WO2002020886A1 - Melt processable perfluoropolymer forms - Google Patents

Melt processable perfluoropolymer forms Download PDF

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Publication number
WO2002020886A1
WO2002020886A1 PCT/US2001/006785 US0106785W WO0220886A1 WO 2002020886 A1 WO2002020886 A1 WO 2002020886A1 US 0106785 W US0106785 W US 0106785W WO 0220886 A1 WO0220886 A1 WO 0220886A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
filtration
melt processable
percent
fabric
Prior art date
Application number
PCT/US2001/006785
Other languages
English (en)
French (fr)
Inventor
Frank Cistone
Gary E. Stanitis
Jin Choi
Original Assignee
Xtreme Fibers, Inc.
Lantor, Inc.
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
Priority claimed from PCT/US2000/023920 external-priority patent/WO2001018289A1/en
Application filed by Xtreme Fibers, Inc., Lantor, Inc. filed Critical Xtreme Fibers, Inc.
Priority to AU2001240012A priority Critical patent/AU2001240012A1/en
Priority to US10/362,788 priority patent/US20050106970A1/en
Priority to EP01914648A priority patent/EP1330567A1/en
Priority to JP2002525288A priority patent/JP2004511665A/ja
Publication of WO2002020886A1 publication Critical patent/WO2002020886A1/en

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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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • 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
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    • 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
    • B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
    • B01D39/086—Filter cloth, i.e. woven, knitted or interlaced material of inorganic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D39/14—Other self-supporting filtering material ; Other filtering material
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    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B5/02—Layered 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 structural features of a fibrous or filamentary layer
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    • 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
    • D04H3/14—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 bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
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    • B01D2239/0233—Island-in-sea
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D2239/04—Additives and treatments of the filtering material
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    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0442—Antimicrobial, antibacterial, antifungal additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0457—Specific fire retardant or heat resistant properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • 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
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0622—Melt-blown
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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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
    • B01D2239/0627—Spun-bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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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
    • B01D2239/064—The fibres being mixed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0654—Support layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0659—The layers being joined by needling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0663—The layers being joined by hydro-entangling
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0668—The layers being joined by heat or melt-bonding
    • 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
    • B01D2239/0672—The layers being joined by welding
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/069—Special geometry of layers
    • B01D2239/0695—Wound layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1291—Other parameters
    • 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
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5414—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
    • 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
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5416—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sea-island
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/04—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of halogenated hydrocarbons
    • D10B2321/042—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of halogenated hydrocarbons polymers of fluorinated hydrocarbons, e.g. polytetrafluoroethene [PTFE]

Definitions

  • the present invention relates to melt processable perfluoropolymer forms, such as woven, non-woven and knitted forms, and products prepared therefrom, such as filtration and filtration support media. More specifically, the melt processable perfluoropolymer forms of the present invention are prepared from melt processable perfluoropolymer fibers and yarns.
  • perfluoropolymers are resistant to UN degradation, which makes them suitable for outdoor exposure as well as in applications where artificial UN light is used, such as in water purification.
  • the preparation of continuously extruded, melt spun, multifilament melt processable yarns and staple fibers prepared from melt processable perfluoropolymers are described by Vita et al. In United States Patent os.: 5,460,882; 5,552,219 and 5,618,481, all of which are incorporated in their entirety by reference. These fibers and yarns can be used to prepare various woven, non-woven and knitted forms.
  • PTFE polytetrafluoroethylene
  • PTFE is not a melt processable perfluoropolymer.
  • the fibers, yarns and subsequent forms derived from it often require special or extraordinary handling and do not lend themselves to typical processes used for manufacturing melt processable forms as do say, polyesters, nylons, etc. Those processes include, but are not limited to, calendering, potting, thermally fusing, and thermally laminating.
  • Second, PTFE fibers are not easily crimpable, and cannot accept a high level of crimp.
  • PTFE fibers create forms which are not easily melt fused and have very poor laminating and potting capability. (Potting is a term given to the process of fusing a filter media into a cartridge filter end cap during the manufacturing process of that cartridge).
  • PTFE fibers do not have smooth surfaces, which are a source of problems in the production of filtration media.
  • Sixth, filtration media derived from PTFE fibers have relatively low levels of purity. Impurities introduced by PTFE need to be removed, later and, PTFE fibers are brown as a result of decomposed orgamc matter present in the fibers. The organic matter is necessary in the production of PTFE fibers to allow a processable "paste" to be made, which can then be formed into fiber structures.
  • PTFE webs are not easily pleated, which can be critical to many cartridge filter applications.
  • PTFE or a modified PTFE e.g. PTFE which contains a small amount of comonomer
  • melt processable perfluoropolymer forms It is yet another object of the present invention to provide relatively relaxed and efficient processing conditions to manufacture melt processable perfluoropolymer forms. It is still another object of the present invention to provide melt processable perfluoropolymer forms which are easily and inexpensively prepared and maintained, and which have a longer service life than conventional forms.
  • This invention also relates to multilobal fibers having a variety of uses. More particularly, this invention relates to such fibers having at least about two lobes which are useful in such diverse applications as filtering, wicking, insulating and other applications.
  • An additional object of the invention is filtration and coalescing components having high purity suitable for semiconductor, pharmaceutical, and other high purity applications.
  • a still further object of the invention is to provide pleatable filtration and coalescing components which are thermally bonded to other media, such as membranes, drainage layers, pleat supports and any other component of filter elements or devices.
  • the invention also relates to a woven fabric having a weight per square yard of about 1 to about 100 ounces per square yard, made from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer yarns; and 99 to 1 percent of fibers or yarns made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, suitable for use in filtration, as a support scrim in nonwoven products.
  • the invention further provides a knitted fabric having a weight per square yard of about 1 to about 100 ounces per square yard made from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer yams; and 99 to 1 percent of fibers or yams made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, suitable for use in filtration, or as a support scrim in nonwoven products.
  • the invention is also directed to filtration and coalescing media, support layers, drainage layers, and other components produced by winding continuous or spun yarns comprising a blend of from 1 to 99 percent melt processable perfluoropolymer yarns or fibers; and 99 to 1 percent by weight of fibers or yarns made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.
  • the invention also provides a self-supported non-woven fabric derived from a blend comprising: from 1 to 99 percent melt processable perfluoropolymer fibers; and from 99 to 1 percent PTFE fibers, said non-woven fabric possessing a Mullen burst strength (ASTM-D3776) between 10 and 1000 psi.
  • the invention is directed to a scrim supported non- woven fabric possessing a Mullen burst strength between 10 and 1000 psi wherein said non- woven fabric is derived from a blend comprising: from 1 to 99 percent melt processable perfluoropolymer fibers; and 99 to 1 percent fibers made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.
  • a scrim supported non-woven fabric possessing a Mullen burst strength between 10 and 1000 psi wherein said non-woven fabric is derived from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer fibers; and 99 to 1 percent PTFE fibers.
  • the instant invention also provides a self-supported or scrim supported non-woven fabric derived from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer fibers and 99 to 1 percent by weight fibers made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, said self supported or scrim supported non-woven fabric possessing an air permeability (ASTM D737) between 1 and 300 cfm/ft 2 at 0.5" water pressure.
  • ASTM D737 air permeability
  • the present invention further describes a self-supported or scrim supported non-woven fabric derived from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer fibers; and 99 to 1 percent PTFE fibers, said self-supported or scrim supported non-woven fabric possessing an air permeability (ASTM 737) between 1 and 300 cfm/ft 2 at 0.5" water pressure.
  • ASTM 737 air permeability
  • the present invention contemplates the use of any melt processable perfluoropolymer, such as ones taught in the above discussed Vita et al patents perfluoropolymers derived from tetrafluoroethylene ("TFE) and other fluorinated monomers, comonomers, termonomers, etc. Examples include, MFA, PFA, and FEP. More specifically, a representable melt processable perfluoropolymer, such as ones taught in the above discussed Vita et al patents perfluoropolymers derived from tetrafluoroethylene (“TFE) and other fluorinated monomers, comonomers, termonomers, etc. Examples include, MFA, PFA, and FEP. More specifically, a representable melt processable
  • the MFA 640 perfluoropolymer is advantageously used to prepare fibers and yarns, which in turn can be converted into non-woven fabric forms by a variety of processes.
  • One common process is for the fibers to be felted, carded or needle punched in a continuous or batch mode.
  • the non-woven form produced by this method can be used as is or can incorporate a woven or knit reinforcing scrim if so desired.
  • This non-woven form may also advantageously contain a blend of perfluoropolymer fibers with other fibers to impart desired properties to the felt.
  • Fibers of different denier can also be made into felts, either with a random distribution, or in a structured or graded fashion to obtain felts with non-homogeneous cross sections.
  • Other processes that can be used to covert the fibers to non-woven forms include Air-Laying techniques, such as with machines made by Rando or Fehrer, and Wetlaid or paper making technology.
  • fiber processes other than those taught by Ausimont can produce non-woven forms directly. These include Spun Bonding processes as well as Melt Blowing processes.
  • weaving the fibers and yarns will produce woven forms, such as scrims and cloth.
  • the yarn is advantageously twisted prior to flat or Leno weaving. Any normal type of weaving process, with or without a pretreatment of the fiber or yarn, can be used.
  • Knitted fabrics can also be advantageously produced with, for example, a circular knitting machine.
  • a variety of weaving, knitting and non-woven techniques may be applied to convert the melt processable perfluoropolymer fibers and yams to melt processable perfluoropolymer forms.
  • the fibers, yams and forms according to the present invention do not require any special or extraordinary handling, other than the mitigation of static electricity due to their very high surface resistivity.
  • Well known techniques such as the use of high humidity (60 to 90%), the generation of ionized air, and the application of finish or anti-static compounds are typically used to overcome static problems with PTFE fibers and can also be used with melt processable perfluoropolymer fibers.
  • Forms made from melt processable perfluoropolymer fibers are suitable for typical processes used for polyesters, polyolefins, nylons, etc., including calendering, potting, thermally fusing and thermally laminating.
  • melt processable fibers are structurally similar to PTFE fibers, it has unexpectedly been found that the melt extruded perfluoropolymer fibers are, unlike PTFE, easily crimpable, and able to accept a high level of crimp, similar to that found in conventional polyester, nylon and polyolefm fibers. These features are both desirable and necessary in order to use standard or normal industry carding and felting equipment.
  • melt processable perfluoropolymer fibers and yarns are easily melt fused and give better laminating and potting capability.
  • the use of melt processable perfluoropolymer fibers and yarns in the manufacture of bearing cloth yields physical property improvements, such as improved lubricity and improved durability over cloths made from PTFE yarn, expanded PTFE yam or slit film yarns, as a result of the same continuous, uniform filament construction and residual elongation.
  • the melt processable perfluoropolymer forms can be used to prepare filtration and filtration support media.
  • melt spinning process used to make melt processable perfluoropolymer fibers and yarns also allows for the production of multilobal fibers.
  • Multilobal fiber forms will advantageously increase the surface area of the individual fibers, leading to even further filtration efficiencies of these forms.
  • each filament in melt processable fluoropolymer fibers and yams allows for improved weavability as compared to the rough surfaces of yams produced from PTFE by any other process, including coextrusion spinning, slit film or slit expanded PTFE membrane processes.
  • This continuity and uniformity, as well as the residual elongation typical of traditional melt spinning processes also allow for improved physical property performance of filtration media, if subjected to typical flexing or pulsing stress in dry gas baghouse filter applications or in wet bag or cartridge filters.
  • Filtration media manufactured from melt processable perfluoropolymer fibers and yams will retain its physical integrity and strength over a longer period of time than filtration media manufactured from PTFE fibers and ya s. Purity is another property of great concern to the filtration industry, especially in the semiconductor manufacturing area. Filtration media made from melt processable perfluoropolymer fibers and yarns have a higher level of purity than media derived from PTFE fibers and yarns, as a result of both the processes used to manufacture the fibers and yarns and processes used to manufacture the forms.
  • a traditional or normal melt spinning process preferably applied to the melt processable perfluoropolymer. This type of process does not require the introduction of any impurities to the extrusion spinning process.
  • the manufacturing of PTFE fibers requires the addition of processing impurities, which if possible, need to be removed later.
  • wet laid webs or filter media can be thermally fused, and therefore, require no bonding agents to form a useful filter or filter support media.
  • another concern in industry is pleatability or the ability of a filter support of filtration media material to be folded by a typical pleating machine and retain that pleat. This a critical feature in many cartridge filter applications. Melt processable perfluoropolymer fibers and yarns unexpectedly can be formed into wet laid, thermally fused materials, which can be much mire easily pleated (and will retain that pleat) than do PTFE fibers and yams.
  • thermal bonding and sealing may be used to form complex shapes, such as filter bags. It may also be used to bond these fabrics to other assemblies, such as flow adapter fittings, mechanical seals, etc.
  • the edges of a cut fabric may be heat sealed in order to reduce dusting and migration of staple fibers cut at that edge. Bonding and sealing operations may be accomplished with heated air or metal dies; ultrasonic welding or other means may also be used to heat the part and melt the polymer. In any case, energy is applied to very localized areas of the part (at the seam) to partially melt the fabric.
  • Alternative technologies include the use of chemical or polymeric adhesives, or simple mechanical means such as sewing.
  • adhesives and other bonding agents are typically expensive, may be hazardous to apply, and often lack the chemical and environmental resistance, and strength, of the base fabric.
  • the surfaces typically require pre-treatment with aggressive solvents in order to permit these adhesives to achieve sufficient bonds. Sewing and other mechanical means are also far from ideal, as the seam is intrinsically non-uniform, and can allow particles to pass through it which would not pass through the fabric itself.
  • the present invention is further directed to multilobal fibers having unique properties. More particularly, the invention is directed to multilobal fibers formed from melt processable perfluoropolymers, wherein said fiber has a cross-section comprised of a central core having two or more shaped lobes projecting therefrom, i.e., the fibers of the invention may bilobal, trilobal, quadrilobal, pentalobal, etc.
  • the fiber spinning composition may be a solution of the polymer and other material used in the formation of the fiber which may be spun by using conventional solution spinning techniques, as for example those described in U.S. Pat. Nos. 2,967,085; 4,413,110; 3,048,465; 4,551,299 and 4,599,267.
  • the synthetic fibers of the present invention are generally prepared by melt spinning of the fiber forming polymer through a spinnerette.
  • Various additives may be added to the respective polymer. These include, but are not limited to, lubricants, nucleating agents, antioxidants, ultraviolet light stabilizers, pigments, dyes, anti-static agents, soil resists, stain resists, anti-microbial agents, and flame retardants.
  • the polymer is fed into an extruder in form of chips or granules, (indirect) melted and directed via jacketed Dowtherm.RTM. (Dow Chemical, Midland, Mich.) heated polymer distribution lines to the spinning head.
  • the polymer melt may be metered by a high efficiency gear pump to spin pack assembly and extruded through a spinnerette with capillaries having least one multilobal opening, like tris-, tetra-, penta- or hexalobal capillary, preferably tri- and tetralobal capillary.
  • the invention is also directed to conjugate multilobal spunbond fiber comprising at least two polymers where the fibers have lobes and each lobe has legs and caps, and the polymers are arranged with a first polymer occupying a portion of the fiber and at least one second polymer having a lower melting point than the first polymer occupying another portion of the fiber.
  • one of the polymers is a melt processable perfluoropolymer.
  • conjugate fibers refers to fibers which have been formed from at least two polymers extruded from separate extruders but spun together to form one fiber. Conjugate fibers are also sometimes referred to as multicomponent or bicomponent fibers.
  • the polymers are usually different from each other though conjugate fibers may be monocomponent fibers.
  • the polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the conjugate fibers and extend continuously along the length of the conjugate fibers.
  • the configuration of such a conjugate fiber may be, for example, a sheath core arrangement wherein one polymer is surrounded by another or may be a side by side arrangement, a segmented configuration or an "islands-in-the-sea" arrangement.
  • Conjugate fibers are taught in U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. Nos. 5,336,552 and 5,482,772 to Strack et al, and U.S. Pat. No. 5,382,400 to Pike et al., hereby incorporated by reference in their entirety.
  • the polymers may be present in ratios of 75/25, 50/50, 25/75 or any other desired ratios.
  • the invention provides blends comprising 1 to 99 percent by weight of melt processable perfluoropolymer yarns; and 99 to 1 percent of fibers or yarns made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.
  • the above blends are useful for manufacturing woven fabrics having a weight per square yard of about 1 to about 100 ounces per square yard and the fabrics are suitable for use in filtration, as a support scrim in nonwoven products.
  • the invention provides blends comprising 10 to 80 percent by weight of melt processable perfluoropolymer yarns; and 90 to 20 percent of fibers or yams made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.
  • the above blends are useful for manufacturing woven fabrics having a weight per square yard of about 1 to about 100 ounces per square yard and the fabrics are suitable for use in filtration, as a support scrim in nonwoven products
  • the most preferred embodiment of the invention provides blends comprising 20 to 50 percent by weight of melt processable perfluoropolymer yams; and 80 to 50 percent of fibers or yams made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.
  • the above blends are useful for manufacturing woven fabrics having a weight per square yard of about 1 to about 100 ounces per square yard and the fabrics are suitable for use in filtration, as a support scrim in nonwoven products
  • a blend comprising 1 to 99 percent by weight of melt processable perfluoropolymer yams; and 99 to 1 percent by weight of fibers or yarns made from polytetrafluoroethylene (PTFE).
  • PTFE polytetrafluoroethylene
  • a more preferred embodiment of the invention provides a blend comprising 10 to 80 percent by weight of melt processable perfluoropolymer yams; and 90 to 20 percent by weight of fibers or yams made from polytetrafluoroethylene (PTFE).
  • PTFE polytetrafluoroethylene
  • the above blend is also useful for manufacturing woven fabrics having a weight per square yard of about 1 to about 100 ounces per square yard and are suitable for use in filtration, as a support scrim in nonwoven products.
  • the most preferred embodiment provides a blend comprising 20 to 50 percent by weight of melt processable perfluoropolymer yams; and 80 to 50 percent by weight of fibers or yams made from polytetrafluoroethylene (PTFE).
  • PTFE polytetrafluoroethylene
  • the above blend is also useful for manufacturing woven fabrics having a weight per square yard of about 1 to about 100 ounces per square yard and are suitable for use in filtration, as a support scrim in nonwoven products
  • blends of the invention are also useful in manufacturing knitted fabrics having a weight per square yard of about 1 to about 100 ounces per square yard, suitable for use in filtration, or as a support scrim in nonwoven products.
  • a further use of the blends of the invention includes filtration and coalescing media, support layers, drainage layers, and other components produced by winding continuous or spun.
  • the fibers in the PTFE yarn show imperfections and roughness which are approximately 10 microns in size (picture 1), and many fractures and fissures which are approximately 0.2 micron in size (picture 2).
  • the melt processable MFA fibers are extremely smooth and regular, with no imperfections measuring 10 microns (picture 3), and have a dramatically reduced number of surface fissures measuring 0.2 micron in size compared with the PTFE.
  • a beam for weaving was produced on a multi-end warping machine using 550 total denier, 109 filament yarn that had been pre-twisted with 3 turns per inch in the Z direction.
  • the beam was placed on a Gem loom and a fabric was woven using a plain weave to yield a flat fabric 24 inches wide by 120 feet long with a mesh count of 64 ends per inch by 46 picks per inch.
  • the selvedge was a Leno selvedge (smooth edges, no fraying) Fabric weight was approximately 8.58 ounces per square yard. Filtration and mechanical characteristics are shown in Table 3. It was observed during the weaving process that the yam was very consistent in diameter and tended to give better tension control than other low tenacity yarns (approximately 1 gram/denier) such as yarns made from PTFE fibers.
  • a beam was produced on a single-end warping machine using 575 total denier, 109 filament yam that had been pre-twisted with 10 twists per inch in the Z direction.
  • the beam was placed on a Gem loom and a fabric was woven using a Leno weave to yield a fabric 42 inches wide by 21 feet long with 16 ends per inch by 16 picks per inch with a weight of approximately 3.4 ounces per square yard. Characteristics of the resulting scrim fabric are shown in table 1.
  • perfluoropolymer was heated to 100° C on a heated godet.
  • the heated yarn was fed
  • the yam from example 4 was continuously fed into a commercial air entangler at 200 meters per minute.
  • the entangler intermittently blows cold, compressed air streams through the fiber bundle to make nodes or points of entangled yarns where the individual filaments become nested. This is done to gather and lock the individual strands of parallel filaments, keeping them from opening in subsequent processing steps, making them easier to handle.
  • the MFA yarn air entangled easily and with good inter-fiber entanglement at the nodes. The yarn was later knitted with good results.
  • a hand held air splicer was also used and shown to be effective for splicing two separate pieces of MFA yarn together to form a uniform, strong, uninterrupted single continuous yarn.
  • Example 6 A more angular and resilient, improved quality crimp was produced under these conditions, with approximately 15 crimps per inch.
  • the crimped tow was suitable for cutting on commercial radial blade tow cutters and was cut to approximately 3.5 inches in length.
  • a 50/50 blend of 4.5 denier and 9.0 denier staple fiber produced from MFA perfluoropolymer was pre-opened by standard practice and fed to a standard 18 inch laboratory- scale nonwovens card, producing a continuous carded web.
  • Static electricity was controlled by the use of high humidity, 60 to 90%, as well as the addition of a commercially available finish onto the fibers.
  • the web was manually layered in the machine direction to yield batts of a target basis weight of 850 grams/meter squared.
  • the web was needlepunched according to condition "A" (table 4). Carding and needling procedures typically used to process other synthetic fibers, such as polyester and polypropylene, were used. This process yielded a nonwoven fabric with excellent strength in the machine direction; physical properties are shown in table 3.
  • Example 12 was repeated, except using 100%> 5.0 denier fiber of example 7.
  • the felt was later calendered as in example 17.
  • the enhanced crimp and resilience of the fiber led to much improved fiber opening in carding, web unifonnity, and overall carding performance. This was even more significant, because no 9.0 denier fiber was needed to be added to improve processing.
  • the improved web quality and cohesion, obtained without the use of a coarse carrier fiber led to needled felts of higher strength and uniformity, and improved filtration performance.
  • Carded webs produced as in example 12 were manually layered such in the cross- machine direction, simulating a cross-lapped material. The web was needlepunched as in example 12. The resulting fabric possessed a good balance of strengths in the machine and cross-machine directions; results are shown in table 3.
  • Example 12 Web was produced as in Example 12 except that a woven scrim, as described in example 3, was placed in the middle of the parallel-layered webs. Needling was performed as in Example 12; results in Table 3.
  • Example 3 The scrim of Example 3 was placed in the middle of webs cross-lapped as in Example 14, yielding a scrim-supported cross lapped product.
  • the needled felt of Example 12 was densified using a heated calendering operation.
  • felt was continuously pre-heated and pressed between a set of nip rolls, at a temperature of 190° C, yielding fabric with higher density, decreased air permeability, and reduced pore size.
  • Fabric gauge was easily controlled by varying the gap between nip rolls, with minimal expansion after calendering. Nip roll gap was adjusted to obtain a fabric density (target) of 0.275 ounces/inches cubed.
  • a felt produced as in Example 12 was thermally bonded to itself, using 325° C hot air
  • a parallel, self-supported carded batt was produced as in Example 12, except with reduced needling according to condition "B" of Table 4. As shown in table 3, these results show the ability to control fabric density, air permeability, and pore size through needling conditions, without negatively affecting fabric strength.
  • Three inch long, 5.5 denier per filament staple fibers made from a blend of 50% by weight perfluoropolymer and 50% aramid fibers were processed through a laboratory carding process and needle felt device. Good felts were produced having favorable physical properties and the ability to be thermally fused to themselves or other materials.
  • a blend of 60% by weight 4.5 denier staple fiber produced from MFA perfluoropolymer and 40% 10 denier aramid fibers was pre-opened by standard practice and fed to a standard 18 inch laboratory-scale nonwovens card, producing a continuous carded web.
  • the web was manually layered in the machine direction to yield batts of a target basis weight of 850 grams/meter squared.
  • the web was needlepunched according to condition "A" (table 4). Carding and needling procedures typically used to process other synthetic fibers, such as polyester and polypropylene, were used. This process yielded a nonwoven fabric with excellent strength in the machine direction; and physical properties, and the ability to be thermally fused to itself and other materials.
  • a blend of 50% by weight of 4.5 denier staple fiber produced from MFA perfluoropolymer and 50% PTFE fibers was pre-opened by standard practice and fed to a standard 18 inch laboratory- scale non-wovens card, producing a continuous carded web.
  • Static electricity was controlled by the use of humidity (in the range of 60 to 90%), ionized air generators, as well as the addition of commercially available anti-static solutions where necessary.
  • the web was manually layered in the machine direction to yield batts of a target basis weight of 850 grams/meter squared.
  • the web was needlepunched according to condition "C" (table 4). Carding and needling procedures typically used to process other synthetic fibers, such as polyester and polypropylene, were used. This process yielded a non-woven fabric with excellent strength in the machine direction and good physical properties.
  • a non-woven fabric was produced using 40%> by weight MFA fibers and 60% by weight PTFE fibers according to the conditions described in example 23, but with a target basis weight of 660 grams/meter squared. The sample was thermally seamed with good results.
  • a non-woven fabric was produced using 20% by weight MFA fibers and 80% by weight PTFE fibers according to the conditions described in example 23, but with a target basis weight of 660 grams/meter squared. The sample was thermally seamed with good results.
  • a non-woven fabric was produced using 20% by weight MFA fibers and 80% by weight PTFE fibers according to the conditions described in example 23, but with a target basis weight of 330 grams/meter squared. The sample could be seamed thermally.
  • Example 27
  • the plate temperature was between 460°and 540°
  • the plate temperature was between 460° and
  • the product had an open structure, which allowed the passing of liquids. It also had sufficient rigidity to be used in filtration pleat support and drainage layer applications
  • a non- woven needled felt was produced as in Example 12 except that a blend of 70 % perfluoroalkoxy fibers, and 30% glass fibers were used.
  • the perfluoroalkoxy fibers were 4.5 denier and the glass fibers were 0.3 denier.
  • the basis weight was 600 grams/meter squared.
  • the product had excellent filtration properties, could be thermally seamed, and could be thermally fused to other components such as membranes, support structures, housings, etc.
  • the non- woven could also be thermally laminated to other forms such as other non-wovens, glass paper, and other woven and knit forms.
  • a non- woven needled felt was produced as in Example 29 except that blend of 35 % perfluoroalkoxy fibers, 35%> PTFE fibers, and 30% glass fibers were used.
  • the perfluoroalkoxy fibers were 4.5 denier, the PTFE fibers 6.7 denier, and the glass fibers were 0.3 denier.
  • the basis weight was 610 grams/meter squared.
  • the product had excellent filtration properties, could be thermally seamed, and could be thermally fused to other components such as membranes, support structures, housings, etc.
  • the non-woven could also be thermally laminated to other forms such as other non-wovens, glass paper, and other woven and knit forms.
  • a non- wo en needled felt was produced as in Example 29 except that a 125 gram/meter squared woven glass scrim was inserted as described in example 15. The final basis weight was 710 grams/meter squared.
  • the product had excellent filtration properties, could be thermally seamed, and could be thermally fused to other components such as membranes, support structures, housings, etc.
  • the non-woven could also be thermally laminated to other forms such as other non-wovens, glass paper, and other woven and knit forms.
  • a non- wo en needled felt was produced as in Example 30 except that a 125 gram/meter squared woven glass scrim was inserted as described in example 15. The final basis weight was 700 grams/meter squared.
  • the product had excellent filtration properties, could be themially seamed, and could be thermally fused to other components such as membranes, support structures, housings, etc.
  • the non-woven could also be thermally laminated to other forms such as other non-wovens, glass paper, and other woven and knit forms.
  • a blend of 80% 5.5 denier MFA fibers and 20% 0.3 denier E-glass fibers were blended and processed on a Rando-Webber air-laying device. The fibers were cut to the appropriate length for use in this type of apparatus. Good quality webs were formed that could be thermally fused to themselves as well as to other components.
  • a blend of 40% 5.5 denier MFA fibers, 40% 6.7 denier PTFE fibers, and 20% 0.3 denier E-glass fibers were blended and processed on a Rando-Webber air-laying device. The fibers were cut to the appropriate length for use in this type of apparatus. Good quality webs were formed that could be thermally fused to themselves as well as to other components.
  • Non-woven webs as described in Example 34 were thermally fused using a spot bonding process to a woven glass support scrim with a basis weight of 100 grams/meter squared to make a non- woven fabric with a basis weight of about 300 grams/meter squared. Good quality webs were formed that could be thermally fused to themselves as well as to other components.
  • Non-woven webs as described in Example 34 were hydrauhcally entangled to a woven glass support scrim with a basis weight of 100 grams/meter squared to make a non-woven fabric with a basis weight of about 280 grams/meter squared. Good quality webs were formed that could be themially fused to themselves as well as to other components.
PCT/US2001/006785 2000-09-01 2001-03-02 Melt processable perfluoropolymer forms WO2002020886A1 (en)

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AU2001240012A AU2001240012A1 (en) 2000-09-01 2001-03-02 Melt processable perfluoropolymer forms
US10/362,788 US20050106970A1 (en) 2000-09-01 2001-03-02 Melt processable perfluoropolymer forms
EP01914648A EP1330567A1 (en) 2000-09-01 2001-03-02 Melt processable perfluoropolymer forms
JP2002525288A JP2004511665A (ja) 2000-09-01 2001-03-02 溶融加工可能なパーフルオロポリマフォーム

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PCT/US2000/023920 WO2001018289A1 (en) 1999-09-03 2000-09-01 Melt processable perfluoropolymer forms
USPCT/US00/23920 2000-09-01

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US7640841B2 (en) 2006-01-05 2010-01-05 Saint-Gobain Performance Plastics Corporation Annular seal and pump including same
US7802796B2 (en) 2006-01-05 2010-09-28 Saint-Gobain Performance Plastics Corporation Composite material and seals formed thereof
EP2510992A1 (de) * 2011-04-11 2012-10-17 Dari GmbH Filtermaterial zum Reinigen eines Fluids
US8603411B2 (en) 2008-12-24 2013-12-10 Saint-Gobain Performance Plastics Corporation Polymer material and seals formed thereof for high pressure pump applications
CN105561677A (zh) * 2016-02-02 2016-05-11 浙江严牌过滤技术股份有限公司 一种单丝机织滤布的制造方法
BE1023284B1 (nl) * 2015-12-30 2017-01-20 Beaulieu International Group Beurs- of evenemententapiit met massieve meerlobbige vezels
BE1023285B1 (nl) * 2015-12-30 2017-01-20 Beaulieu International Group Motorvoertuigtapijt met massieve meerlobbige vezels

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JP4857151B2 (ja) * 2007-03-08 2012-01-18 日本ピラー工業株式会社 グランドパッキン

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US4988364A (en) * 1989-02-28 1991-01-29 E. I. Du Pont De Nemours And Company Coated cation exchange yarn and process

Patent Citations (1)

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Publication number Priority date Publication date Assignee Title
US4988364A (en) * 1989-02-28 1991-01-29 E. I. Du Pont De Nemours And Company Coated cation exchange yarn and process

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7640841B2 (en) 2006-01-05 2010-01-05 Saint-Gobain Performance Plastics Corporation Annular seal and pump including same
US7802796B2 (en) 2006-01-05 2010-09-28 Saint-Gobain Performance Plastics Corporation Composite material and seals formed thereof
US8603411B2 (en) 2008-12-24 2013-12-10 Saint-Gobain Performance Plastics Corporation Polymer material and seals formed thereof for high pressure pump applications
EP2510992A1 (de) * 2011-04-11 2012-10-17 Dari GmbH Filtermaterial zum Reinigen eines Fluids
BE1023284B1 (nl) * 2015-12-30 2017-01-20 Beaulieu International Group Beurs- of evenemententapiit met massieve meerlobbige vezels
BE1023285B1 (nl) * 2015-12-30 2017-01-20 Beaulieu International Group Motorvoertuigtapijt met massieve meerlobbige vezels
WO2017114807A1 (en) * 2015-12-30 2017-07-06 Beaulieu International Group Nv Event or exhibition carpet with solid multilobal fibre
WO2017114808A1 (en) * 2015-12-30 2017-07-06 Beaulieu International Group Nv Automotive carpet with solid multilobal fibre
CN105561677A (zh) * 2016-02-02 2016-05-11 浙江严牌过滤技术股份有限公司 一种单丝机织滤布的制造方法

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