WO2001021283A1 - Filtration media and the manufacture thereof - Google Patents
Filtration media and the manufacture thereof Download PDFInfo
- Publication number
- WO2001021283A1 WO2001021283A1 PCT/GB2000/003538 GB0003538W WO0121283A1 WO 2001021283 A1 WO2001021283 A1 WO 2001021283A1 GB 0003538 W GB0003538 W GB 0003538W WO 0121283 A1 WO0121283 A1 WO 0121283A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibres
- component
- filtration medium
- web
- blend
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—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
- D04H1/72—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
- D04H1/732—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
-
- 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
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—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
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—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
- D04H1/46—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
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—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
- D04H1/74—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 orientated, e.g. in parallel (anisotropic fleeces)
Definitions
- This invention relates to the manufacture of filtration media and in particular to the manufacture of electrostatic filtration media suitable inter alia for respiratory filtration applications, and to novel filtration media produced thereby.
- Filtration media are widely used in many applications, for example for the capture of airborne particles (bacteria, dust etc). In such filters it is desirable for the resistance to airflow to be low, without sacrificing the filtration efficiency (ie the effectiveness with which the filter captures the airborne particles).
- a known measure intended to achieve these objectives is the creation of electrostatic charge on the filter material. Such a charge serves to attract the airborne material.
- One particular field of application of such electrostatically-charged filter media is respiratory filtration.
- US 4,798,850 describes the formation of filter material with a felt structure composed of a blend of clean polypropylene fibres and clean fibres of an addition polymer comprising one or more halogen-substituted hydrocarbons.
- the felt is made by carding fibres into a web and needling them to form a coherent fabric structure.
- fibres are worked by a series of toothed rollers, which serve to disentangle the fibre and provide some mixing to increase the homogeneity of the blend.
- the product from the carding machine is a continuous web, which is peeled from the last main roller on the machine (doffer).
- the orientation of fibres in the web leaving the doffer is substantially dictated by the orientation of fibres leaving the doffer and is predominantly in the machine direction.
- the assembly of the web takes place mainly on the doffer and fibres are controlled by fibre to metal friction in the machine.
- the web is subsequently layered to produce a so-called batt structure that is then mechanically bonded.
- filtration media In general, it is desirable to be able to produce filtration media having satisfactory filtration efficiencies and low resistance to airflow, without having excessively high weight or thickness. It is also desirable to be able to achieve these objectives without having to resort to multi-layer structures in which the filtration medium is laminated with, or bonded to, other material.
- a process for the manufacture of a filtration medium which process comprises air-laying fibres to form a non-woven web.
- the air-laid web structure can be characterised by pronounced orientation in the z-direction (or perpendicular to the web surface). This gives the structure higher bulk (for a given area density) than a carded web.
- the former approach (roller-based air-laying) is presently preferred.
- the mechanical working treatment is much shorter than that used in carding but is sufficient to electrostatically charge the fibre.
- the effect can be created solely at the site of interaction between the feed rollers and the opening roller. No further working points (eg worker rollers) are required. Electrostatic charging of the fibres is believed to be achieved as the fibres are separated between a set of feed rollers and a single rapidly rotating roller, or as they are contacted by the rotors and mesh yarns of the grid. Multiple rollers as used in carding are not required.
- the charged fibres are then dispersed freely in a moving air stream to form an air/fibre mixture.
- the air then transports fibres from the rotating cylinder (or sifting area) to a suctioned mesh conveyor belt, screen or drum where the fibres are landed to form the web.
- the belt/drum acts as an air/fibre separator. The process is continuous and web weight depends on the speed of the landing drum or conveyor.
- consolidation of the web structure may be achieved using needle-punching.
- the weight of the filtration media produced in accordance with the invention may be varied from approximately 200g/m 2 up to 1000g/m 2 .
- basis weights in the range S ⁇ O-SOOg/m 2 would normally be selected.
- scrims or films can be attached to fabrics produced in accordance with the invention.
- a filtration medium comprising a non-woven web of fibrous material, said web having an MD:CD ratio of less than 2:1. More preferably, the MD:CD ratio is less than 1.5:1.
- a blend of two or more types of fibre is used in the process of the invention.
- the blend comprises (a) a polyolefin and (b) an addition polymer comprising one or more halogen-substituted hydrocarbons.
- the former component of the blend is preferably polypropylene and the latter may be, for instance, polyvinylchloride or polyvinylidene chloride.
- the blend may contain other fibres, either alternatively or in addition to those mentioned above.
- other fibre types which may be included are polyethylene and "modacrylic", ie a copolymer comprising from 35 to 85 weight percent acrylonitrile units and preferably having the balance made up substantially of other addition polymer-forming units, being halogenated hydrocarbon such as vinyl chloride or vinylidene chloride.
- the components of the blend may be present in any suitable proportions.
- the weight ratio of (a):(b) is in the range 70:30 to 30:70.
- the two classes of fibre are present in approximately equal proportions ie in each case between 45% and 55% by weight.
- dtex weight in grams of 10,000m of fibre.
- the fibres are of less than 3.3 dtex.
- the diameter is most preferably 12 ⁇ m or less.
- the fibres are preferably substantially free from any fibre finishes, oils or other extraneous matter prior to blending.
- Such chemicals are ideally removed from the fibres by an aqueous scouring process using a solution containing a synthetic detergent, sodium carbonate or a potassium carbonate solution.
- Other scouring regimes may also be suitable.
- the scouring process should be followed by thorough rinsing and drying stages prior to further processing.
- Figure 1 is a schematic diagram of a roller-based air-laying process
- Figure 2 is a schematic diagram of a sifting-based air-laying process.
- Roller-based systems can take many forms.
- a basic embodiment is illustrated in Figure 1.
- raw fibres are transferred first from a feed conveyor 11 to a clothed feed roller system 12 and then to a rapidly rotating cylinder 13 which is clothed with teeth and interacts with fixed carding elements 14,15 or some other clothed surface (eg clothed rollers).
- Electrostatic charging of the fibres is achieved as the fibres are opened on the clothed cylinders 12,13.
- An air knife 16 displaces fibres from the cylinder 13 on to a perforated conveyor 17 to which suction is applied from below.
- a non-woven web of fibre is built up on the perforated conveyor 17 from which the web is drawn off and consolidated by needle-punching.
- FIG. 2 An example of a sifting-based air-laying process is illustrated in Figure 2.
- loose fibre is contained within a drum 21 having a grid 22 at its base.
- Rotors 23 within the drum 21 displace fibres in an air stream on to the top surface of a perforated conveyor 24, to which suction is applied from below.
- the non-woven web is built up on the conveyor from which it is drawn off and consolidated by needle-punching.
- Airflow in the system is constrained between a pair of rollers 25,26, the downstream one of which 26 also applies compression to the web.
- Other systems that use rotating rollers or brushes instead of a static grid and rotors may also be used.
- fibre blends which may be used are:
- the proportion of PVC in the blend is approximately 50%.
- All the fibres have diameters of 12 ⁇ m or less and lengths in the range 2 to 12mm.
- Typical results (resistance to flow and filtration efficiency) for fabrics produced using the method of the invention are given in Table 1. These samples were a 50:50 blend of polyvinylchloride and polypropylene. Test results for fabrics produced by the prior art (50:50 modacrylic/polyvinylchloride) are given in Table 2 for comparison.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002383975A CA2383975A1 (en) | 1999-09-14 | 2000-09-14 | Filtration media and the manufacture thereof |
EP00962665A EP1214134A1 (en) | 1999-09-14 | 2000-09-14 | Filtration media and the manufacture thereof |
AU74315/00A AU7431500A (en) | 1999-09-14 | 2000-09-14 | Filtration media and the manufacture thereof |
JP2001524704A JP2003509204A (en) | 1999-09-14 | 2000-09-14 | Filtration medium and method for producing the same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB9921534.5A GB9921534D0 (en) | 1999-09-14 | 1999-09-14 | Manufacture of electrostatic filtration media |
GB9921534.5 | 1999-09-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2001021283A1 true WO2001021283A1 (en) | 2001-03-29 |
Family
ID=10860770
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB2000/003538 WO2001021283A1 (en) | 1999-09-14 | 2000-09-14 | Filtration media and the manufacture thereof |
Country Status (6)
Country | Link |
---|---|
EP (1) | EP1214134A1 (en) |
JP (1) | JP2003509204A (en) |
AU (1) | AU7431500A (en) |
CA (1) | CA2383975A1 (en) |
GB (2) | GB9921534D0 (en) |
WO (1) | WO2001021283A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1208900A1 (en) * | 2000-11-28 | 2002-05-29 | Carl Freudenberg KG | Process of manufacturing a triboelectrically charged nonwoven |
WO2003000976A1 (en) * | 2001-06-22 | 2003-01-03 | University Of Leeds | Fabrics composed of waste materials |
WO2006128237A1 (en) * | 2005-05-31 | 2006-12-07 | Commonwealth Scientific And Industrial Research Organisation | Electrostatic filter media and a process for the manufacture thereof |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP4757523B2 (en) * | 2004-11-15 | 2011-08-24 | 日本バイリーン株式会社 | Automotive interior base material and manufacturing method thereof |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3568846A (en) * | 1968-04-29 | 1971-03-09 | Ethyl Corp | Plastic filter media |
US4097965A (en) * | 1976-08-17 | 1978-07-04 | Scott Paper Company | Apparatus and method for forming fibrous structures comprising predominantly short fibers |
US4374894A (en) * | 1980-11-03 | 1983-02-22 | The B F Goodrich Company | Polyolefin nonwovens with high wet strength retention bonded with vinyl chloride copolymers |
EP0406485A1 (en) * | 1989-07-03 | 1991-01-09 | NPBI Nederlands Produktielaboratorium voor Bloedtransfusieapparatuur en Infusievloeistoffen B.V. | A method for the removal of leukocytes from a leukocyte-containing suspension and filter unit for use with the method |
US5230800A (en) * | 1992-02-20 | 1993-07-27 | Minnesota Mining And Manufacturing Company | Scrim inserted electrostatic fibrous filter web |
US5454946A (en) * | 1991-07-22 | 1995-10-03 | Lydall, Inc. | Filter material for filtering leucocytes from blood |
US5595659A (en) * | 1995-02-17 | 1997-01-21 | Lydall, Inc. | Filter material for removing chlorine from cold water in preparing a human-consumable beverage |
WO1997022743A2 (en) * | 1995-12-08 | 1997-06-26 | E.I. Du Pont De Nemours And Company | Method and apparatus for improving the air flow through an air duct in a dry fiber web forming system |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4600462A (en) * | 1981-09-29 | 1986-07-15 | James River/Dixie-Northern, Inc. | Incorporation of a hydrophile in fibrous webs to enhance absorbency |
US4812283A (en) * | 1986-05-02 | 1989-03-14 | Allied-Signal Inc. | Method of manufacture of formed article |
GB8612070D0 (en) * | 1986-05-19 | 1986-06-25 | Brown R C | Blended-fibre filter material |
US5076774A (en) * | 1989-02-16 | 1991-12-31 | Chicopee | Apparatus for forming three dimensional composite webs |
US5985411A (en) * | 1994-03-14 | 1999-11-16 | Upf Corporation | Self-supporting pleated filter composite |
ZA984078B (en) * | 1997-05-30 | 1998-11-25 | Kimberly Clark Wordlwide Inc | Face mask |
-
1999
- 1999-09-14 GB GBGB9921534.5A patent/GB9921534D0/en not_active Ceased
-
2000
- 2000-09-14 WO PCT/GB2000/003538 patent/WO2001021283A1/en not_active Application Discontinuation
- 2000-09-14 GB GB0022673A patent/GB2355215B/en not_active Expired - Lifetime
- 2000-09-14 CA CA002383975A patent/CA2383975A1/en not_active Abandoned
- 2000-09-14 JP JP2001524704A patent/JP2003509204A/en active Pending
- 2000-09-14 AU AU74315/00A patent/AU7431500A/en not_active Abandoned
- 2000-09-14 EP EP00962665A patent/EP1214134A1/en not_active Withdrawn
Patent Citations (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3568846A (en) * | 1968-04-29 | 1971-03-09 | Ethyl Corp | Plastic filter media |
US4097965A (en) * | 1976-08-17 | 1978-07-04 | Scott Paper Company | Apparatus and method for forming fibrous structures comprising predominantly short fibers |
US4374894A (en) * | 1980-11-03 | 1983-02-22 | The B F Goodrich Company | Polyolefin nonwovens with high wet strength retention bonded with vinyl chloride copolymers |
EP0406485A1 (en) * | 1989-07-03 | 1991-01-09 | NPBI Nederlands Produktielaboratorium voor Bloedtransfusieapparatuur en Infusievloeistoffen B.V. | A method for the removal of leukocytes from a leukocyte-containing suspension and filter unit for use with the method |
US5454946A (en) * | 1991-07-22 | 1995-10-03 | Lydall, Inc. | Filter material for filtering leucocytes from blood |
US5230800A (en) * | 1992-02-20 | 1993-07-27 | Minnesota Mining And Manufacturing Company | Scrim inserted electrostatic fibrous filter web |
US5595659A (en) * | 1995-02-17 | 1997-01-21 | Lydall, Inc. | Filter material for removing chlorine from cold water in preparing a human-consumable beverage |
WO1997022743A2 (en) * | 1995-12-08 | 1997-06-26 | E.I. Du Pont De Nemours And Company | Method and apparatus for improving the air flow through an air duct in a dry fiber web forming system |
US5778494A (en) * | 1995-12-08 | 1998-07-14 | E. I. Du Pont De Nemours And Company | Method and apparatus for improving the air flow through an air duct in a dry fiber web forming system |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1208900A1 (en) * | 2000-11-28 | 2002-05-29 | Carl Freudenberg KG | Process of manufacturing a triboelectrically charged nonwoven |
TR200103364A3 (en) * | 2000-11-28 | 2002-06-21 | Carl Freudenberg | Production method of a triboelectrically charged fleece. |
TR200103364A2 (en) * | 2000-11-28 | 2002-06-21 | Carl Freudenberg | Production method of a triboelectrically charged fleece material. |
WO2003000976A1 (en) * | 2001-06-22 | 2003-01-03 | University Of Leeds | Fabrics composed of waste materials |
WO2006128237A1 (en) * | 2005-05-31 | 2006-12-07 | Commonwealth Scientific And Industrial Research Organisation | Electrostatic filter media and a process for the manufacture thereof |
Also Published As
Publication number | Publication date |
---|---|
GB2355215A (en) | 2001-04-18 |
EP1214134A1 (en) | 2002-06-19 |
GB9921534D0 (en) | 1999-11-17 |
AU7431500A (en) | 2001-04-24 |
GB2355215B (en) | 2003-05-07 |
JP2003509204A (en) | 2003-03-11 |
CA2383975A1 (en) | 2001-03-29 |
GB0022673D0 (en) | 2000-11-01 |
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