Filter media comprising a pre-filter layer and related components, systems, and methods associated therewith are provided. In some embodiments, the pre-filter layer may be designed to impart desirable properties to the filter media, such as a high gamma and/or long service life, while having relatively minimal or no adverse effects on another property of the filter media that is important for a given application. For instance, a pre-filter layer may be used to improve the upstream removal of fine particulate matter, which may clog a downstream efficiency layer comprising submicron fibers and reduce filtration performance. The pre-filter layer may be configured to increase service life and/or increase the gamma of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
B01D 46/62 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
A41D 13/11 - Protective face masks, e.g. for surgical use, or for use in foul atmospheres
B01D 46/52 - Particle separators, e.g. dust precipitators, using filters embodying folded material
B01D 46/54 - Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
Battery separators comprising ribs are generally described. In some embodiments, the ribs have one or more features that enhance the performance of the battery separator.
H01M 50/463 - Separators, membranes or diaphragms characterised by their shape
H01M 50/457 - Separators, membranes or diaphragms characterised by the material having a layered structure comprising three or more layers
H01M 50/446 - Composite material consisting of a mixture of organic and inorganic materials
H01M 50/454 - Separators, membranes or diaphragms characterised by the material having a layered structure comprising a non-fibrous layer and a fibrous layer superimposed on one another
Filtration articles and filter elements comprising reversibly stretchable layer filter media are generally provided. The filtration articles and filter elements described herein may be used for various applications, including applications as a respirator or respiratory protective equipment, a medical filter, an indoor air filtration article for HVAC and HEPA applications, a cabin air filter for vehicles, a room air purifier filter, a vacuum cleaner filter, a heavy duty air filter, a hydraulic fluid filter, and a process liquid filtration filter.
Thermal insulation materials for batteries are generally described. The thermal insulation materials described herein have a number of advantages. For example, in some embodiments, the thermal insulation materials have desirable thermal properties, such as low thermal conductivity and/or high thermal stability. As another example, in some embodiments, the thermal insulation materials described herein have desirable structural properties, such as having a relatively low thickness, and/or beneficial mechanical properties. The thermal insulation materials described herein may also have a combination of desirable thermal and structural properties.
H01M 10/658 - Means for temperature control structurally associated with the cells by thermal insulation or shielding
H01M 10/651 - Means for temperature control structurally associated with the cells characterised by parameters specified by a numeric value or mathematical formula, e.g. ratios, sizes or concentrations
D04H 1/732 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
D04H 1/4391 - 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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
D04H 1/58 - 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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
Articles and methods involving filter media are generally provided. In certain embodiments, a filter media has a design and/or comprises one or more layers that enhances its efficiency and/or performance.
B01D 46/62 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
B01D 46/12 - Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces in multiple arrangements
6.
FILTER MEDIA INCLUDING FIBERS COMPRISING POLYVINYLIDENE FLUORIDE AND/OR A COPOLYMER THEREOF, AND RELATED METHODS
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
B01D 39/14 - Other self-supporting filtering material
B01D 46/62 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/18 - Other self-supporting filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
9.
ARTICLES COMPRISING BINDERS, CROSS-LINKING AGENTS AND/OR OTHER COMPONENTS, AND RELATED METHODS
Filter media comprising non-woven fiber webs having one or more advantageous physical properties are generally described. In some embodiments, a filter media and/or non-woven fiber web described herein comprises a combination of fibers that results in enhanced physical properties. For example, the non-woven fiber web may comprise a combination of fiber types that is advantageous, such as a combination comprising fibrillated fibers, glass fibers, and/or binder fibers. In some cases, the filter media and/or non-woven fiber web comprising the combination of fibers may be formed into undulations (e.g., by a creping and/or microcreping process) to further enhance the physical properties of the filter media and/or non-woven fiber.
Filter media having a relatively small pore size and related components, systems, and methods associated therewith are provided. The filter media may include a fibrous efficiency layer, a fibrous support layer, and a third layer adjacent to the efficiency layer. The efficiency layer may impart a relatively homogeneous pore structure to the filter media without adding substantial bulk to the filter media. The support layer may promote the homogeneity of the pore structure. For example, the support layer may prevent and/or minimize defects in the relatively thin efficiency layer that may result from manufacturing and/or processing. The third layer may serve to impart beneficial filtration (e.g., efficiency, dust holding capacity) and/or non-filtration (e.g., layer protection) properties to the filter media without adversely affecting one or more properties of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve liquid filtration, amongst other applications.
Articles and methods relating to filter media are generally provided. In some embodiments, a filter media has an irregular surface structure. For instance, the filter media may comprise a plurality of peaks that are irregular in one or more ways. A ratio of a peak height standard deviation to an average peak height may be greater than or equal to 0.05, and/or a ratio of a peak spacing standard deviation to an average peak spacing may be greater than or equal to 0.08. In some embodiments, a filter media comprises a non-woven fiber web having a layer thickness of greater than 0.3 mm and/or a stiffness of less than or equal to 100 mg.
Articles and methods relating to filter media are generally provided. In some embodiments, a filter media has an irregular surface structure. For instance, the filter media may comprise a plurality of peaks that are irregular in one or more ways. A ratio of a peak height standard deviation to an average peak height may be greater than or equal to 0.05, and/or a ratio of a peak spacing standard deviation to an average peak spacing may be greater than or equal to 0.08. In some embodiments, a filter media comprises a non-woven fiber web having a layer thickness of greater than 0.3 mm and/or a stiffness of less than or equal to 100 mg.
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
Articles such as filter media, which include dendrimers and/or other components, are provided. The filter media may further include a water repellant (e.g., a fluorinated species) to impart desirable properties to the media such as high water repellency. The filter media may also have a high efficiency as a function of pressure drop (i.e., high gamma values). In some embodiments, the filter media includes a fiber web which may be formed of various components such as glass fibers. The fiber web can also include additional components such as synthetic fibers, binder components, as well as other additives. The media may be incorporated into a variety of filter element products.
Filter media, filter elements, and methods for filtering an gas stream are described herein. In some embodiments, the filter media may comprise a fiber web comprising a plurality of fibers and having a particular oil repellency level. For instance, in certain embodiments, the surface chemistry of the fiber web may be tailored to impart a particular surface energy density that matches the surface energy density of the fluid (e.g., an oil, a lubricant, and/or a cooling agent) being removed from the gas stream. In some embodiments, the fiber web may be wrapped around a core. For example, the fiber web may be wrapped around the core such that it forms two or more layers around the core. In some cases, the fiber web may be perforated. In certain embodiments, an gas stream comprising a fluid (e.g., an oil, a lubricant, and/or a cooling agent) may be passed through the fiber web, filter media, and/or filter element such that at least a portion of the fluid coalesces on the fiber web. Fiber webs, filter media, and/or filter elements as described herein may be particularly well-suited for applications that involve filtering gas streams containing oil, lubricants, and/or cooling agents (e.g., gas streams generated by a compressor) though the media may also be used in other applications. Advantageously, the fiber webs, filter media, and/or filter elements described herein may significantly reduce or prevent fouling of the filter caused by oil or other liquids.
Battery components are generally provided. In some embodiments, the battery components can be used as pasting paper and/or capacitance layers for batteries, such as lead acid batteries. The battery components described herein may comprise a plurality of fibers. The battery component may include, in some embodiments, a plurality of fibers and, optionally, one or more additives such as conductive carbon and/or activated carbon. In certain embodiments, the plurality of fibers include relatively coarse glass fibers (e.g., having an average diameter of greater than or equal to 2 microns), relatively fine glass fibers (e.g., having an average diameter of less than 2 microns), and/or fibrillated fibers. In some instances, such fibers may be present in amounts such that the battery component has a particular surface area, mean pore size, and/or dry tensile strength.
H01M 50/489 - Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
18.
FILTER MEDIA COMPRISING FIBRILLATED FIBERS AND GLASS FIBERS
Filter media comprising non-woven fiber webs having one or more advantageous physical properties are generally described. In some embodiments, a filter media and/or non-woven fiber web described herein comprises a combination of fibers that results in enhanced physical properties. For example, the non-woven fiber web may comprise a combination of fiber types that is advantageous, such as a combination comprising fibrillated fibers, glass fibers, and/or binder fibers. In some cases, the filter media and/or non-woven fiber web comprising the combination of fibers may be formed into undulations (e.g., by a creping and/or microcreping process) to further enhance the physical properties of the filter media and/or non-woven fiber.
Filter media comprising non-woven fiber webs and having one or more advantageous structural properties are generally described. In some embodiments, a filter media and/or non-woven fiber web described herein has one or more properties that are both beneficial and easily obtainable by undulating the non-woven fiber web, such as by performing a creping procedure. This property may be characteristic of the procedure employed to form the undulations (e.g., creping and/or microcreping), or may be attainable via one or more methods of undulation.
Filter media comprising fluorinated water-repellent additives and/or water-repellent additives having minimal or no fluorine atoms are generally provided. Filter media disclosed herein may include fluorinated water-repellent additives but not water-repellent additives having minimal or no fluorine atoms, water-repellent additives having minimal or no fluorine atoms but not fluorinated water-repellent additives, or both fluorinated water-repellent additives and water-repellent additives having minimal or no fluorine atoms.
Disclosed are battery separators comprising glass fibers and having a basis weight (gsm), a specific surface area (m2/g), a density (gsm/mm) and a mean pore size (μm), which satisfy the equation disclosed herein, provided that: the specific surface area is less than 1.5 m2/g, or the density is greater than 180 gsm/mm. Also disclosed are batteries comprising the battery separators, and processes for making the separators.
Filter media comprising water-repellent additives having minimal or no fluorine atoms are generally provided. In some embodiments, the water-repellent additives comprise one or more water-repellent functional groups. The water-repellent functional groups may comprise a carbon chain including three or more carbon atoms. In some embodiments, some or all of the water-repellent functional group(s) are bonded to a silicon atom and/or a metal atom. It is also possible for some or all of the water-repellent functional group(s) to form side chain(s) attached to a polymer backbone.
Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.
Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.
Filter media comprising a pre-filter layer and related components, systems, and methods associated therewith are provided. In some embodiments, the pre-filter layer may be designed to impart desirable properties to the filter media, such as a high gamma and/or long service life, while having relatively minimal or no adverse effects on another property of the filter media that is important for a given application. For instance, a pre-filter layer may be used to improve the upstream removal of fine particulate matter, which may clog a downstream efficiency layer comprising submicron fibers and reduce filtration performance. The pre-filter layer may be configured to increase service life and/or increase the gamma of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
B01D 53/22 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by diffusion
B01D 46/62 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
A41D 13/11 - Protective face masks, e.g. for surgical use, or for use in foul atmospheres
B01D 46/52 - Particle separators, e.g. dust precipitators, using filters embodying folded material
B01D 46/54 - Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
A62B 23/02 - Filters for breathing-protection purposes for respirators
Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B03C 3/28 - Plant or installations without electricity supply, e.g. using electrets
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
27.
FILTER MEDIA COMPRISING A POLYETHERSULFONE-BASED FINE FIBER LAYER
Filter media comprising adsorptive particles are generally described. In some embodiments, the adsorptive particles are present in a relatively large amount, in a layer discrete from one or more other layers and/or fiber webs also present in the filter media, and/or in a layer that comprises a relatively low amount of fibers. In some embodiments, the filter media further comprises a non-woven fiber web comprising fibers with relatively small diameters.
B01D 53/04 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
29.
FILTER MEDIA INCLUDING OUT-OF-PLANE SOLID ELEMENTS, METHODS OF FORMING THEM, AND USES THEREOF
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
B01D 39/14 - Other self-supporting filtering material
B01D 46/62 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with multiple filtering elements, characterised by their mutual disposition connected in series
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/18 - Other self-supporting filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
Battery separators comprising embossments are generally provided. The embossments may take the form of indentations formed in a surface of the battery separator, such as indentations formed by an embossing process. The embossments may comprise intersections with a first edge and a second edge of the battery separator, which may be the same or different.
Filter media including a filtration layer comprising fibers (e.g., synthetic fibers) comprising a flame retardant and related components, systems, and methods associated herewith are provided. In some embodiments, a filtration layer may include a nonwoven web (e.g., wet-laid nonwoven web) comprising fibers including a certain flame retardant that has a relatively low concentration of or is substantially free of certain undesirable and/or toxic components (e.g., halogens). In certain embodiments, the nonwoven web may also comprise a blend of fibers. For instance, in some embodiments, the nonwoven web may also comprise a blend of coarse and fine diameter synthetic fibers that impart beneficial performance properties to the filtration layer. In some embodiments, the filtration layer may be designed to have a desirable flame retardancy (e.g., F1 rating, K1 rating) and performance properties without compromising certain mechanical properties (e.g., pleatability of the media) and/or environmental attributes (e.g., relatively low toxicity). Filter media described herein may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.
Fine fiber products including fiber webs, as well as related assemblies, systems and methods, are described. In some embodiments, fiber webs described herein may include fine fibers and relatively low amounts of degraded polymer formed during a fiber extrusion process. The fiber webs may be used for filter media applications.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D04H 3/16 - 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 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
Filter media having a gradient in a property and methods associated with such media are provided. In some embodiments, a filter media may have a gradient in mean pore size. The gradient in mean pore size may be across at least a portion of the thickness of the filter media. In some embodiments, the gradient can be represented by an exponential function. The exponential gradient in mean pore size may impart desirable properties to the filter media including enhanced filtration properties (e.g., relatively high dust holding capacity and efficiency), amongst other benefits. The filter media may be particularly well-suited for applications that involve filtering liquids (e.g., hydraulics, fuel, lube, water), though the media may also be used in other applications.
B01D 39/14 - Other self-supporting filtering material
B01D 29/00 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 33/00 - Filters with filtering elements which move during the filtering operation
Filter media comprising nanofibers and related components, systems, and methods associated therewith are provided. In some embodiments, a filter media may comprise a first fiber web and a second fiber web designed to impart beneficial properties to the filter media. For instance, in some embodiments, the first fiber web may provide high particulate efficiency and the second fiber web may provide suitable capacity. In some embodiments, the first and second fiber webs may have certain properties (e.g., water contact angle, surface energy) that are similar or substantially the same. The similarities between the first and second fiber webs may serve to enhance the structural stability of the filter media under various conditions (e.g., high temperature, high pressure, steam sterilization) and/or permeability to certain fluids (e.g., water). Filter media, as described herein, may be particularly well-suited for applications that involve liquid filtration.
Filter media, filter elements, and methods for filtering an gas stream are described herein. In some embodiments, the filter media may comprise a fiber web comprising a plurality of fibers and having a particular oil repellency level. For instance, in certain embodiments, the surface chemistry of the fiber web may be tailored to impart a particular surface energy density that matches the surface energy density of the fluid (e.g., an oil, a lubricant, and/or a cooling agent) being removed from the gas stream. In some embodiments, the fiber web may be wrapped around a core. For example, the fiber web may be wrapped around the core such that it forms two or more layers around the core. In some cases, the fiber web may be perforated. In certain embodiments, an gas stream comprising a fluid (e.g., an oil, a lubricant, and/or a cooling agent) may be passed through the fiber web, filter media, and/or filter element such that at least a portion of the fluid coalesces on the fiber web. Fiber webs, filter media, and/or filter elements as described herein may be particularly well-suited for applications that involve filtering gas streams containing oil, lubricants, and/or cooling agents (e.g., gas streams generated by a compressor) though the media may also be used in other applications. Advantageously, the fiber webs, filter media, and/or filter elements described herein may significantly reduce or prevent fouling of the filter caused by oil or other liquids.
Articles and methods relating to filter media are generally provided. In some embodiments, a filter media has an irregular surface structure. For instance, the filter media may comprise a plurality of peaks that are irregular in one or more ways. A ratio of a peak height standard deviation to an average peak height may be greater than or equal to 0.05, and/or a ratio of a peak spacing standard deviation to an average peak spacing may be greater than or equal to 0.08. In some embodiments, a filter media comprises a non-woven fiber web having a layer thickness of greater than 0.3 mm and/or a stiffness of less than or equal to 100 mg.
B01D 53/22 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by diffusion
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/08 - Filter cloth, i.e. woven, knitted or interlaced material
40.
Filter media including adhesives and/or oleophobic properties
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
Filter media having a relatively small pore size and related components, systems, and methods associated therewith are provided. The filter media may include a fibrous efficiency layer, a fibrous support layer, and a third layer adjacent to the efficiency layer. The efficiency layer may impart a relatively homogeneous pore structure to the filter media without adding substantial bulk to the filter media. The support layer may promote the homogeneity of the pore structure. For example, the support layer may prevent and/or minimize defects in the relatively thin efficiency layer that may result from manufacturing and/or processing. The third layer may serve to impart beneficial filtration (e.g., efficiency, dust holding capacity) and/or non-filtration (e.g., layer protection) properties to the filter media without adversely affecting one or more properties of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve liquid filtration, amongst other applications.
Articles and methods relating to filter media are generally provided. In some embodiments, a filter media has an irregular surface structure. For instance, the filter media may comprise a plurality of peaks that are irregular in one or more ways. A ratio of a peak height standard deviation to an average peak height may be greater than or equal to 0.05, and/or a ratio of a peak spacing standard deviation to an average peak spacing may be greater than or equal to 0.08. In some embodiments, a filter media comprises a non-woven fiber web having a layer thickness of greater than 0.3 mm and/or a stiffness of less than or equal to 100 mg.
B01D 53/22 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by diffusion
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
Protective clothing materials and related methods and garments are provided. In some embodiments, a protective clothing material may comprise a fibrous layer that serves as a barrier to certain fluids (e.g., bodily fluids, water) and microbes. The impermeability of the fibrous layer may be due, at least in part, to the structural uniformity and/or relatively small pore size of the fibrous layer. In some embodiments, the fibrous layer may have a relatively high air permeability that imparts beneficial properties (e.g., relatively high air flow, breathability) to the protective clothing material without adversely affecting its protection rating. In certain embodiments, the protective clothing material may also comprise one or more coarse nonwoven webs that impart beneficial properties (e.g., splash resistance) to the protective clothing material. The protective clothing materials, described herein, may be particularly useful for a wide variety of applications, including the formation of AAMI level 4 protective garments.
D04H 1/559 - 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 the fibres being within layered webs
A41D 13/12 - Surgeons' or patients' gowns or dresses
D04H 1/4374 - 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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
A41H 43/04 - Joining garment parts or blanks by gluing or welding
D04H 1/56 - 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 in association with fibre formation, e.g. immediately following extrusion of staple fibres
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 7/02 - Physical, chemical or physicochemical properties
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
B32B 37/14 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
B32B 38/00 - Ancillary operations in connection with laminating processes
Filter media comprising a pre-filter layer and related components, systems, and methods associated therewith are provided. In some embodiments, the pre-filter layer may be designed to impart desirable properties to the filter media, such as a high gamma and/or long service life, while having relatively minimal or no adverse effects on another property of the filter media that is important for a given application. For instance, a pre-filter layer may be used to improve the upstream removal of fine particulate matter, which may clog a downstream efficiency layer comprising submicron fibers and reduce filtration performance. The pre-filter layer may be configured to increase service life and/or increase the gamma of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
B01D 53/22 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by diffusion
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
A41D 13/11 - Protective face masks, e.g. for surgical use, or for use in foul atmospheres
B01D 46/52 - Particle separators, e.g. dust precipitators, using filters embodying folded material
B01D 46/54 - Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
A62B 23/02 - Filters for breathing-protection purposes for respirators
Surface modified filter media, including surface modified filter media having enhanced performance characteristics, are provided. In some embodiments, a filter media may comprise two or more layers designed to enhance fluid separation efficiency. One or more of the layers may have at least a portion of a surface that is modified to alter and/or enhance the wettability of the surface with respect to a particular fluid. In certain embodiments involving a filter media including more than one surface modified layer, at least one surface modified layer may have a greater air permeability and/or mean flow pore size than that of another surface modified layer. Such a configuration of layers may result in the media having enhanced fluid separation properties compared to filter media that do not include such modified layers or configuration of layers, all other factors being equal. The filter media may be well-suited for a variety of applications, including filtering fuel, air, and lube oil.
Fiber webs which are used in filter media are described herein. In some embodiments, the fiber webs include fibrillated fibers and optionally non-fibrillated fibers, amongst other optional components (e.g., binder resin). In some embodiments, the fiber webs include limited amounts of, or no, glass fiber. The respective characteristics and amounts of the fibrillated fibers are selected to impart desirable properties including mechanical properties and filtration properties (e.g., dust holding capacity and efficiency), amongst other benefits.
Filter media comprising a filtration layer comprising synthetic fibers (e.g., pleatable backer layer) and related components, systems, and methods associated herewith are provided. In some embodiments, the filtration layer comprising synthetic fibers may be a non-woven web comprising a blend of coarse and fine diameter fibers. The filtration layer comprising synthetic fibers may be designed to have desirable performance properties without compromising certain mechanical properties, such as the pleatability of the media. In some embodiments, a filter media, described herein, may comprise the filtration layer comprising synthetic fibers and an efficiency layer. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
Fiber webs that may be used as filter media are provided. In some embodiments, the filter media may include multiple layers. Each layer may be designed to have separate functions in the filter media. For example, a first layer may be provided for improving dust holding capacity, a second layer for improving efficiency, and a third layer for providing support and strength to the media. By designing the layers to have separate functions, each layer may be optimized to enhance its function without negatively impacting the performance of another layer of the media.
Articles and methods involving pasting papers are generally provided. In certain embodiments, a pasting paper may comprise a plurality of cellulose fibers, a plurality of multicomponent fibers, and a plurality of glass fibers. In some embodiments, the average fiber diameter of each plurality of fibers is greater than or equal to 1 micron. In some embodiments, a pasting paper may have a thickness of less than 0.2 mm, an air permeability of less than or equal to 300 CFM, a 1.28 spg sulfuric acid wicking height of greater than 3 cm, and/or may be configured to have a dry tensile strength in a machine direction of greater than or equal to 1 lb/in after storage in 1.28 spg sulfuric acid at 75° C. for 168 hours. In some embodiments, a pasting paper may be disposed on a battery paste, such as a battery paste for use in a lead-acid battery. In certain cases, forming a battery plate may comprise disposing a pasting paper on a battery paste. In certain cases, a lead-acid battery may be assembled by assembling a first battery plate comprising a pasting paper with a separator and a second battery plate.
2/g), a density (gsm/mm) and a mean pore size (μm), which satisfy the equation disclosed herein. Also disclosed are batteries comprising the battery separators, and processes for making the separators.
Fine fiber products including fiber webs, as well as related assemblies, systems and methods, are described. In some embodiments, fiber webs described herein may include fine fibers and relatively low amounts of degraded polymer formed during a fiber extrusion process. The fiber webs may be used for filter media applications.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D04H 3/16 - 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 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
B01D 29/56 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor with multiple filtering elements, characterised by their mutual disposition in series connection
Battery components are generally provided. In some embodiments, the battery components can be used as pasting paper and/or capacitance layers for batteries, such as lead acid batteries. The battery components described herein may comprise a plurality of fibers. The battery component may include, in some embodiments, a plurality of fibers and, optionally, one or more additives such as conductive carbon and/or activated carbon. In certain embodiments, the plurality of fibers include relatively coarse glass fibers (e.g., having an average diameter of greater than or equal to 2 microns), relatively fine glass fibers (e.g., having an average diameter of less than 2 microns), and/or fibrillated fibers. In some instances, such fibers may be present in amounts such that the battery component has a particular surface area, mean pore size, and/or dry tensile strength.
Protective clothing materials and related methods and garments are provided. In some embodiments, a protective clothing material may comprise a fibrous layer that serves as a barrier to certain fluids (e.g., bodily fluids, water) and microbes. The impermeability of the fibrous layer may be due, at least in part, to the structural uniformity and/or relatively small pore size of the fibrous layer. In some embodiments, the fibrous layer may have a relatively high air permeability that imparts beneficial properties (e.g., relatively high air flow, breathability) to the protective clothing material without adversely affecting its protection rating. In certain embodiments, the protective clothing material may also comprise one or more coarse nonwoven webs that impart beneficial properties (e.g., splash resistance) to the protective clothing material. The protective clothing materials, described herein, may be particularly useful for a wide variety of applications, including the formation of AAMI level 4 protective garments.
A41D 13/12 - Surgeons' or patients' gowns or dresses
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
B32B 38/00 - Ancillary operations in connection with laminating processes
B32B 37/14 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
B32B 7/02 - Physical, chemical or physicochemical properties
A41D 31/00 - Materials specially adapted for outerwear
A41H 43/04 - Joining garment parts or blanks by gluing or welding
D04H 1/56 - 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 in association with fibre formation, e.g. immediately following extrusion of staple fibres
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
Filter media comprising a waved filtration layer having a gradient in a property and associated methods are provided. The waved filtration layer may include fibers that form one or more fiber webs. In some embodiments, the diameter of the fibers may vary across at least a portion of the thickness of the waved filtration layer to produce a gradient in fiber diameter. The gradient may be designed to impart beneficial properties to the filter media, such as low pressure drop and long lifetime. In some embodiments, the gradient may be characterized by mathematical equations that describe the change in fiber diameter across at least a portion of the thickness of the waved filtration layer. The filter media, described herein, may be particularly well-suited for applications that involve filtering liquids, though the media may also be used in other applications.
Filter media, including those suitable for hydraulic applications, and related components, systems, and methods associated therewith are provided. The filter media described herein may include two or more layers, at least one of the layers having a relatively high percentage of microglass fibers. Additionally, the filter media may be designed such that the ratio of average fiber diameters between two layers is relatively small, which can lead to a relatively low resistance ratio between the layers. In some embodiments, at least one layer of the filter media comprises synthetic polymer fibers. Certain filter media described herein may have desirable properties including high dirt holding capacity and a low resistance to fluid flow. The media may be incorporated into a variety of filter element products including hydraulic filters.
B01D 29/56 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor with multiple filtering elements, characterised by their mutual disposition in series connection
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
G06K 9/00 - Methods or arrangements for reading or recognising printed or written characters or for recognising patterns, e.g. fingerprints
B01D 29/00 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor
B01D 39/06 - Inorganic material, e.g. asbestos fibres, glass beads or fibres
In some embodiments, a battery separator described herein may comprise a layer having a relatively low apparent density; for example, the density that includes any unoccupied space within the outermost boundaries of the layer may be relatively low. The low apparent density may be attributed to, at least in part, the geometry of the layer. For instance, in some embodiments, the layer may include undulations and/or have at least one non-planar surface (e.g., a corrugated layer; an embossed layer). In some embodiments, a battery comprising a layer having a relatively low apparent density may have desirable properties, including relatively low electrical resistance and/or relatively high capacity. The battery separators described herein may be well suited for a variety of battery types, including lead acid batteries.
Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
B03C 3/28 - Plant or installations without electricity supply, e.g. using electrets
H01G 7/02 - Electrets, i.e. having a permanently-polarised dielectric
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B01D 35/06 - Filters making use of electricity or magnetism
D04H 1/498 - 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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
Filter media, such as electret-containing filtration media for filtering gas streams (e.g., air), are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency over the lifetime of the filter media, increased normalized gamma, relatively low pressure drop (i.e. resistance), and/or relatively low basis weight. In certain embodiments, the filter media may be a composite of two or more types of fiber layers where each layer may be designed to enhance its function without substantially negatively impacting the performance of another layer of the media. For example, one layer of the media may be designed to have a relatively low basis weight and/or a relatively high air permeability, and another layer of the media may be designed to have stable filtration efficiency and/or a relatively high efficiency throughout the filter media's lifetime. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, room filtration, furnace filtration, respirator equipment, residential or industrial HVAC filtration, high-efficiency particulate arrestance (HEPA) filters, ultra-low particular air (ULPA) filters, medical equipment), though the media may also be used in other applications.
Battery components are generally provided. In some embodiments, the battery components can be used as pasting paper and/or capacitance layers for batteries, such as lead acid batteries. The battery components described herein may comprise a plurality of fibers. The battery component may include, in some embodiments, a plurality of fibers and, optionally, one or more additives such as conductive carbon and/or activated carbon. In certain embodiments, the plurality of fibers include relatively coarse glass fibers (e.g., having an average diameter of greater than or equal to 2 microns), relatively fine glass fibers (e.g., having an average diameter of less than 2 microns), and/or fibrillated fibers. In some instances, such fibers may be present in amounts such that the battery component has a particular surface area, mean pore size, and/or dry tensile strength.
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
Articles and methods involving filter media are generally provided. In certain embodiments, the filter media includes at least a first layer, a second layer, and an adhesive resin positioned between the first layer and the second layer. In some embodiments, the first layer may be a pre-filter layer or a support layer. The second layer may, for example, comprise fibers formed by a solution spinning process and/or may comprise fine fibers. In some embodiments, the adhesive resin may be present in a relatively low amount and/or may have a low glass transition temperature. The filter media as a whole may have one or more advantageous properties, including one or more of a high stiffness, a high bond strength between the first layer and the second layer, a high gamma, and/or a low increase in air resistance after being subjected to an IPA vapor discharge. The filter media may be, for example, a HEPA filter and/or an ULPA filter.
Various high performance, high efficiency filter media are provided that are cost effective and easy to manufacture. In particular, various filter media are provided having at least one layer with a waved configuration that results in an increased surface area, thereby enhancing various properties of the filter media. The filter media can be used to form a variety of filter elements for use in various applications.
B01D 69/02 - Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
Filter media for filtering gas streams (e.g., air) are described herein. In some embodiments, the filter media may be designed to have desirable properties such as stable filtration efficiency, high oil repellency, low instantaneous resistance, and/or stable service life. In certain embodiments, one or more layers of the media may have a certain value of basis weight over air permeability (and/or a ratio of a value of basis weight over air permeability between two layers). The filter media may optionally comprise a support layer with a relatively high air permeability (e.g., greater than or equal to 1100 CFM). In some cases, the filter media may have a relatively low initial resistance and/or may have a particular final E1 efficiency. The filter media described herein may be particularly well-suited for applications that involve filtering gas streams (e.g., face masks, cabin air filtration, vacuum filtration, respirator equipment, as well as residential heating ventilation and air conditioning (HVAC) and industrial HVAC systems), though the media may also be used in other applications.
Battery separators are generally provided. In some embodiments, the battery separators may comprise a non-woven web including a plurality of inorganic particles (e.g., silica). The non-woven web may include, in some embodiments, a plurality of relatively coarse glass fibers (e.g., having an average diameter of greater than about 1.5 microns), e.g., such that the non-woven web has a particular largest pore size and median pore size. The combination of inorganic particles with a non-woven web having features described herein may exhibit enhanced electrolyte stratification distance and/or reduced electrolyte filling time. In some embodiments, such improvements may be achieved while having relatively minimal or no adverse effects on another property of the battery separator and/or the overall battery.
Filter media, filter elements, and methods for filtering an gas stream are described herein. In some embodiments, the filter media may comprise a fiber web comprising a plurality of fibers and having a particular oil repellency level. For instance, in certain embodiments, the surface chemistry of the fiber web may be tailored to impart a particular surface energy density that matches the surface energy density of the fluid (e.g., an oil, a lubricant, and/or a cooling agent) being removed from the gas stream. In some embodiments, the fiber web may be wrapped around a core. For example, the fiber web may be wrapped around the core such that it forms two or more layers around the core. In some cases, the fiber web may be perforated. In certain embodiments, an gas stream comprising a fluid (e.g., an oil, a lubricant, and/or a cooling agent) may be passed through the fiber web, filter media, and/or filter element such that at least a portion of the fluid coalesces on the fiber web. Fiber webs, filter media, and/or filter elements as described herein may be particularly well-suited for applications that involve filtering gas streams containing oil, lubricants, and/or cooling agents (e.g., gas streams generated by a compressor) though the media may also be used in other applications. Advantageously, the fiber webs, filter media, and/or filter elements described herein may significantly reduce or prevent fouling of the filter caused by oil or other liquids.
Filter media comprising a filtration layer comprising synthetic fibers (e.g., pleatable backer layer) and related components, systems, and methods associated herewith are provided. In some embodiments, the filtration layer comprising synthetic fibers may be a non-woven web comprising a blend of coarse and fine diameter fibers. The filtration layer comprising synthetic fibers may be designed to have desirable performance properties without compromising certain mechanical properties, such as the pleatability of the media. In some embodiments, a filter media, described herein, may comprise the filtration layer comprising synthetic fibers and an efficiency layer. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
Filter media including a filtration layer comprising fibers (e.g., synthetic fibers) comprising a flame retardant and related components, systems, and methods associated herewith are provided. In some embodiments, a filtration layer may include a nonwoven web (e.g., wet-laid nonwoven web) comprising fibers including a certain flame retardant that has a relatively low concentration of or is substantially free of certain undesirable and/or toxic components (e.g., halogens). In certain embodiments, the nonwoven web may also comprise a blend of fibers. For instance, in some embodiments, the nonwoven web may also comprise a blend of coarse and fine diameter synthetic fibers that impart beneficial performance properties to the filtration layer. In some embodiments, the filtration layer may be designed to have a desirable flame retardancy (e.g., F1 rating, K1 rating) and performance properties without compromising certain mechanical properties (e.g., pleatability of the media) and/or environmental attributes (e.g., relatively low toxicity). Filter media described herein may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
Fiber webs which are used in filter media are described herein. In some embodiments, the fiber webs include fibrillated fibers and optionally non-fibrillated fibers, amongst other optional components (e.g., binder resin). In some embodiments, the fiber webs include limited amounts of, or no, glass fiber. The respective characteristics and amounts of the fibrillated fibers are selected to impart desirable properties including mechanical properties and filtration properties (e.g., dust holding capacity and efficiency), amongst other benefits.
Disclosed is a battery separator, comprising two fiber regions comprising glass fibers, and a middle fiber region disposed between them comprising larger average diameter fibers and specified amounts of silica, or fine fibers, or both; and processes for making the separator. Also disclosed is a battery separator, comprising a fiber region and either one or two silica-containing region(s) adjacent thereto, each of the regions containing a specified amount of silica; and processes for making the separator. Such separators are useful, e.g., in lead-acid batteries.
Filter media including a waved filtration layer are described herein. The filtration layer may be held in a waved configuration by a support layer. In some cases, the filtration layer may have a combination of characteristics (e.g., mean flow pore size, basis weight, amongst others) that can lead to enhanced filtration performance (e.g., reduced air permeability decrease), in particular, in high humidity environments. The filter media may be used to form a variety of filter elements for use in various applications.
Filter media comprising nanofibers and related components, systems, and methods associated therewith are provided. In some embodiments, a filter media may comprise a first fiber web and a second fiber web designed to impart beneficial properties to the filter media. For instance, in some embodiments, the first fiber web may provide high particulate efficiency and the second fiber web may provide suitable capacity. In some embodiments, the first and second fiber webs may have certain properties (e.g., water contact angle, surface energy) that are similar or substantially the same. The similarities between the first and second fiber webs may serve to enhance the structural stability of the filter media under various conditions (e.g., high temperature, high pressure, steam sterilization) and/or permeability to certain fluids (e.g., water). Filter media, as described herein, may be particularly well-suited for applications that involve liquid filtration.
Battery separators are generally provided. In some embodiments, the battery separators may comprise a non-woven web including a plurality of inorganic particles (e.g., silica). The non-woven web may include, in some embodiments, a plurality of relatively coarse glass fibers (e.g., having an average diameter of greater than about 1.5 microns), e.g., such that the non-woven web has a particular largest pore size and median pore size. The combination of inorganic particles with a non-woven web having features described herein may exhibit enhanced electrolyte stratification distance and/or reduced electrolyte filling time. In some embodiments, such improvements may be achieved while having relatively minimal or no adverse effects on another property of the battery separator and/or the overall battery.
Filter media are described. The filter media may include multiple layers. In some embodiments, the filter media include a nanofiber layer adhered to another layer. In some embodiments, the layer to which the nanofiber layer is adhered is formed of multiple fiber types (e.g., fibers that give rise to structures having different air permeabilities and/or pressure drops). In some embodiments, the nanofiber layer is adhered to a single-phase or a multi-phase layer. In some embodiments, the nanofiber layer is manufactured from a meltblown process. The filter media may be designed to have advantageous properties including, in some cases, a high dust particle capture efficiency and/or a high dust holding capacity.
Filter media comprising a pre-filter layer and related components, systems, and methods associated therewith are provided. In some embodiments, the pre-filter layer may be designed to impart desirable properties to the filter media, such as a high gamma and/or long service life, while having relatively minimal or no adverse effects on another property of the filter media that is important for a given application. For instance, a pre-filter layer may be used to improve the upstream removal of fine particulate matter, which may clog a downstream efficiency layer comprising submicron fibers and reduce filtration performance. The pre-filter layer may be configured to increase service life and/or increase the gamma of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
B01D 53/22 - Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by diffusion
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
A41D 13/11 - Protective face masks, e.g. for surgical use, or for use in foul atmospheres
B01D 46/52 - Particle separators, e.g. dust precipitators, using filters embodying folded material
B01D 46/54 - Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
A62B 23/02 - Filters for breathing-protection purposes for respirators
Fine fiber products including fiber webs, as well as related assemblies, systems and methods, are described. In some embodiments, fiber webs described herein may include fine fibers and relatively low amounts of degraded polymer formed during a fiber extrusion process. The fiber webs may be used for filter media applications.
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B29C 48/88 - Thermal treatment of the stream of extruded material, e.g. cooling
B01D 29/00 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor
B01D 29/03 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor with flat filtering elements self-supporting
2/g, or the density is greater than 180 gsm/mm. Also disclosed are batteries comprising the battery separators, and processes for making the separators.
Surface modified filter media, including surface modified filter media having enhanced performance characteristics, are provided. In some embodiments, a filter media may comprise two or more layers designed to enhance fluid separation efficiency. One or more of the layers may have at least a portion of a surface that is modified to alter and/or enhance the wettability of the surface with respect to a particular fluid. In certain embodiments involving a filter media including more than one surface modified layer, at least one surface modified layer may have a greater air permeability and/or mean flow pore size than that of another surface modified layer. Such a configuration of layers may result in the media having enhanced fluid separation properties compared to filter media that do not include such modified layers or configuration of layers, all other factors being equal. The filter media may be well-suited for a variety of applications, including filtering fuel, air, and lube oil.
Disclosed is a battery separator, comprising two fiber regions comprising glass fibers, and a middle fiber region disposed between them comprising larger average diameter fibers and specified amounts of silica, or fine fibers, or both; and processes for making the separator. Also disclosed is a battery separator, comprising a fiber region and either one or two silica-containing region(s) adjacent thereto, each of the regions containing a specified amount of silica; and processes for making the separator. Such separators are useful, e.g., in lead-acid batteries.
Surface modified filter media, including surface modified filter media having enhanced performance characteristics, are provided. In some embodiments, a filter media may comprise two or more layers designed to enhance fluid separation efficiency. One or more of the layers may have at least a portion of a surface that is modified to alter and/or enhance the wettability of the surface with respect to a particular fluid. In certain embodiments involving a filter media including more than one surface modified layer, at least one surface modified layer may have a greater air permeability and/or mean flow pore size than that of another surface modified layer. Such a configuration of layers may result in the media having enhanced fluid separation properties compared to filter media that do not include such modified layers or configuration of layers, all other factors being equal. The filter media may be well-suited for a variety of applications, including filtering fuel, air, and lube oil.
Filter media suitable for various applications (e.g., hydraulic) and related components, systems, and methods associated therewith are described. The filter media may include a fiber web having a mixture of glass fibers and fibers that are fibrillated. The fibrillated fibers, for example, may be formed of lyocell.
B01D 29/03 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor with flat filtering elements self-supporting
B01D 35/02 - Filters adapted for location in special places, e.g. pipe-lines, pumps, stop-cocks
B01D 39/18 - Other self-supporting filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
Filter media, including those suitable for hydraulic applications, and related components, systems, and methods associated therewith are provided. The filter media described herein may include two or more layers, at least one of the layers having a relatively high percentage of microglass fibers. Additionally, the filter media may be designed such that the ratio of average fiber diameters between two layers is relatively small, which can lead to a relatively low resistance ratio between the layers. The filter media has desirable properties including high dirt holding capacity with low basis weight and a low resistance to fluid flow. The media may be incorporated into a variety of filter element products including hydraulic filters.
Filter media, including those suitable for hydraulic applications, and related components, systems, and methods associated therewith are provided. The filter media described herein may include two or more layers, at least one of the layers having a relatively high percentage of microglass fibers. Additionally, the filter media may be designed such that the ratio of average fiber diameters between two layers is relatively small, which can lead to a relatively low resistance ratio between the layers. In some embodiments, at least one layer of the filter media comprises synthetic polymer fibers. Certain filter media described herein may have desirable properties including high dirt holding capacity and a low resistance to fluid flow. The media may be incorporated into a variety of filter element products including hydraulic filters.
B01D 29/56 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor with multiple filtering elements, characterised by their mutual disposition in series connection
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
G06K 9/00 - Methods or arrangements for reading or recognising printed or written characters or for recognising patterns, e.g. fingerprints
B01D 29/00 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor
B01D 39/06 - Inorganic material, e.g. asbestos fibres, glass beads or fibres
Various high performance, high efficiency filter media are provided that are cost effective and easy to manufacture. In particular, various filter media are provided having at least one layer with a waved configuration that results in an increased surface area, thereby enhancing various properties of the filter media. The filter media can be used to form a variety of filter elements for use in various applications.
B01D 69/02 - Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
The fiber webs described herein may be incorporated into filter media and filter elements. The fiber webs may exhibit a high dust holding capacity. The fiber webs may also exhibit a low thickness. The fiber webs may be sufficiently flexible and/or deformable so that they may be processed to include a series of waves (also known as flutes) that extend along the cross-machine direction.
Systems and methods for forming fiber webs, including those suitable for use as filter media and battery separators, are provided. In some embodiments, the systems and methods involve a first system for forming a fiber web (e.g., a wet laid system or non-wet laid system) and additionally one or more coating units. The first system for forming a fiber web may be used to form one or more fibrous layers of the fiber web, and the coating unit may be used to form an additional fibrous layer of the fiber web. In some embodiments, the systems and methods can be used to form fiber webs having a gradient in a property across a portion of, or the entire, thickness of the fiber web.
Systems and methods for forming fiber webs, including those suitable for use as filter media and battery separators, are provided. In some embodiments, the systems and methods involve designs which allow improved control of the fiber web forming process. For example, in certain embodiments involving the flowing of more than one fiber mixtures, the amount of mixing of the fiber mixtures may be controlled to produce fiber webs having different structural and/or performance characteristics. In some embodiments, the systems and methods can be used to form fiber webs having a gradient in a property across a portion of, or the entire, thickness of the fiber web.
Fiber webs which are used in filter media are described herein. In some embodiments, the fiber webs include fibrillated fibers and optionally non-fibrillated fibers, amongst other optional components (e.g., binder resin). In some embodiments, the fiber webs include limited amounts of, or no, glass fiber. The respective characteristics and amounts of the fibrillated fibers are selected to impart desirable properties including mechanical properties and filtration properties (e.g., dust holding capacity and efficiency), amongst other benefits.
B01D 39/18 - Other self-supporting filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
B01D 24/00 - Filters comprising loose filtering material, i.e. filtering material without any binder between the individual particles or fibres thereof
Fiber webs that may be coated and used in filter media are provided. In some embodiments, the fiber web is a non-woven web that is coated with a resin comprising fibers. For example, the resin may include fibers that have sizes (e.g., diameters) in the nano or micron range. In some cases, the fibers distributed within the resin are fibrillated fibers. The respective characteristics and amounts of the fibers in the resin may be selected to impart desirable properties including enhanced mechanical properties and filtration properties (e.g., relatively high strength and air permeability), amongst other benefits.
Various high performance, high efficiency filter media are provided that are cost effective and easy to manufacture. In particular, various filter media are provided having at least one layer with a waved configuration that results in an increased surface area, thereby enhancing various properties of the filter media. The filter media can be used to form a variety of filter elements for use in various applications.
B01D 46/52 - Particle separators, e.g. dust precipitators, using filters embodying folded material
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
B01D 46/16 - Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces arranged on non-filtering conveyors
Filter media are described. The filter media may include multiple layers. In some embodiments, the filter media include a nanofiber layer adhered to another layer. In some embodiments, the layer to which the nanofiber layer is adhered is formed of multiple fiber types (e.g., fibers that give rise to structures having different air permeabilities and/or pressure drops). In some embodiments, the nanofiber layer is adhered to a single-phase or a multi-phase layer. In some embodiments, the nanofiber layer is manufactured from a meltblown process. The filter media may be designed to have advantageous properties including, in some cases, a high dust particle capture efficiency and/or a high dust holding capacity.
The fiber webs described herein may be incorporated into filter media and filter elements. The fiber webs may exhibit a high dust holding capacity. The fiber webs may also exhibit a low thickness. The fiber webs may be sufficiently flexible and/or deformable so that they may be processed to include a series of waves (also known as flutes) that extend along the cross-machine direction.
Filter media suitable for various applications and related components, systems, and methods associated therewith are described. The filter media may include a fiber web having a mixture comprising non-fibrillated synthetic fibers and fibrillated fibers, such as lyocell. The fiber web may also include multi-component fibers (e.g., bi-component fibers). In some embodiments, glass fibers are not incorporated into the fiber web.
The fiber webs described herein may be incorporated into filter media and filter elements. The fiber webs may exhibit a high dust holding capacity. The fiber webs may also exhibit a low thickness. The fiber webs may be sufficiently flexible and/or deformable so that they may be processed to include a series of waves (also known as flutes) that extend along the cross-machine direction.
The fiber webs described herein may be incorporated into filter media and filter elements. The fiber webs may exhibit a high dust holding capacity. The fiber webs may also exhibit a low thickness. The fiber webs may be sufficiently flexible and/or deformable so that they may be processed to include a series of waves (also known as flutes) that extend along the cross-machine direction.
Systems and methods for forming fiber webs, including those suitable for use as filter media and battery separators, are provided. In some embodiments, the systems and methods involve a first system for forming a fiber web (e.g., a wet laid system or non-wet laid system) and additionally one or more coating units. The first system for forming a fiber web may be used to form one or more fibrous layers of the fiber web, and the coating unit may be used to form an additional fibrous layer of the fiber web. In some embodiments, the systems and methods can be used to form fiber webs having a gradient in a property across a portion of, or the entire, thickness of the fiber web.
Various high performance, high efficiency filter media are provided that are cost effective and easy to manufacture. In particular, various filter media are provided having at least one layer with a waved configuration that results in an increased surface area, thereby enhancing various properties of the filter media. The filter media can be used to form a variety of filter elements for use in various applications.
B01D 46/00 - Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B01D 39/20 - Other self-supporting filtering material of inorganic material, e.g. asbestos paper or metallic filtering material of non-woven wires
B01D 69/02 - Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
B01D 46/52 - Particle separators, e.g. dust precipitators, using filters embodying folded material
Systems and methods for forming fiber webs, including those suitable for use as filter media and battery separators, are provided. In some embodiments, the systems and methods may involve the use of one or more fiber mixtures to form a fiber web. The fiber mixtures may flow in different portions of a system for forming a fiber web that may be separated by a lamella, and may join at a fiber web forming zone to produce a fiber web having multiple layers. The amount of mixing of the fiber mixtures at or near the fiber web forming zone may be controlled to produce fiber webs having different structural and/or performance characteristics. In some embodiments, the systems and methods described herein can be used to form fiber webs having a gradient in a property across a portion of, or the entire, thickness of the fiber web.
Fine fiber products including fiber webs, as well as related assemblies, systems and methods, are described. In some embodiments, fiber webs described herein may include fine fibers and relatively low amounts of degraded polymer formed during a fiber extrusion process. The fiber webs may be used for filter media applications.
B32B 17/00 - Layered products essentially comprising sheet glass, or fibres of glass, slag or the like
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D04H 3/16 - 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 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
B01D 29/56 - Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups ; Filtering elements therefor with multiple filtering elements, characterised by their mutual disposition in series connection
The present disclosure generally relates to filter media including glass fibers. The fiber characteristics (e.g., composition, dimensions) are selected to impart the desired solubility, filtration and mechanical properties so that the filter media may be used in the desired application.
B01D 24/00 - Filters comprising loose filtering material, i.e. filtering material without any binder between the individual particles or fibres thereof
patents
