Filter Having Melt-Blown and Electrospun Fibers
원문보기
IPC분류정보
국가/구분
United States(US) Patent
공개
국제특허분류(IPC7판)
B01D-039/14
B01D-027/06
B32B-037/02
출원번호
US-0357499
(2009-01-22)
공개번호
US-0181249
(2010-07-22)
발명자
/ 주소
Green, Thomas B.
Li, Lei
출원인 / 주소
Clarcor Air Filtration Products, Inc.
대리인 / 주소
REINHART BOERNER VAN DEUREN P.C.
인용정보
피인용 횟수 :
0인용 특허 :
0
초록▼
A multi-layer filter media including at least one layer of melt-blown fiber filter media and at least one layer of electrospun nanofiber filter media is provided. The multi-layer filter media of the present invention is configured such that the at least one layer of the melt-blown fiber filter media
A multi-layer filter media including at least one layer of melt-blown fiber filter media and at least one layer of electrospun nanofiber filter media is provided. The multi-layer filter media of the present invention is configured such that the at least one layer of the melt-blown fiber filter media is on the upstream and the at least one electrospun nanofiber filter media is positioned downstream of the at lest one melt-blown fiber filter media.
대표청구항▼
What is claimed is: 1. A multi-layer filter media, comprising: at least one melt-blown fiber filter media layer having a basis weight of greater than 40 grams/m2 and a median fiber diameter of at least 1 micron and less than 50 micron; and at least one electrospun nanofiber media layer downstream o
What is claimed is: 1. A multi-layer filter media, comprising: at least one melt-blown fiber filter media layer having a basis weight of greater than 40 grams/m2 and a median fiber diameter of at least 1 micron and less than 50 micron; and at least one electrospun nanofiber media layer downstream of the at least one melt-blown fiber filter media layer, the at least one electrospun nanofiber media layer comprising fibers having a median fiber diameter of less than 0.8 micron and having a basis weight of greater than 0.010 grams/m2. 2. The multi-layer filter media of claim 1, wherein the at least one melt-blown fiber filter media layer has a layer thickness of at least 1 mm. 3. The multi-layer filter media of claim 1, wherein the basis weight of the at least one melt-blown fiber filter media layer is greater than 70 grams/m2. 4. The multi-layer filter media of claim 1, wherein the basis weight of the at least one melt-blown fiber filter media layer is greater than 90 grams/m2. 5. The multi-layer filter media of claim 1, wherein the at least one melt-blown fiber filter media has Frazier air permeability at a differential pressure of 0.5 inch of water between 400 CFM and 600 CFM. 6. The multi-layer filter media of claim 1, wherein the multi-layer filter media has an initial pressure drop of less than 22 Pa. 7. The multi-layer filter media of claim 1, further comprising a first scrim layer, wherein the at least one melt-blown fiber media layer includes a first melt-blown fiber media layer and the at least one electrospun nanofiber media layer includes a first electrospun nanofiber media layer, wherein the first electrospun nanofiber media layer is electrospun and deposited onto a downstream surface of the first melt-blown fiber filter media layer, wherein the first scrim layer is bonded to and downstream of the first electrospun nanofiber media, wherein the multi-layer filter media comprises three layers including the first melt-blown fiber filter media on upstream of the first electrospun nanofiber filter media and the first scrim layer on downstream of the first electrospun nanofiber media layer. 8. The multi-layer filter media of claim 1, further comprising a first scrim layer, wherein the at least one melt-blown fiber media layer includes a first melt-blown fiber media layer and the at least one electrospun nanofiber media layer includes a first electrospun nanofiber media layer, wherein the first electrospun nanofiber media layer is electrospun and deposited onto a downstream surface of the first scrim layer, wherein the multi-layer filter media comprises three layers including the first melt-blown fiber filter media on upstream of the first scrim layer, and the first electrospun nanofiber filter media on downstream of the first scrim layer. 9. The multi-layer filter media of claim 8, wherein the first scrim layer has thickness of at least 0.1 mm and less than 0.5 mm, average fiber size between 1 micron and 50 micron, and Frazier air porosity at 0.5 inch of water between 500 CFM and 600 CFM. 10. The multi-layer filter media of claim 8, wherein the multi-layer filter media has a thickness between 1.5 mm and 2 mm, a filtration efficiency greater than 90% for 1 micron particle size, and an initial pressure drop of less than 22 Pa. 11. The multi-layer filter media of claim 1, further comprising a first scrim layer and a second scrim layer, wherein the at least one melt-blown fiber filter media layer includes a first melt-blown fiber media layer and the at least one electrospun nanofiber media layer includes a first electrospun nanofiber media layer, wherein the multi-layer filter media comprises four layers including the first scrim layer bonded to a downstream surface of the first melt-blown fiber media layer, the first electrospun nanofiber layer electrospun and deposited onto a downstream surface of the first scrim layer, and the second scrim layer bonded to a downstream surface of the first electrospun nanofiber layer. 12. The multi-layer filter media of claim 11, further comprising a second melt-blown fiber filter media layer bonded to upstream of the first melt-blown fiber filter media layer. 13. The multi-layer filter media of claim 1, further comprising a first scrim layer, wherein the at least one melt-blown fiber filter media layer includes a first melt blown fiber filter media layer and a second melt-blown fiber filter media layer, and the at least one electrospun nanofiber media layer includes a first electrospun nanofiber media layer, wherein the multi-layer filter media comprises four layers including the second melt-blown fiber filter layer bonded to a downstream surface of the first melt-blown fiber filter media layer, and the first electrospun nanofiber media layer electrospun and deposited onto a downstream surface of the second melt-blown fiber filter media layer, and the first scrim layer bonded to a downstream surface of the first electrospun nanofiber layer. 14. The multi-layer filter media of claim 1, further comprising a first scrim layer, wherein the at least one melt-blown fiber filter media layer includes a first melt blown fiber filter media layer and a second melt-blown fiber filter media layer, and the at least one electrospun nanofiber media layer includes a first electrospun nanofiber media layer, wherein the multi-layer filter media comprises four layers including the second melt-blown fiber filter layer bonded to a downstream surface of the first melt-blown fiber filter media layer, and the first electrospun nanofiber media layer electrospun and deposited onto a upstream surface of the scrim layer, and an upstream surface of the first electrospun nanofiber media layer bonded to a downstream surface of the second melt-blown fiber filter media layer. 15. The multi-layer filter media of claim 1, wherein the multi-layer filter media is formed in a consolidated structural configuration. 16. The multi-layer media of claim 15, wherein the multi-layer filter media is pleated. 17. A method of forming a multi-layer filter media, comprising steps of: providing a melt-blown fiber filter media layer by melt blowing a web of a polymer fibers having a median fiber diameter of at least 1 micron and less than 50 micron to form the melt-blown fiber filter media layer having a basis weight of greater than 40 grams/m2; providing a nanofiber media layer by electrospinning nanofibers having a median fiber diameter of less than 0.8 micron to form the nanofiber layer having a basis weight of greater than 0.010 grams/m2; and bonding the nanofiber layer to downstream of the melt-blown fiber filter media layer. 18. The method of claim 17, wherein bonding the nanofiber media layer comprises electrospinning nanofibers onto a downstream surface of the melt-blown fiber filter media layer. 19. The method of claim 17, wherein bonding the nanofiber media layer comprises electrospinning nanofibers onto a downstream surface of a scrim layer, and laminating the melt-blown fiber onto a upstream surface of the scrim layer. 20. The method of claim 17, further including enhancing bonding between layers of the multi-layer filter media by pressure bonding, wherein the multi-layer filter media is compressed through a set of calendaring rollers. 21. The method of claim 17, further including enhancing bonding between layers of the multi-layer filter media by heat bonding, wherein the multi-layer filter media is heated to a glass transition temperature of a polymer comprising the nanofiber media layer.
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