the fiberglass media provides an excellent means to capture and hold large dust particulates while avoiding the face-loading of the media common in other types of filtration media. By varying application rates of the spray composition, a specific formulation can be achieved that provides for greater precision.
- the density of the skin surfaces on the air outflow and air inflow can be controlled while still maintaining an initial pressure drop of less than 0.20 WG for the finished filter.
- the skinning on the air inflow surface can be maintained as thin as various needs require, preventing stray fibers from projecting randomly from the surface and facilitating glue adhesion in the customers' filter framing processes.
- the fiber is then oven cured. After oven curing, the finished media feels and looks different from fiberglass. It is relatively soft, springy and dry to the touch. The fibers look more like plastic than fiberglass.
- a fiberglass filtration media with the ability to attract and hold dust and achieve a MERV 8 rating and above, without the addition of an undesirable oil coating, is made possible by producing a fiberglass filtration media with progressively increasing density from air inflow to air outflow comprising thin filaments (for example, 21 to 25 microns) and adding polymer combined with a dry adhering agent and a resin binder (urea formaldehyde).
- a fiberglass filtration media with progressively increasing density from air inflow to air outflow comprising thin filaments (for example, 21 to 25 microns) and adding polymer combined with a dry adhering agent and a resin binder (urea formaldehyde).
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Abstract
Description
- This application is a continuation of U.S. patent application Ser. No. 15/151,478, filed on May 10, 2016, now U.S. Pat. No. 9,695,084, which claims the benefit of U.S. Patent Application No. 62/179,572, filed on May 11, 2015.
- The present disclosure relates to air filtration media and, more particularly, to air filtration media manufactured to a Minimum Efficiency Reporting Value (MERV) 8 rating and above with an initial pressure drop of less than or equal to 0.20 inches water gravity (WG). The MERV 8 rating and greater can be achieved with fiberglass media without the addition of an undesirable oil coating.
- Today, fiberglass air filtration manufacturing methods and formulations can involve the use of oil added after the fiberglass media exits the curing oven to provide for increased entrainment of air contaminants such as dust and particulates. Present solutions handle the problem of capturing increased amounts of dust using the oil method.
- The oil additive is undesirable since the oil makes the process more expensive in additive costs, handling costs, and environmental costs and is cosmetically undesirable. Binders are applied to the fibers as they are wound on the drum. Binder mixtures often are comprised of 65% urea formaldehyde and 35% water. In other methods, 1 butyl tackifiers may be mixed into a water emulsion and then mixed with a urea formaldehyde emulsion binder. Urea formaldehyde emulsion is typically used as a binder of glass fibers in the fiberglass filtration industry.
- Other patents have mentioned the use of a dry tackifier binder such as polybutene added to a composition to create a tackifier for spraying fiberglass filtration media. For example, see Miller U.S. Pat. No. 6,136,058, entitled “Uniformly Tacky Filter Media,” and Miller U.S. Pat. No. 5,846,603, entitled “Uniformly Tacky Filter Media.” However, the addition of polybutene, while useful, does not reach the MERV 8 rating and higher. In fact, the addition of polybutene barely achieves a MERV 7 rating by itself and then not routinely. Modigliani U.S. Pat. No. 2,546,230, entitled “Glass Product and Method of Making the Same,” and Modigliani U.S. Pat. No. 2,729,582, entitled “Method for Making Unwoven Fabrics,” both mention the use of additives to the fiberglass media. However, in Modigliani U.S. Pat. No. 2,546,230, the binder cited is being utilized for fiber board insulation and is water mixed with urea formaldehyde resin with the addition of an acrylic resin. In Modigliani U.S. Pat. No. 2,729,582, the resin is a vinyltrichlorosilane in a 3.5% solution of xylol, which is not suitable for fiberglass filtration media, but rather more suitable for composites. This disclosure presents a composition that achieves and sustains a MERV 8 rating and higher.
- MERV, Minimum Efficiency Reporting Value, commonly known as MERV rating, is a measurement scale designed in 1987 by the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) to rate the effectiveness of filters. The scale “represents a quantum leap in the precision and accuracy of air-cleaner” and allows for improved health, reduced cost and energy efficiency in heating, ventilation and air conditioning (HVAC) design as well as increased efficiency. For example, a HEPA filter is often impractical in central HVAC systems due to the large initial pressure drop the dense filter material causes. Experiments indicate that less obstructive, medium-efficiency filters of MERV 7 to 13 are almost as effective as true HEPA filters at removing allergens, with much lower associated system and operating costs. In like fashion, the addition of a polymer compounded with a dry adherent and a resin binder provides for a filter media without a high initial pressure drop.
- The scale is designed to represent the worst-case performance of a filter when dealing with particles in the range of 0.3 to 10 micrometers. The MERV rating is from 1 to 16. Higher MERV ratings correspond to a greater percentage of particles captured on each pass, with a MERV 16 filter capturing more than 95% of particles over the full range.
- Shown in
FIG. 1 is a table grouping MERV ratings by particle size: - Prior techniques exist however for the addition of resins such as acrylate polymers to polyester pleat filtration media and binder (with no urea formaldehyde). However, acrylate polymers have never been combined with urea formaldehyde and polybutene and then applied to fiberglass filtration media.
- It would be advantageous to provide a system and method of air filtration formation and media that increase dust holding capacity.
- It would also be advantageous to provide a method of formation of MERV 8 or higher air filtration media with fiberglass that does not require the use of oil.
- It would further be advantageous to provide a method of controlling the cross-sectional density of the fiber to maximize the dust holding capacity of the filter media while controlling the initial pressure drop.
- It would also be advantageous to provide for a finished filter media that feels and looks different from fiberglass.
- It would also be advantageous to provide for a fiber that is relatively soft, springy and dry to the touch, with fibers that look more like plastic than fiberglass.
- Thus there remains considerable need for binder compositions that provide for less mess and are cosmetically more pleasing to customers while providing for increased dust holding capability at a MERV 8 or better. Additionally, the fiber should be capable of progressive density with a soft springy texture.
- In accordance with the present disclosure, there is provided a system and method of forming air filtration media that does not involve the use of an oil additive to fiberglass, yet creates a MERV filter rating of 8 or better. The manufacturing method of forming the air filtration media is mentioned in a co-pending U.S. patent application Ser. No. 14/181,426, filed on Feb. 14, 2014, which is incorporated by reference herein.
- To achieve MERV 8 or better without undesirable oil additives, a polymer, wherein the polymer is one of a group of polymers consisting of acrylates and methyl acrylic acids, is added to a dry adhering agent consisting essentially of a group of polybutene during the fiberglass air filtration media formation. Both the polymer and the dry adhering agent mix in varying percentages with a resin binder (urea formaldehyde) and are applied to the fiberglass as it is spun onto a drum. In varying the application rates of the combined binder resin mixed with a polymer selected from a group of polymers formed from acrylic acid or methyl-acrylic acid and a dry adhering agent, e.g. polybutene in a specific formulation, so that the end result can be controlled with greater precision.
- Various objects, features, aspects, and advantages of the present disclosure will become more apparent from the following description of the disclosure, along with the accompanying drawings.
- The detailed description makes reference to the accompanying figures wherein:
-
FIG. 1 shows a table grouping MERV ratings by particle size. -
FIG. 2 depicts a chemical structure indicative of a selected group of acrylate polymers, consisting of a 1-butyl, a methyl, an n-butyl acrylate and others in a polymeric structure. -
FIG. 3 depicts a chemical structure representative of the structures of acrylic and methyl-acrylic acid which are the basis of the methyl-acrylic polymers discussed herein. -
FIG. 4A shows an electron micrograph of a polymer discussed herein. -
FIG. 4B shows information presented by an analysis of the polymer by electron micrograph. -
FIG. 5 is a chemical formula for the most common form of anacrylate polymer 10 utilized in one embodiment of this disclosure. - Other objects, features, and characteristics will become more apparent upon consideration of the following detailed description with reference to the accompanying figures.
- The chemical structure shown in
FIG. 2 is the general structure that is indicative of a selected group of acrylate polymers, consisting of a 1-butyl, a methyl, an n-butyl acrylate and others in a polymeric structure. For purposes of comparison, the IUPAC lists this selection of acrylates as -prop-2-enoate (either butyl or methyl). The chemical reaction of a selected polymer with a dry adherent and a resin binder (which also acts as an additional adherent) creates a polymeric-based tackifying agent with substantial dust holding capabilities. Ingredients in the acrylates copolymer group all contain the monomers acrylic acid and methyl-acrylic acid or one of their salts or esters. The drawing shown inFIG. 3 is more closely representative of the structures of acrylic and methyl-acrylic acid which are the basis of the methyl-acrylic polymers discussed. - These ingredients are considered similar in that they are uniformly produced in chemical reactions that leave very little residual monomer. Although residual acrylic acid may be as high as 1500 ppm, typical levels are 10 to 1000 ppm. Concentrations may be as high as 25% if used as a binder, film former, or fixative; or as low as 0.5% if used as a viscosity-increasing agent, suspending agent, or emulsion stabilizer.
- Analysis of polymer 10 (shown in
FIG. 5 ) by electron micrograph presents the information shown inFIGS. 4A and 4B . - The structure presented provides a desirable basis for binding and adhesive properties with the carbon and oxygen bonds being of the most significance with the sulfur presenting minimally in the base formulation. The sodium presents as a salt of the acrylic or meth-acrylic acid.
- The dry adhering agent is a polymer of the group consisting essentially of 1-butene and 2-butene and isobutene. The structure of the 1-butene and the 2-butene is seen in the repeat units, where, in the case of 1-butene, the structure is:
-
-[—CH2-CH(CH2CH3)-]n- - and in the case of 2-butene, the repeat unit structure is:
-
-[—CH(CH3)-CH(CH3)-]n- - The C4 polymer typically includes various forms of butene, for example isobutene, 1-butene, 2-butene, and others, and can contain a small amount of propene and minor amounts of polymerization byproducts. For simplicity, the polymer is referred to herein as polybutene polymer. Typically, isobutene constitutes from about 80% to about 95% of the total polybutene polymer. The polybutene polymer has at least one double bond per molecule.
- The thickness of the skinning of the fiberglass on the air outflow surface and the air inflow surface are controlled such that the skinning process on the air outflow can be densified while still maintaining an initial pressure drop of less than 0.20 WG for the finished fiberglass air filtration media. Furthermore, the skinning on the air inflow surface can be maintained as thin as varying needs require preventing stray fibers from projecting randomly from the surface. The fiber media between the two skins progressively increases in density such that the fiber on the air inflow is less dense than the fiber on the air outflow of the fiberglass filtration media. Progressive density is achieved by varying the speed of the traverses of the furnace over the drum. This density control is achieved in a substantially linear fashion.
- After oven curing of the fiber, the finished media feels and looks different from normal fiberglass. It is relatively soft, springy and dry to the touch. The fibers look more like plastic than fiberglass, due in part to the polymeric spray mixture bound to the fiberglass media. The progressive density of the skin of the fiberglass filtration media along with the polymer, resin binder and the dry adhering agent mixture provide for increased dust holding capability by allowing for proper airflow and help to hold the initial pressure drop to 0.20 WG.
- The addition of a
polymer 10 combined with a dry adhering agent and resin binder increases the ability of the fibers to attract and hold dust such that a MERV 8 rating and above can be achieved with a sustainably low initial pressure drop of 0.20 WG. This is achieved with a fiberglass based media without the addition of an undesirable oil coating. The low initial pressure drop is due in part to the substantially linear progressive density of the fiberglass media coupled with the high dust holding capability. This prevents face loading of the skin surface by large particles. - As indicated in the enclosed drawing and discussion, the
polymer 10 is an isotactic polymeric acrylate, which is sticky and typically used in formulations to aid in viscosity and ability to emulsify. In accordance with the present disclosure, there is provided a system and method of forming air fiberglass filtration media that does not involve the addition of oil during the fiberglass manufacture process. A spray composition is formed by combining an acrylate polymer 10 (consisting essentially of the group of polymers such as -prop-2-enoate), a dry adhering agent (a polybutene consisting essentially of a group of 1-butene, 2-butene, and isobutene), and a resin binder. The spray composition is applied during the fiberglass air filtration media formation, as the fiberglass is wound onto the rotating drum. The addition of apolymer 10 and varying percentages of the dry adhering agent with the resin binder mixture increases the dust holding capacity of the resulting fiberglass filtration media. - The progressive density of the fiberglass media progresses from a lower density of fiberglass media at the air inflow surface to higher density of the fiberglass media at the air outflow surface. In the preferred embodiment, the fibers are 21-25 microns with a median size of 23 microns. However, the principles disclosed herein may be used with fibers of other sizes. The progressive density of the fiberglass media, along with the application of the spray composition, acts to impede large particulate movement within the fiberglass media bulk. This increased impedance occurs between the two faces of the skin surfaces from the air inflow skin surface to the air outflow skin surface. These large particulates move less freely through the progressively denser fiberglass bulk and are trapped by the lower density in the region of the air inflow surface of the fiberglass media. This allows finer particles to be trapped in the higher density region of the air outflow surface and outflow side skin.
- The spray composition (acrylates, polybutene, and urea formaldehyde) is applied without clogging and is applied to the fiberglass as it is spun onto a drum. The spray composition may comprise 55-79% urea formaldehyde, 20-40% polymer compound, and 1-5% polybutene. In the preferred embodiment, the spray composition comprises 67% urea formaldehyde resin, 30% polymer compound, and 3% polybutene. The spray composition along with the progressive density of the fiberglass media provides an excellent means to capture and hold large dust particulates while avoiding the face-loading of the media common in other types of filtration media. By varying application rates of the spray composition, a specific formulation can be achieved that provides for greater precision.
- The density of the skin surfaces on the air outflow and air inflow can be controlled while still maintaining an initial pressure drop of less than 0.20 WG for the finished filter. The skinning on the air inflow surface can be maintained as thin as various needs require, preventing stray fibers from projecting randomly from the surface and facilitating glue adhesion in the customers' filter framing processes. The fiber is then oven cured. After oven curing, the finished media feels and looks different from fiberglass. It is relatively soft, springy and dry to the touch. The fibers look more like plastic than fiberglass.
- As disclosed herein, a fiberglass filtration media with the ability to attract and hold dust and achieve a MERV 8 rating and above, without the addition of an undesirable oil coating, is made possible by producing a fiberglass filtration media with progressively increasing density from air inflow to air outflow comprising thin filaments (for example, 21 to 25 microns) and adding polymer combined with a dry adhering agent and a resin binder (urea formaldehyde).
- Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the examples chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of the disclosure herein.
Claims (14)
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US16/167,309 US20190119152A1 (en) | 2014-02-14 | 2018-10-22 | System and Method of Continuous Glass Filament Manufacture |
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US201562179572P | 2015-05-11 | 2015-05-11 | |
US15/151,478 US9695084B2 (en) | 2015-05-11 | 2016-05-10 | Preparation for fiberglass air filtration media |
US15/640,503 US20180044230A1 (en) | 2015-05-11 | 2017-07-01 | Preparation For Fiberglass Air Filtration Media |
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US14/181,426 Continuation-In-Part US9446978B2 (en) | 2014-02-14 | 2014-02-14 | System and method for continuous strand fiberglass media processing |
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2016
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- 2016-05-10 WO PCT/US2016/031687 patent/WO2016183107A1/en unknown
- 2016-05-10 CN CN201680027469.1A patent/CN107530606A/en active Pending
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2017
- 2017-07-01 US US15/640,503 patent/US20180044230A1/en not_active Abandoned
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Publication number | Priority date | Publication date | Assignee | Title |
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US9695084B2 (en) * | 2015-05-11 | 2017-07-04 | Charles Douglas Spitler | Preparation for fiberglass air filtration media |
Also Published As
Publication number | Publication date |
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WO2016183107A1 (en) | 2016-11-17 |
US9695084B2 (en) | 2017-07-04 |
EP3294435A1 (en) | 2018-03-21 |
EP3294435B1 (en) | 2019-11-20 |
US20160332907A1 (en) | 2016-11-17 |
CN107530606A (en) | 2018-01-02 |
EP3294435A4 (en) | 2018-12-12 |
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