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WO1991016119A1 - Element non tisse comprenant un liant en fibride - Google Patents

Element non tisse comprenant un liant en fibride Download PDF

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Publication number
WO1991016119A1
WO1991016119A1 PCT/US1990/002065 US9002065W WO9116119A1 WO 1991016119 A1 WO1991016119 A1 WO 1991016119A1 US 9002065 W US9002065 W US 9002065W WO 9116119 A1 WO9116119 A1 WO 9116119A1
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WO
WIPO (PCT)
Prior art keywords
fibers
filter element
fibrids
woven
inlet
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.)
Ceased
Application number
PCT/US1990/002065
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English (en)
Inventor
Homan B. Kinsley, Jr.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Georgia Pacific Consumer Products LP
Original Assignee
James River Paper Co Inc
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Filing date
Publication date
Application filed by James River Paper Co Inc filed Critical James River Paper Co Inc
Publication of WO1991016119A1 publication Critical patent/WO1991016119A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2055—Carbonaceous material
    • B01D39/2065—Carbonaceous material the material being fibrous
    • 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
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • 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
    • B01D39/18—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
    • 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
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003—Glass or glassy material
    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
    • 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
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2055—Carbonaceous material
    • 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
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass 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
    • D04H1/40—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
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose 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
    • D04H1/42—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
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43838—Ultrafine fibres, e.g. microfibres
    • 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
    • D04H1/58—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
    • D04H1/587—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 characterised by the bonding agents used
    • 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
    • D04H1/58—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
    • D04H1/64—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 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/02—Synthetic cellulose fibres
    • D21H13/06—Cellulose esters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/26—Polyamides; Polyimides
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0618—Non-woven
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0636—Two or more types of fibres present in the filter material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/064—The fibres being mixed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/08—Special characteristics of binders
    • B01D2239/086—Binders between particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1233—Fibre diameter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/125—Size distribution

Definitions

  • This invention relates to the field of non- woven elements, and, in particular, non-woven fibrous elements composed of polymeric fibrids.
  • a papery product using a binder, such as a suitable resin, is known.
  • a binder such as a suitable resin
  • U.S. Patent No. 3,573,158 discloses the formation of icroporous sheets which are useful as filters.
  • a binding agent can be employed in order to strengthen the adhesion between fibers, which binding agent can be liquid or solid.
  • Liquid condensation polymer resins are noted as being particularly advantageous binding agents, with representative resins including phenol- formaldehyde resins, urea-formaldehyde resins, melamine-formaldehyde resins, polyester resins and polyepoxide resins.
  • thermoplastic solid binders comprised of polyethylene, polypropylene, poly ethylen ⁇ , polybutylene, polyisobutylene, copolymers of vinyl chloride and vinyl acetate, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, polyvinyl butyrol and polytetrafluoroethylene.
  • polymers derived from natural products are appropriate, such as lignin-sulfonate resins, starch binders and casein binders, among others.
  • U.S. Patent No. 3,920,428 A combination of glass fibers and aromatic polyamide fibers and fibrids is disclosed in U.S. Patent No. 3,920,428.
  • This patent relates to a filter element adapted to remove particulate from the exhaust of an internal combustion engine comprising a non-woven mat of glass fibers fused with aromatic polyamide fibers.
  • the aromatic polyamide fibers may be mixtures of fibrids and short fibers as described in U.S. Patent No. 3,756,908.
  • the materials described in U.S. Patent No. 3,920,428 may be satisfactory for high temperature applications, it is not a very economically suitable filter under the contemplated circumstances.
  • such a filter element is found to exhibit decreased permeability and a low void fraction.
  • U.S. Patent No. 4,398,995 relates to a papery product composed of a fibrous web, at least part of which is made up of wholly aromatic polyamide fibers having a readily soluble skin layer and a sparingly soluble or insoluble core layer.
  • the skin layer is softened and fuses the polyamide fibers.
  • the papery product may, optionally, include fibers of glass and cellulose acetate.
  • the method of forming papery products in accordance with this patent involves complicated treatment steps to form the core/shell polymer fiber used in the formation of the papery product. This renders the product extremely expensive, and hence impractical, to manufacture.
  • Still another object of the present invention is to provide a flexible, non-woven element, useful as a filter, which is of increased permeability, and which is strong and ideally suited for use at lower temperatures.
  • Yet another object of the present invention is to provide an inexpensive, practical filter element having minimal energy requirements for its manufacture.
  • a wet-laid non-woven element of high strength and good flexibility and permeability is comprised of a wet- laid non-woven mat of fibers and polymer fibrids having a softening point below the softening point of the fibers contained in the wet-laid non-woven mat.
  • the fibers are bound to one another by the polymer fibrids, which act as a binder.
  • the resulting non-woven element exhibits good strength and flexibility, improved permeability and can be manufactured in an efficient and cost effective manner.
  • the non-woven elements are suitable as filter elements which are particularly well suited for use in lower temperature filtering applica ⁇ tions, i.e., at temperatures lower than the softening point of the fibrids.
  • a non-woven element which is particularly applicable as a filter element for use at temperatures below about
  • the non-woven element is comprised of a wet- laid non-woven mat of (i) glass fibers, (ii) synthetic short ' fibers, e.g., aromatic polyamide short fibers and (iii) polymer fibrids having a softening point below the softening point of the short fibers.
  • the synthetic short fibers are believed bound to the glass fibers by the polymer fibrids, which act as a binder.
  • the Figure of the Drawing is a plan view of a portion of a non-woven fiber mat of this invention.
  • the present invention provides a non-woven element of high strength and good flex.
  • Such non-woven elements have many conventional applications, and are particularly useful as a filter in the filtration of particulates from a medium at lower temperatures.
  • the non-woven element generally is comprised of a non-woven mat of fibers and polymer fibrids having a softening point below the softening point of the fibers.
  • the fibers are bound to each other by use of the polymer fibrids as a binder. This binding effect is evident even when the fibrids are present in a non-melted state, but most substantial improvements are realized when the fibrids are melted, i.e., heat- bonded or melt-bonded. It should be noted, however, that the contribution of the fibrids is believed to be more than just that of a binder.
  • the polymer fibrids also add to the unique structural and physical characteristics of the fibrous mat of the instant invention.
  • the fibers contained in the non-woven element of the present invention can be any useful fiber. Synthetic fibers, including polymeric fibers and graphite fibers, carbon fibers, natural fibers, glass fibers, are all contemplated. Mixtures of fibers, including mixtures of different types of fibers, can also be used. It is only important that the polymeric fibrids employed as a binder have a softening point below that of all the fibers used in the non-woven element.
  • useful polymeric fibers are the polyamides, polyesters, polyethylene, polypro ⁇ pylene, polyaramids, polybenzi idazole, polyphenylene sulfide, liquid crystal polymers, and polyfuorocarbon ⁇ .
  • Useful natural organic fibers include, but are not limited to, those of wood, flax, cotton, bamboo, grass (esparto) , ramie, silk and wool.
  • Useful manmade inorganic fibers include those of glass, metal, silica carbide, polyphosphates and mineral wool.
  • Illustrative of natural inorganic fibers are asbestos fibers.
  • the fibers of the present invention can have about any conventional fiber diameter and length. Mixtures of fibers having different diameters and/or lengths can also be used.
  • the preferred polymeric fibers used in the non-woven element of the present invention are those conventionally used to make synthetic papers.
  • Glass fibers which are useful in the practice of the present invention generally can have any diameter, but preferably have a diameter of from about 0.05-15 microns, and lengths from about 1/4 to 3 inches.
  • the glass fibers can comprise macro fibers, micro fibers or a mixture thereof.
  • the glass fibers comprise a mixture of glass macro fibers having a diameter of about 6-15 microns, and glass micro fibers having a diameter of about 0.05-2 microns, and most preferably about 0.6 micron.
  • the macro fiber can be of any length up to about 3 inches or more, while the micro fibers are preferably less than one inch, and more preferably less than 1/4 inch long. For example, good results are obtained using micro fibers of about 0.6 micrometers in diameter and about 1/16 through 1/4 inch in length. During blending they may became chopped up into random lengths. Mixtures containing about 50-90 weight percent macro fibers and 10-50 weight percent micro fibers relative to the total glass fiber content are preferred. Other inorganic fibers besides glass fibers, as discussed above, can also be successfully used.
  • the fibrids according to the present invention are small, non-granular, non-rigid, fibrous or film-like particles. Two of their three dimensions are on the order of microns. Their smallness and suppleness allows them to be deposited in physically entwined configurations such as the fiber mat.
  • the polymer fibrids of the present invention also have a softening point below the softening point of the fibers used in the non-woven element. Thus, when heat is applied to a mixture of fibers and the polymer fibrids, the fibrids soften and surround the fibers thereby binding the fibers together and forming a mat.
  • the fibrids may be composed of any polymeric material, e.g., a nitrile polymer, nylon, polyester or cellulose acetate, so long as its softening point is below the softening point of the fibers used.
  • the polymer fibrids are comprised of cellulose acetate fibrids. While it is most preferred that heat-bonding or melt-bonding of the fibrids be employed in formulating the non-woven element of the present invention, the fibrids can be employed in the non- melted state. Heat or melt-bonding occurs when heat is applied to a mixture of fibers and fibrids so that the fibrids soften and surround the fibers.
  • the fibrids In the non- melted state, the fibrids have also been found to act as a binder due to their high surface area. It is this binding effect in the non-melted state which permits the formation of the non-woven web when using many synthetic fibers. Melt-bonding of the fibrids, however, is most preferred in that, generally, added web strength is realized. As well, the porosity of the non-woven element is increased upon melt-bonding the fibrids.
  • the relative softening point of the fibrids as compared to the fibers can be realized in any environment, whether it be air or an inert environment.
  • the fibers do not actually have a softening point, but begin to destructively oxidize in air at high temperatures.
  • temperatures of 600°F and higher can be safely reached in a superheated steam environment or some other inert atmosphere for brief periods. It is considered within the purview of the present invention to include such combinations of fibers and fibrids, e.g., cellulosic fibers and fibrids which have a softening point below that of the cellulosic fibers in an inert atmosphere.
  • the melt-bonding of a non-woven web comprised of cellulosic fibers and a particular fibrid can occur in a superheated stream environment or under a nitrogen atmosphere.
  • the ratio of fibers to polymeric fibrids in the non-woven element can vary widely. A preferred range, however, is from about 5 to about 75 weight percent of polymer fibrids and from about 25 to about 95 weight percent of fibers, and more preferably from about 15 to about 50 weight percent of polymer fibrid and about 50 to about 85 weight percent of the fibers.
  • the non-woven element is a three-component element comprised of a mixture of different types of fibers.
  • the mixture contains glass fibers and synthetic short fibers, most preferably aromatic polyamide short fibers.
  • the polymeric fibrids employed are most preferably comprised of cellulose acetate.
  • Such a non-woven element is particularly applicable as a filter element for use at temperatures below about 400°F. Excellent chemical resistance is exhibited by such a filter element.
  • the glass fibers employed in the above- described three component non-woven element can generally be any glass fiber, but are preferably comprised of a mixture of macro and micro glass fibers as hereinbefore described.
  • aromatic polyamide short fibers are the aromatic polyamide short fibers, as well as short fibers of polybenzimidazole, polyphenylene sulfide, polyamides (nylons) , polyesters, liquid crystal polymers, polypropylene or carbon short fibers.
  • aromatic polyamide includes wholly aromatic polyamides as well as non-wholly aromatic polyamids, both of which are contemplated. Examples of suitable aromatic polyamides are described in U.S. Pat. No. 3,094,511 and British Pat. No. 1,106,190, which are incorporated herein by reference.
  • the preferred wholly aromatic polyamide contains repeating units of formulae (I) and (II) ,
  • Ar l Ar and Ar 3 respectively represent, independently from each other, an unsubstituted or substituted divalent aromatic radical which comprises a single aromatic ring, or two or more aromatic rings that are condensed together, or are linked together by a single bond, or by a bridging atom or radical, and which is oriented either eta or para, and R ⁇ , R 2 and R 3 respectively represent, independently from each other, a hydrogen atom or an alkyl radical having 1 to 3 carbon atoms.
  • r lf Ar and Ar 3 be respectively selected, independently from each other, from the group consisting of the radicals of the formulae:
  • R represents a member selected from the group consisting of lower alkyl radicals having 1 to 6 carbon atoms, lower alkoxy radicals having 1 to 6 carbon atoms, halogen atoms and a nitro radical
  • n represents zero or an integer of from 1 to 4
  • X ⁇ represents a member selected from the group consisting of:
  • Y 2 represents a member selected from the group consisting of a hydrogen atom and lower alkyl radicals having 1 to 6 carbon atoms.
  • Ar 1; Ar 2 and Ar respectively represent, independently from each other, a member selected from p-phenylene radical, m-phenylene radical, biphenylene and radicals of the formulae:
  • Y 2 represents a hydrogen atom or an alkyl radical having 1 to 3 carbon atoms.
  • Ar ⁇ , Ar 2 and Ar 3 be respectively a p-phenylene or m-phenylene radical.
  • the aromatic polyamide contain the repeating units of the formula (II) in which Ar 2 and Ar 3 are respectively a p- phenylene or m-phenylene radical, most preferably, a m- phenylene radical.
  • the aromatic polyamide may contain 30 molar % or less of one or more comonomers, for example, aliphatic diamines, such as hexamethylene diamine and piperazine, and aliphatic dicarboxylic acid, such as adipic acid, based on the entire molar amount of the comonomers contained in the polyamide.
  • comonomers for example, aliphatic diamines, such as hexamethylene diamine and piperazine, and aliphatic dicarboxylic acid, such as adipic acid, based on the entire molar amount of the comonomers contained in the polyamide.
  • the preferred aromatic polyamides are those having a softening temperature above about 350°C.
  • Examples include: poly(4,4*-diphenylene terephthala ide) poly(3,3'-dimethyl-4,4'-diphenylene terephthalamide) poly(ethylene terephthalamide) poly(4,4 '-methylenediphenylene terephthalamdie) poly(4,4 '-diphenylene isophthalamide) poly(4,4 '-methylenediphenylene isophthalamide) poly(tri ethylene terephthalamide) poly(m-phenylene isophthalamide) poly(ethylene-N,N'-dimethylterephthalamide) poly(3,3'-dimethy1-4,4 '-methylenediphenylene tereph ⁇ thalamide) poly(p-xylene terephthalamide) poly(3,3 '-dimethyl-4,4 '-diphenylene isophthalamide)
  • the most preferred aromatic polyamide is poly(m- phenylene isophthalamide) , which is commercially available under the name "Nomex
  • the synthetic short fibers used in this, or any other embodiment of the present invention can have about any conventional fiber diameter and length. Generally, these short fibers are referred to as "floe" and comprise fibers less than one inch in length, and generally about 0.25 inch in length.
  • the fibrids soften and deform around the glass fibers and the short fibers, thereby binding them to each other.
  • the resulting element exhibits good strength and flexibility, and also exhibits improved permeability after the heat treatment.
  • the ratio of glass fibers to synthetic fibers in the three-component non-woven element can vary widely.
  • a useful range is from about 30-95 weight percent glass fiber and from about 5-70 weight percent of a mixture of synthetic short fibers and polymer fibrids.
  • Excellent filters can be made in a preferred embodiment of the three-component non-woven element using a mixture of glass micro fibers, poly(m-phenylene isophthalamide) short fibers and cellulose acetate fibrids.
  • the glass micro fibers are in the 0.05-2 micron range, and more preferably in the 0.6 through 1.6 micron range.
  • From about 5 to about 70 weight percent of the mat can be poly(m-phenylene isophthalamide) short fibers and cellulose acetate fibrids, and the balance glass micro fibers. More preferably, from about 10-50 weight percent of the mat is poly(m-phenylene isophthalamide) short fibers and cellulose acetate fibrids and the balance glass micro fibers having a diameter of about 0.6-1.6 microns.
  • the filter element is seen to be a random nonwoven mat of glass micro fibers 1, aromatic polyamide short fibers 2, and polymer fibrids 3, e.g., cellulose acetate fibrids.
  • the polyamide short fibers 2 are bonded to the glass micro fibers 1 by the melting fibrids 3, thus binding the mat into a unitary flexible filter element of high strength.
  • a non-woven element in accordance with the present invention can be made by (a) forming an aqueous slurry of the fibrids and fibers, or mixture of fibers to be used, (b) filtering the aqueous slurry to form a non-woven mat, and preferably, (c) then heating the web for a short period of time to a temperature which is at least the softening point of the fibrids and is preferably at or above the melting temperature of the polymeric fibrids.
  • cellulose acetate good results are obtained by heating the dried web or pad in an oven set at about 525 to 575 °F.
  • a mechanical device with more positive means of heat transfer than an oven will, of course, bond the sheet more rapidly and at a lower temperature. Once the sheet is heated to the melting temperature of the fibrid, the melting occurs almost instantaneously.
  • Useful wet-laid, non-woven elements can be prepared using a handsheet mold or, for example, a Fourdrinier machine.
  • the element thickness is determined by the thickness of the web laid down on the wire.
  • the porosity can be varied by varying the amount and content of the fibers used.
  • the resulting non-woven elements exhibit excellent wet web strength and dry strength, and are useful in many different applications depending on the composition of the web, with a particular usefulness being realized in filtration applications.
  • the use of cellulose acetate fibrids has been found to provide particularly useful and strong non-woven elements for low temperature applications, which elements are cost- effectively made.
  • a series of filter elements can be made from an aqueous slurry of glass macro fibers (6.5 microns, 0.25 inch long), glass micro fibers (about 0.6 microns) and a mixture of poly(m-phenylene isophthalamide) short fibers and cellulose acetate fibrids.
  • the short fibers can be prepared, for example, by disintegrating a synthetic poly(m-phenylene isophthalamide) paper in a Waring blender. All the ingredients can then be combined in the slurry and blended further.
  • the filter sheets can be made from the furnish by filtering the furnish on a 150 mesh wire.
  • the wet pad can be couched with dry blotters, removed from the wire, and oven dried.
  • the resultant pad can then be heat-bonded by placing in a convection oven at 550°F for about 10 minutes. (If an efficient positive heat transfer means is employed, the heat-bonding may be substantially instantaneous.)
  • the following table exemplifies various proportions of the foregoing components (in percentage by weight) useful in preparing filter elements in accordance with the present invention.
  • a series of handsheets were made from an aqueous slurry using different fibers and fibrids.
  • a handsheet mold was used to filter the aqueous slurries and form the handsheets. Melt-bonding of the fibrid was employed only for the handsheets of Example 17 (17A, 17B and 17C) , while the handsheets in the remaining examples were heated only to the drying temperature. Different fibers and fibrids were used in making the series of handsheets, as were different proportions of the fiber and fibrid. The physical properties of the handsheets were measured, as reflected in the Table below: TARTft
  • EXAMPLE 19 In order to demonstrate the significance between using a polymeric fibrid in accordance with the present invention as a binder vis-a-vis a particulate powder or saturated solution, several experimental runs were made. Briefly, handsheets were made, tested and photographed to demonstrate the significant differences between using a saturated solution and a particulate powder, vis-a-vis a fibrid.
  • the fibers used were glass, although any fiber could have been used having a softening point greater than the fibrid, and cellulose acetate fibrids were used.
  • the compositions of the handsheets were as follows:
  • the handsheets were formed from water at a pH of 3 to obtain good formation.
  • the cellulose acetate polymer was added to the glass fiber slurry prior to the sheet being formed.
  • the dry handsheet was saturated with a solution of cellulose acetate and acetone. The same cellulose acetate polymer was used for the fibrid, the powder (60 mesh) and the solution.
  • Handsheet No. 4 used the same mass of glass fibers as the other handsheets, except that no cellulose acetate was added thereto.
  • Frazier is cubic feet of air per square foot of surface area per minute at 0.5 inch water pressure drop.
  • Photomicrographs were also taken after the heat treatment. These photomicrographs reveal a structural change in the sheets.
  • the fibrid bonded sheet (Sheet No. 3) was observed to be the most uniform in fiber distribution.
  • the structure reinforced with a polymeric fibrid is unique in strength and uniformity. Prior to the heat treatment, the fibrid dominated the sheet structure and reinforced it. After the heat treatment (which melted the polymer) , the sheet made with fibrid was the most uniform in structure and was the strongest.

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  • Textile Engineering (AREA)
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  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
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Abstract

Elément fibreux non tissé, posé à l'eau, souple et solide comprenant un liant à base de fibrides polymères. Les fibrides polymères ont un point d'amollissement inférieur au point d'amollissement des fibres de l'élément non tissé, et sont de préférence des fibrides d'acétate de cellulose. De tels éléments non tissés font preuve d'une excellente solidité sous forme mouillée et sèche, et sont particulièrement utiles comme éléments de filtration. Selon un mode de réalisaton préféré, l'élément non tissé est composé de fibres de verre (1), de fibres courtes synthétiques (2) et des fibrides de polymère (3). De tels éléments non tissés présentent une résistance chimique excellente et sont utiles comme filtres pour enlever des matières particulaires de gaz à des températures très basses.
PCT/US1990/002065 1990-04-13 1990-04-16 Element non tisse comprenant un liant en fibride Ceased WO1991016119A1 (fr)

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US507,591 1990-04-13

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Cited By (39)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2257992A (en) * 1991-07-22 1993-01-27 Ahlstrom Filtration Inc Medium for blood separation
EP0570803A1 (fr) * 1992-05-15 1993-11-24 Hoechst Aktiengesellschaft Procédé de fabrication de pièces moulées par compression d'une matière fibreuse avec collage simultané et les objets obtenus selon ce procédé
US5288402A (en) * 1991-04-12 1994-02-22 Mitsubishi Paper Mills Limited Liquid filter medium including a fibrillated filtering layer and an organic fiber support
EP1369160A1 (fr) * 2002-05-31 2003-12-10 Mann+Hummel Gmbh Elément filtrant, notamment pour séparer des liquides de gaz
EP1689510A4 (fr) * 2003-11-07 2008-01-09 Kx Technologies Llc Composites en fibres-fibres
EP1860236A3 (fr) * 2006-05-24 2008-10-15 Johns Manville Tapis à fibres non tissées pour filtre MERV et procédé de fabrication
DE102011114400A1 (de) * 2011-09-22 2013-03-28 Hydac Filtertechnik Gmbh Filtermaterial
CN109891015A (zh) * 2016-10-24 2019-06-14 王子控股株式会社 无机纤维片材、蜂巢式成形体及蜂巢式过滤器
WO2020041253A1 (fr) * 2018-08-23 2020-02-27 Eastman Chemical Company Composition et processus pour fabriquer des articles comprenant de la cellulose et un ester de cellulose
CN113811377A (zh) * 2019-04-05 2021-12-17 奥斯龙-明士克公司 烟气过滤介质
US11230811B2 (en) 2018-08-23 2022-01-25 Eastman Chemical Company Recycle bale comprising cellulose ester
US11286619B2 (en) 2018-08-23 2022-03-29 Eastman Chemical Company Bale of virgin cellulose and cellulose ester
US11299854B2 (en) 2018-08-23 2022-04-12 Eastman Chemical Company Paper product articles
US11306433B2 (en) 2018-08-23 2022-04-19 Eastman Chemical Company Composition of matter effluent from refiner of a wet laid process
US11313081B2 (en) 2018-08-23 2022-04-26 Eastman Chemical Company Beverage filtration article
US11332885B2 (en) 2018-08-23 2022-05-17 Eastman Chemical Company Water removal between wire and wet press of a paper mill process
US11332888B2 (en) 2018-08-23 2022-05-17 Eastman Chemical Company Paper composition cellulose and cellulose ester for improved texturing
US11339537B2 (en) 2018-08-23 2022-05-24 Eastman Chemical Company Paper bag
US11390991B2 (en) 2018-08-23 2022-07-19 Eastman Chemical Company Addition of cellulose esters to a paper mill without substantial modifications
US11390996B2 (en) 2018-08-23 2022-07-19 Eastman Chemical Company Elongated tubular articles from wet-laid webs
US11401660B2 (en) 2018-08-23 2022-08-02 Eastman Chemical Company Broke composition of matter
US11401659B2 (en) 2018-08-23 2022-08-02 Eastman Chemical Company Process to produce a paper article comprising cellulose fibers and a staple fiber
US11408128B2 (en) 2018-08-23 2022-08-09 Eastman Chemical Company Sheet with high sizing acceptance
US11414791B2 (en) 2018-08-23 2022-08-16 Eastman Chemical Company Recycled deinked sheet articles
US11414818B2 (en) 2018-08-23 2022-08-16 Eastman Chemical Company Dewatering in paper making process
US11421385B2 (en) 2018-08-23 2022-08-23 Eastman Chemical Company Soft wipe comprising cellulose acetate
US11420784B2 (en) 2018-08-23 2022-08-23 Eastman Chemical Company Food packaging articles
US11421387B2 (en) 2018-08-23 2022-08-23 Eastman Chemical Company Tissue product comprising cellulose acetate
US11441267B2 (en) 2018-08-23 2022-09-13 Eastman Chemical Company Refining to a desirable freeness
US11466408B2 (en) 2018-08-23 2022-10-11 Eastman Chemical Company Highly absorbent articles
US11479919B2 (en) 2018-08-23 2022-10-25 Eastman Chemical Company Molded articles from a fiber slurry
US11492757B2 (en) 2018-08-23 2022-11-08 Eastman Chemical Company Composition of matter in a post-refiner blend zone
US11492756B2 (en) 2018-08-23 2022-11-08 Eastman Chemical Company Paper press process with high hydrolic pressure
US11492755B2 (en) 2018-08-23 2022-11-08 Eastman Chemical Company Waste recycle composition
US11512433B2 (en) 2018-08-23 2022-11-29 Eastman Chemical Company Composition of matter feed to a head box
US11519132B2 (en) 2018-08-23 2022-12-06 Eastman Chemical Company Composition of matter in stock preparation zone of wet laid process
US11525215B2 (en) 2018-08-23 2022-12-13 Eastman Chemical Company Cellulose and cellulose ester film
US11530516B2 (en) 2018-08-23 2022-12-20 Eastman Chemical Company Composition of matter in a pre-refiner blend zone
US11639579B2 (en) 2018-08-23 2023-05-02 Eastman Chemical Company Recycle pulp comprising cellulose acetate

Citations (1)

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US4917714A (en) * 1988-12-08 1990-04-17 James River Corporation Filter element comprising glass fibers

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4917714A (en) * 1988-12-08 1990-04-17 James River Corporation Filter element comprising glass fibers

Cited By (44)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5288402A (en) * 1991-04-12 1994-02-22 Mitsubishi Paper Mills Limited Liquid filter medium including a fibrillated filtering layer and an organic fiber support
EP0593814A1 (fr) * 1991-04-12 1994-04-27 Mitsubishi Paper Mills, Ltd. Milieu filtrant pour filtration de liquide
GB2257992A (en) * 1991-07-22 1993-01-27 Ahlstrom Filtration Inc Medium for blood separation
GB2257992B (en) * 1991-07-22 1995-04-19 Ahlstrom Filtration Inc Blood separation media
EP0570803A1 (fr) * 1992-05-15 1993-11-24 Hoechst Aktiengesellschaft Procédé de fabrication de pièces moulées par compression d'une matière fibreuse avec collage simultané et les objets obtenus selon ce procédé
EP1369160A1 (fr) * 2002-05-31 2003-12-10 Mann+Hummel Gmbh Elément filtrant, notamment pour séparer des liquides de gaz
EP1689510A4 (fr) * 2003-11-07 2008-01-09 Kx Technologies Llc Composites en fibres-fibres
EP1860236A3 (fr) * 2006-05-24 2008-10-15 Johns Manville Tapis à fibres non tissées pour filtre MERV et procédé de fabrication
DE102011114400A1 (de) * 2011-09-22 2013-03-28 Hydac Filtertechnik Gmbh Filtermaterial
WO2013041178A3 (fr) * 2011-09-22 2013-11-07 Hydac Filtertechnik Gmbh Matériau filtrant
CN109891015A (zh) * 2016-10-24 2019-06-14 王子控股株式会社 无机纤维片材、蜂巢式成形体及蜂巢式过滤器
US11642652B2 (en) 2016-10-24 2023-05-09 Oji Holdings Corporation Inorganic fiber sheet, honeycomb molded body and honeycomb filter
US11390996B2 (en) 2018-08-23 2022-07-19 Eastman Chemical Company Elongated tubular articles from wet-laid webs
US11414818B2 (en) 2018-08-23 2022-08-16 Eastman Chemical Company Dewatering in paper making process
US11286619B2 (en) 2018-08-23 2022-03-29 Eastman Chemical Company Bale of virgin cellulose and cellulose ester
US11299854B2 (en) 2018-08-23 2022-04-12 Eastman Chemical Company Paper product articles
US11306433B2 (en) 2018-08-23 2022-04-19 Eastman Chemical Company Composition of matter effluent from refiner of a wet laid process
US11313081B2 (en) 2018-08-23 2022-04-26 Eastman Chemical Company Beverage filtration article
US11332885B2 (en) 2018-08-23 2022-05-17 Eastman Chemical Company Water removal between wire and wet press of a paper mill process
US11332888B2 (en) 2018-08-23 2022-05-17 Eastman Chemical Company Paper composition cellulose and cellulose ester for improved texturing
US11339537B2 (en) 2018-08-23 2022-05-24 Eastman Chemical Company Paper bag
US11390991B2 (en) 2018-08-23 2022-07-19 Eastman Chemical Company Addition of cellulose esters to a paper mill without substantial modifications
WO2020041253A1 (fr) * 2018-08-23 2020-02-27 Eastman Chemical Company Composition et processus pour fabriquer des articles comprenant de la cellulose et un ester de cellulose
US11401660B2 (en) 2018-08-23 2022-08-02 Eastman Chemical Company Broke composition of matter
US11401659B2 (en) 2018-08-23 2022-08-02 Eastman Chemical Company Process to produce a paper article comprising cellulose fibers and a staple fiber
US11408128B2 (en) 2018-08-23 2022-08-09 Eastman Chemical Company Sheet with high sizing acceptance
US11414791B2 (en) 2018-08-23 2022-08-16 Eastman Chemical Company Recycled deinked sheet articles
US11230811B2 (en) 2018-08-23 2022-01-25 Eastman Chemical Company Recycle bale comprising cellulose ester
US11421385B2 (en) 2018-08-23 2022-08-23 Eastman Chemical Company Soft wipe comprising cellulose acetate
US11420784B2 (en) 2018-08-23 2022-08-23 Eastman Chemical Company Food packaging articles
US11421387B2 (en) 2018-08-23 2022-08-23 Eastman Chemical Company Tissue product comprising cellulose acetate
US11441267B2 (en) 2018-08-23 2022-09-13 Eastman Chemical Company Refining to a desirable freeness
US11466408B2 (en) 2018-08-23 2022-10-11 Eastman Chemical Company Highly absorbent articles
US11479919B2 (en) 2018-08-23 2022-10-25 Eastman Chemical Company Molded articles from a fiber slurry
US11492757B2 (en) 2018-08-23 2022-11-08 Eastman Chemical Company Composition of matter in a post-refiner blend zone
US11492756B2 (en) 2018-08-23 2022-11-08 Eastman Chemical Company Paper press process with high hydrolic pressure
US11492755B2 (en) 2018-08-23 2022-11-08 Eastman Chemical Company Waste recycle composition
US11512433B2 (en) 2018-08-23 2022-11-29 Eastman Chemical Company Composition of matter feed to a head box
US11519132B2 (en) 2018-08-23 2022-12-06 Eastman Chemical Company Composition of matter in stock preparation zone of wet laid process
US11525215B2 (en) 2018-08-23 2022-12-13 Eastman Chemical Company Cellulose and cellulose ester film
US11530516B2 (en) 2018-08-23 2022-12-20 Eastman Chemical Company Composition of matter in a pre-refiner blend zone
US11639579B2 (en) 2018-08-23 2023-05-02 Eastman Chemical Company Recycle pulp comprising cellulose acetate
CN113811377A (zh) * 2019-04-05 2021-12-17 奥斯龙-明士克公司 烟气过滤介质
CN113811377B (zh) * 2019-04-05 2023-06-20 奥斯龙-明士克公司 烟气过滤介质

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