CA2419849A1 - Filter structure with two or more layers of fine fiber having extended useful service life - Google Patents

Filter structure with two or more layers of fine fiber having extended useful service life Download PDF

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Publication number
CA2419849A1
CA2419849A1 CA002419849A CA2419849A CA2419849A1 CA 2419849 A1 CA2419849 A1 CA 2419849A1 CA 002419849 A CA002419849 A CA 002419849A CA 2419849 A CA2419849 A CA 2419849A CA 2419849 A1 CA2419849 A1 CA 2419849A1
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CA
Canada
Prior art keywords
efficiency
fine fiber
layer
less
filter media
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002419849A
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French (fr)
Other versions
CA2419849C (en
Inventor
James D. Benson
Douglas G. Crofoot
Mark A. Gogins
Thomas M. Weik
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Donaldson Co Inc
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Individual filed Critical Individual
Publication of CA2419849A1 publication Critical patent/CA2419849A1/en
Application granted granted Critical
Publication of CA2419849C publication Critical patent/CA2419849C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
    • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/02—Particle separators, e.g. dust precipitators, having hollow filters made of flexible material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/10—Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
    • B01D46/12—Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces in multiple arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2411—Filter cartridges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • B01D46/546—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms using nano- or microfibres
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/90—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyamides
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/88—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/92—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2275/10—Multiple layers

Abstract

The use of fine fiber of fiber having a fiber diameter of about 0.0001 to 0. 5 microns has become an important design tool for filter media. Common filter media have been prepared with a layer of fine fiber on typically formed the upstream or intake side of the media structure. The fine fiber increases the efficiency of filtration by trapping small particles which increases the overall particulate filtration efficiency of the structure. Improved fine fiber structures have been developed in which a controlled amount of fine fiber is placed on both sides of the media to result in an improvement in filter efficiency but a substantial improvement in lifetime.

Claims (35)

1. A fine fiber filter media comprising a sheet-like filter substrate, the sheet having a first surface and a second surface, the first surface and the second surface each comprising a layer of fine fiber having a diameter of about 0.001 to 0.5 microns, the layer having a thickness of less than 5 microns, the fine fiber formed in an amount effective to obtain an overall efficiency under ASTM-1215-89 with monodisperse 0.78 micron polystyrene latex particles at 20 ft/min velocity of less than 90% in any one layer and to obtain an efficiency of greater than 90% in both layers combined.
2. The filter media of claim 1 wherein the efficiency of the fine fiber layer on the first surface is different than the efficiency of the fine fiber layer on the second surface.
3. The filter media of claim 1 wherein the efficiency of the fine fiber layer on a downstream surface is greater than the efficiency of the fine fiber layer on an upstream surface.
4. The filter media of claim 1 wherein the sheet-like filter substrate has a thickness of about 0.1 to 3 millimeters, the first surface and the second surface each comprising a layer of fine fiber having a diameter of about 0.01 to 0.3 microns the layer having a thickness of less than 3 microns, the fine fiber selected such that after test exposure for a test period of 16 hours to test conditions of 140°F air and a relative humidity of 100% retains greater than 50% of the fiber unchanged for filtration purposes.
5. The filter media of claim 1 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of less than 85% and in both layers combined to obtain an overall efficiency of greater than 90% and the substrate has an efficiency of about 5 % to about 80%.
6. The filter media of claim 1 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of less than 80% and in both layers combined to obtain an overall efficiency of greater than 85% and the substrate has an efficiency of about 20% to about 80%.
7. The filter media of claim 1 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of about 40% to 85%
and in both layers combined to obtain an overall efficiency of greater than 65% and the substrate has an efficiency of about 5% to about 80%.
8. The filter media of claim 1 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of about 40% to 80%
and in both layers combined to obtain an overall efficiency of greater than 65% and the substrate has an efficiency of about 20% to about 80%.
9. The filter media of claim 4 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an overall efficiency of less than 75% and in both layers combined to obtain an efficiency of greater than 80%, and retains greater than 30% of the fiber unchanged for filtration purposes.
10. The filter media of claim 1 wherein the fine fiber forming an interlocking mesh of fiber having on the average a pore size between fibers in the web of less than about 3 microns; wherein the substrate has an efficiency greater than the efficiency of a single sided media and has a lifetime, defined as an increase in pressure drop over the filter of about 3 inches H2O at test conditions of 10 ft/min.
11. A method of removing a particulate from an air borne stream, the particulate comprising a liquid particulate, a solid particulate or mixtures thereof, the method comprises:
(a) placing a filter structure in an air stream; and (b) directing the air stream through the filter structure while monitoring the useful life of the filter structure; said filter structure comprising a fine fiber filter media and sheet-like filter substrate, the sheet having a first surface and a second surface, the first surface and the second surface each comprising a layer of fine fiber having a diameter of about 0.001 to 0.5 microns the layer having a thickness of less than 5 microns, the fine fiber layer formed in an amount effective to obtain an efficiency under ASTM-1215-89 with monodisperse 0.78 micron polystyrene latex particles at 20 ft/min velocity of less than 90% in any one layer and to obtain an efficiency of greater than 90% in both layers combined.
12. The method of claim 11 wherein the efficiency of the fine fiber layer on the first surface is different than the efficiency of the fine fiber layer on the second surface.
13. The method of claim 11 wherein the efficiency of the fine fiber layer on a downstream surface is greater than the efficiency of the fine fiber layer on an upstream surface.
14. The method of claim 11 wherein the sheet-like filter substrate has a thickness of about 0.01 to 0.5 millimeters, the first surface and the second surface each comprising a separate layer of fine fiber having a diameter of about 0.01 to 0.3 microns the layer having a thickness of less than 3 microns, the fine fiber selected such that after test exposure for a test period of 16 hours to test conditions of 140°F
air and a relative humidity of 100% retains greater than 50% of the fiber unchanged for filtration purposes.
15. The method of claim 11 wherein the fine fiber layer formed in an amount effective to obtain an efficiency of less than 85% in any one layer and to obtain an efficiency of greater than 90% in both layers combined.
16. The method of claim 11 wherein the fine fiber layer formed in an amount effective to obtain an efficiency of less than 80% in any one layer and to obtain an efficiency of greater than 85% in both layers combined.
17. The method of claim 11 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of about 40% to 85%
and in both layers combined to obtain an overall efficiency of greater than 65% and the substrate has an efficiency of about 20% to about 80%.
18. The method of claim 11 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of about 40% to 80%
and in both layers combined to obtain an overall efficiency of greater than 65% and the substrate has an efficiency of about 20% to about 80%.
19. The method of claim 11 wherein the fine fiber layer formed in an amount effective to obtain an efficiency of less than 75% in any one layer and to obtain an efficiency of greater than 80% in both layers combined.
20. The method of claim 11 wherein the fine fiber forming an interlocking mesh of fiber having on the average a pore size between fibers in the web of less than about 3 microns; wherein the filter media has an efficiency greater than the efficiency of a single sided media and has a lifetime, defined as an increase in pressure drop over the filter of about 3 inches H2O at test conditions of 10 ft/min.
21. The method of claim 11 wherein the particulate comprises a solid particulate, a liquid particulate or mixtures thereof.
22. The method of claim 21 wherein the particulate comprises residual components of combustion.
23. The method of claim 21 wherein the particulate comprises a fatty oil, a fatty acid or mixtures thereof.
24. The method of claim 21 wherein the particulate comprises soot, a grit or mixtures thereof.
25. A filter structure comprising one or more sheet like filter substrate and three or more layers of fine fiber, each sheet like substrate having a first surface and a second surface, the surfaces comprising three or more layers of the fine fiber on the substrate, each layer comprising fine fiber having a diameter of about 0.01 to 0.5 micron, each layer having a thickness of less than 5 microns, the fine fiber formed in the amount effective to obtain an efficiency under ASTM-1215-89 with monodisperse 0.78 micron polystyrene latex particles at 20 ft/min velocity of less than 90% in any one layer and to obtain an overall efficiency of greater than 90% in the layers combined.
26. The filter media of claim 25 wherein the efficiency of the fine fiber layer on the first surface is different than the efficiency of the fine fiber layer on the second surface.
27. The filter media of claim 25 wherein the efficiency of a fine fiber layer on a downstream surface is greater than the efficiency of a fine fiber layer on an upstream surface.
28. The filter media of claim 25 wherein the sheet-like filter substrate has a thickness of about 0.01 to 3 millimeters, any surface comprising a layer of fine fiber having a diameter of about 0.01 to 0.5 microns the layer having a thickness of less than 3 microns, the fine fiber selected such that after test exposure for a test period of 16 hours to test conditions of 140°F air and a relative humidity of 100%
retains greater than 50% of the fiber unchanged for filtration purposes.
29. The filter media of claim 25 wherein the sheet-like filter substrate has a thickness of about 0.3 to 1 millimeters.
30. The filter media of claim 25 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of less than 85% and in both layers combined to obtain an overall efficiency of greater than 90%.
31. The filter media of claim 25 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of less than 80% and in both layers combined to obtain an overall efficiency of greater than 85%.
32. The filter media of claim 25 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of about 40% to 85%
and in both layers combined to obtain an overall efficiency of greater than 65% and the substrate has an efficiency of about 5% to about 80%.
33. The filter media of claim 25 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an efficiency of about 40% to 80%
and in both layers combined to obtain an overall efficiency of greater than 65% and the substrate has an efficiency of about 20% to about 80%.
34. The filter media of claim 25 wherein the fine fiber layer formed in an amount effective, in each layer, to obtain an overall efficiency of less than 75% and in both layers combined to obtain an efficiency of greater than 80%, and retains greater than 30% of the fiber unchanged for filtration purposes.
35. The filter media of claim 25 wherein the fine fiber forming an interlocking mesh of fiber having on the average a pore size between fibers in the web of less than about 3 microns; wherein the substrate has an efficiency greater than the efficiency of a single sided media and has a lifetime, defined as an increase in pressure drop over the filter of about 3 inches H2O at test conditions of 10 ft/min.
CA002419849A 2000-09-05 2001-08-21 Filter structure with two or more layers of fine fiber having extended useful service life Expired - Fee Related CA2419849C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US23013800P 2000-09-05 2000-09-05
US60/230,138 2000-09-05
US09/871,156 US6746517B2 (en) 2000-09-05 2001-05-31 Filter structure with two or more layers of fine fiber having extended useful service life
US09/871,156 2001-05-31
PCT/US2001/026045 WO2002020130A2 (en) 2000-09-05 2001-08-21 Filter structure with two or more layers of fine fiber having extended useful service life

Publications (2)

Publication Number Publication Date
CA2419849A1 true CA2419849A1 (en) 2002-03-14
CA2419849C CA2419849C (en) 2009-12-15

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA002419849A Expired - Fee Related CA2419849C (en) 2000-09-05 2001-08-21 Filter structure with two or more layers of fine fiber having extended useful service life

Country Status (14)

Country Link
US (1) US6746517B2 (en)
EP (1) EP1326697B1 (en)
JP (1) JP5021142B2 (en)
KR (1) KR100820748B1 (en)
CN (1) CN1318121C (en)
AT (1) ATE297798T1 (en)
AU (1) AU2001288333B2 (en)
BR (1) BR0113656A (en)
CA (1) CA2419849C (en)
DE (1) DE60111554T2 (en)
IL (2) IL154570A0 (en)
MX (1) MXPA03001929A (en)
RU (1) RU2280491C2 (en)
WO (1) WO2002020130A2 (en)

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