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Method for manufacturing composite filter media

A technology of composite materials and filter media, applied to spray spinning into many nanofibers and coating nanofiber layers, solution electrospray spinning into many nanofibers and coating nanofiber layers, application serial number 60/893,008 Priority areas to be able to address issues such as expensive turbine downtime

Inactive Publication Date: 2010-03-17
BHA ALTAIR
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Turbine downtime is expensive because the turbine is not running and therefore stops producing electricity

Method used

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  • Method for manufacturing composite filter media
  • Method for manufacturing composite filter media
  • Method for manufacturing composite filter media

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0053] Example 1 is a spunbond polyester bicomponent fiber base media substrate and Example 2 is the base media substrate of Example 1 plus a 2 g / m 2 nanofiber layer. Comparative Example 3 is a known dry-laid polyester base media substrate and Comparative Example 4 is the known dry-laid polyester base media substrate of Example 3 plus 2 g / m 2 nanofiber layer. Comparative Example 5 is wet-laid synthetic paper plus 2 nanofiber layer. Comparative Example 6 is a wet-laid synthetic paper and Comparative Example 7 is the wet-laid synthetic paper of Example 6 plus 20 g / m 2 Melt blown fiber layer. Examples The results are shown in Table 1 below. In comparing the composites of Example 2 with Comparative Examples 4, 5 and 7, efficiency was not sacrificed at the expense of reduced drag, resulting in the associated high quality factor values.

[0054] Table 1

[0055] Example

[0056] Efficiency was determined at 0.3 μm, 5.3 cm / s face velocity (ASHRAE 52.2-1999).

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Abstract

A method of making a composite filter media 10 includes forming a nonwoven fabric substrate 12 that includes a plurality of bicomponent synthetic fibers by a spunbond process, calendering the nonwovenfabric substrate with embossing calender rolls to form a bond area pattern having a plurality of substantially parallel discontinuous lines of bond area to bond the synthetic bicomponent fibers 30 together to form a nonwoven fabric. The nonwoven fabric having a minimum filtration efficiency of about 50%, measured in accordance with ASHRAE 52.2-1999 test procedure. The method also includes applying a nanofiber layer 20 by electro-blown spinning a polymer solution to form a plurality of nanofibers on at least one side of the nonwoven fabric. The composite filter media 10 having a filtration efficiency of at least about 75%, measured in accordance with ASHRAE 52.2-1999 test procedure. The method further includes corrugating the composite filter media using opposing corrugating rollers 40 ata temperature of about 90 DEG C to about 140 DEG C.

Description

[0001] Related Application Cross Reference [0002] This application is a continuation-in-part of U.S. Patent Application Serial No. 12 / 184,634, filed August 1, 2008, which is a continuation-in-part of U.S. Patent Application Serial No. 11 / 843,228, filed August 22, 2007, claiming March 2007 Priority to Provisional Patent Application Serial No. 60 / 893,008 filed on the 5th. Background of the invention [0003] The field of the invention relates generally to composite nonwoven filter media and, more particularly, to corrugated or embossed composite nonwoven filter media. [0004] Some known filter media composite constructions combine a wet-laid papermaking process to produce the substrate and electrospinning to deposit a lightweight nanofiber coating on one or both sides of the filter media substrate. Generally, the basis weight of the dielectric substrate is 100-120g / m 2 , the basis weight of the nanofiber layer is 0.5g / m 2 or smaller. [0005] It is known that lightweight...

Claims

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Application Information

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IPC IPC(8): B01D39/08B01D46/54D04H3/14
CPCB29L2031/14B01D2275/10B01D2239/025B01D63/065B01D2239/065B01D63/067B01D69/02B29C53/24B01D46/0001B01D2239/0216B01D2325/32B01D39/1623B01D71/06B29K2105/162B01D46/546B01D63/10D01D5/0084D04H13/002B01D69/10B01D46/521B01D2325/20D04H1/4374D04H1/559D04H1/728D04H3/147D01D5/0069B01D69/1071
Inventor A·斯米蒂斯J·T·克莱门茨J·梅
Owner BHA ALTAIR