CN101341283B - 具有增强透气性的膨体复合材料 - Google Patents

具有增强透气性的膨体复合材料 Download PDF

Info

Publication number
CN101341283B
CN101341283B CN2005800231819A CN200580023181A CN101341283B CN 101341283 B CN101341283 B CN 101341283B CN 2005800231819 A CN2005800231819 A CN 2005800231819A CN 200580023181 A CN200580023181 A CN 200580023181A CN 101341283 B CN101341283 B CN 101341283B
Authority
CN
China
Prior art keywords
composite
fiber
particle
varicosity
active particle
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.)
Active
Application number
CN2005800231819A
Other languages
English (en)
Other versions
CN101341283A (zh
Inventor
R·D·肯德里克
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.)
KX Technologies LLC
Original Assignee
KX Industries LP
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
Application filed by KX Industries LP filed Critical KX Industries LP
Publication of CN101341283A publication Critical patent/CN101341283A/zh
Application granted granted Critical
Publication of CN101341283B publication Critical patent/CN101341283B/zh
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • D04H1/407—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 containing absorbing substances, e.g. activated carbon
    • 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
    • D04H1/413—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 containing granules other than absorbent substances
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • 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
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0407—Additives and treatments of the filtering material comprising particulate additives, e.g. adsorbents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/02—Loose filtering material, e.g. loose fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/103—Metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0207—Particles made of materials belonging to B32B25/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249933—Fiber embedded in or on the surface of a natural or synthetic rubber matrix
    • Y10T428/249939—Two or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/673—Including particulate material other than fiber

Abstract

本发明的复合材料包含在其表面上沉积了活性颗粒、膨体纤维和粘结剂颗粒的干燥混合物的基材。该复合材料与没有引入膨体纤维的现有复合材料相比具有增加的透气性和更低的空气阻力。

Description

具有增强透气性的膨体复合材料
技术领域
本发明涉及其中包含活性颗粒、膨体(lofting)纤维和粘结剂颗粒的复合平板结构，此种复合材料在流体过滤应用中是有用的，其中复合材料增强的透气性是有利的。
附图简述
本发明的特征据信是新颖的，而且本发明的要素特性将在所附权利要求书中详细地阐明。附图仅用于说明并且没有按比例绘出。然而，通过结合附图并随后参考优选实施方案(一个或多个)的描述可以从构成和操作方法方面最佳地理解本发明本身，在附图中：
图1是本发明复合材料的剖面图。
发明公开
在描述本发明优选实施方案的过程中，本文将参考附图的图1，其中同样的数字是指本发明同样的特征。本发明的特征在附图中未必按比例示出。
本发明的复合材料包括沉积到离散基材表面上的膨体纤维、活性颗粒和粘结剂颗粒的干燥混合物，其中将该复合材料加热到该粘结剂颗粒的软化温度，但该温度低于该膨体纤维或活性颗粒的熔化温度，以使该活性颗粒和膨体纤维彼此地接合并将它们与该离散基材接合。通过将基本上不围绕着活性颗粒弯曲的高旦尼尔膨体纤维引入复合材料内部，该膨体纤维在透气性方面提供高于大约20％的增加而不会牺牲该复合材料的动力学性能，并且在空气阻力方面提供显著的降低。优选地，本发明复合材料的透气性在0.5英寸水柱下高于大约200scfm。
该复合材料是平板结构，其具有由活性颗粒的高负载率提供的优异的吸附或吸收容量。粘结剂颗粒的小尺寸使得该粘结剂颗粒通过静电力和范德华力附着于活性颗粒和膨体纤维，却仍然保留了该活性颗粒用于最佳动力学性能的大部分表面积。除了它们粘着活性颗粒和膨体纤维的倾向之外，粘结剂颗粒还具有高的固有内聚性。
本发明的平板复合材料在流体过滤应用中是有用的，尤其作为用于建筑物的加热、通风、空气调节(HVAC)体系的空气过滤器，汽车空气过滤器和水或其它液体的过滤应用。该平板复合材料可以是打褶的、螺旋卷绕的、或同时是打褶且螺旋卷绕的。
优选地，本发明的复合材料使用连续方法制备以获得规模经济和低成本，并可以生产成卷材(roll)商品。也可以联机进行随后的切割、切口和/或打褶操作。
用于本发明复合材料的基材可以是任何离散的平板结构，包括但不限于带子、纸、薄绢、毛巾布、织物和机织或无纺材料。基材可以是相对易碎的或坚固的。优选地，基材能够耐受用于连续生产该复合材料的滚花辊(knurled roller)的处理。
用于制造本发明复合材料的优选的基材是无纺材料，它在大约0.5英寸水柱下具有高于大约600scfm(静立方英尺/分钟)，更优选高于大约800scfm的透气性。基材自身极其高的透气性进一步有助于本发明所得的复合材料的透气性。
最优选的基材可以是具有热塑性粘结剂的湿法成网或干法成网的无纺材料。优选地，该热塑性粘结剂是胶乳粘结剂，其以大约20wt％到大约30wt％，更优选大约25wt％的量存在。此种优选的基材可以从American Nonwovens Corporation，Columbus，Mississippi以商品名SRF5037B商购。该无纺基材可以具有大约20到大约25克/码2的基重，但是如果要将所得复合材料打褶，则优选将无纺基材的基重增加到大约30到大约35克/码2或更高。
可以在复合材料中提供呈颗粒、纤维、晶须或粉末形式的一类或多类活性颗粒以为本发明的复合材料添加功能性和/或增强性。有用类型的活性颗粒可以包括，但不限于，金属、金属盐、金属氧化物、氧化铝、碳、活性炭、硅酸盐、陶瓷、沸石、硅藻土、活性矾土、漂白土、硫酸钙、二氧化钛、氧化镁、氢氧化镁、锰氧化物、铁氧化物、珍珠岩、滑石、粘土、骨炭、氢氧化钙、钙盐或它们的结合物。这些活性剂可以帮助吸附污染物如重金属或挥发性有机化合物(VOC)。也可以用化学方式处理该活性剂以赋予微生物拦截能力，这取决于特定的应用。
活性颗粒优选以这样的量存在，即该量足以使得当该复合材料用作过滤介质时流经该复合材料的流体基本上不受到阻碍。活性颗粒的量也取决于复合材料的特定用途。优选地，基于待铺放在基材上的干燥混合物的总重量，活性颗粒的存在量高于大约80wt％，更优选高于大约85wt％。活性颗粒的更高浓度，例如高达大约90wt％也被考虑并在本发明的范围之内。活性颗粒的优选铺列量为大约250克/米2到高于大约600克/米2。对于过滤应用来说，优选的铺列量可以是370克/米2到大约450克/米2。
活性颗粒的粒度可以是大约1到大约5000μm。随着活性颗粒的粒度减小，可以获得该活性颗粒在纸中的更高的负载率。然而，在一些应用中，较大的颗粒可能是更合乎需要的，因为粒度越小，活性颗粒可以越密集地填充在复合材料内。对于具有增强透气性的空气过滤应用来说，筛目尺寸为大约20×50的椰壳基炭(coconut based carbon)可以是优选的。
本发明复合材料中的膨体纤维优选具有高于大约25，优选高于大约30，更优选高于大约45的高旦尼尔。通过使用此类高旦尼尔纤维来使复合材料蓬松(loft)，该纤维更可能基本上保持直且呈棒状的形状而不会围绕活性颗粒弯曲，从而增加了活性颗粒周围的气流。
纤维优选是可容易分散的，而且没有明显的相当大的成团。因此，基于纤维的总重量，让该纤维或纤维束具有小于或等于大约5wt％的低的含湿量是有利的。也可以用施胶剂处理纤维或纤维束以降低在它们上面的静电荷以进一步减少成团。此类施胶剂在本领域中是熟知的。
优选地，基于待在基材上铺放的干燥混合物的总重量，膨体纤维以大约3wt％到大约12wt％，更优选大约5wt％到大约10wt％，最优选大约6wt％到8wt％的量存在。优选将纤维束切成大约6.35毫米(0.25英寸)或更短，优选大约3.175毫米(0.125英寸)的纤维长度。当与活性颗粒和粘结剂混合时，长于大约6.35毫米的纤维可能有缠绕或包裹活性颗粒和/或粘结剂颗粒的倾向并可能无法良好地分散。
优选使用具有高内在强度的纤维。此类纤维包括，但不限于，聚合物如聚酯、聚酰胺、丙烯酸类、丙烯腈、液晶聚合物如“VECTRAN”等；金属；玻璃；离子交换树脂；工程树脂；或它们的结合物。有机和无机纤维和/或晶须的结合物也被考虑并在本发明范围之内。例如，可以一起使用玻璃、陶瓷或金属纤维和聚合物纤维。
优选的膨体纤维是旦尼尔为大约45、切成大约6.35毫米的长度且含湿量小于或等于大约5wt％的聚酯纤维。此类聚酯纤维是可以从William Barnet&Son，LLC(Arcadia，South Carolina)商购的。
粘结剂用来使活性颗粒和膨体纤维接合并将它们粘附到底层基材上。为此，粘结剂必须呈非常小的颗粒形式并且必须以足够小的体积存在，以致它们不会妨碍活性颗粒的功能也不会使膨体纤维缠绕。优选地，粘结剂将具有不多于平均40微米的有效直径，其中最佳尺寸为平均20微米。
有用的粘结剂包括，但不限于，聚烯烃、聚卤乙烯、聚乙烯基酯、聚乙烯基醚、聚乙烯基硫酸酯、聚乙烯基磷酸酯、聚乙烯基胺、聚酰胺、聚酰亚胺、聚噁二唑(polyoxidiazole)、聚三唑、聚碳二亚胺、聚砜、聚碳酸酯、聚醚、聚芳醚、聚酯、聚芳酯、酚醛树脂、蜜胺-甲醛树脂、甲醛-脲、乙烯(ethyl)-乙酸乙烯酯共聚物、它们的共聚物和嵌段互聚物、和它们的结合物。上述材料的变体和其它有用的聚合物包括基团如羟基、卤素、低级烷基、低级烷氧基、单环芳基等的取代物。其它可能适用的材料包括聚合物如聚苯乙烯和丙烯腈-苯乙烯共聚物、苯乙烯-丁二烯共聚物和其它非结晶或无定形聚合物和结构。
在本发明中可以使用的粘结剂的更详述的目录包括封端的聚缩醛，如聚(氧亚甲基)或聚甲醛、聚(三氯乙醛)、聚(正戊醛)、聚(乙醛)和聚(丙醛)；丙烯酸类聚合物，如聚丙烯酰胺、聚(丙烯酸)、聚(甲基丙烯酸)、聚(丙烯酸乙酯)和聚(甲基丙烯酸甲酯)；碳氟聚合物，如聚(四氟乙烯)、全氟化乙烯-丙烯共聚物、乙烯-四氟乙烯共聚物、聚(三氟氯乙烯)、乙烯-三氟氯乙烯共聚物、聚(偏二氟乙烯)和聚氟乙烯；聚酰胺，如聚(6-氨基己酸)或聚(e-己内酰胺)、聚(六亚甲基己二酰二胺)、聚(六亚甲基癸二酰胺)和聚(11-氨基十一烷酸)；聚芳酰胺，如聚(亚氨基-1，3-亚苯基亚氨基间苯二甲酰基)或聚(间亚苯基间苯二甲酰胺)；聚对二甲苯，如聚-2-亚二甲苯基和聚(氯-1-亚二甲苯基)；聚芳醚，如聚(氧-2，6-二甲基-1，4-亚苯基)或聚(对苯醚)；聚芳砜，如聚(氧-1，4-亚苯基磺酰基-1，4-亚苯基-氧-1，4-亚苯基异丙叉基-1，4-亚苯基)和聚(磺酰基-1，4-亚苯基-氧-1，4-亚苯基磺酰基-4，4′-亚联苯基)；聚碳酸酯，如聚(双酚A)或聚(羰基二氧基-1，4-亚苯基异丙叉基-1，4-亚苯基)；聚酯，如聚(对苯二甲酸乙二醇酯)、聚(四亚甲基对苯二甲酸酯)和聚(亚环己基-1，4-二亚甲基对苯二甲酸酯)或聚(氧亚甲基-1，4-亚环己基亚甲基氧基对苯二甲酰基)；聚芳硫醚，如聚(对苯硫醚)或聚(硫代-1，4-亚苯基)；聚酰亚胺，如聚(均苯四酰亚胺-1，4-亚苯基)；聚烯烃，如聚乙烯、聚丙烯、聚(1-丁烯)、聚(2-丁烯)、聚(1-戊烯)、聚(2-戊烯)、聚(3-甲基-1-戊烯)和聚(4-甲基-1-戊烯)；乙烯基聚合物，如聚乙酸乙烯酯、聚(偏二氯乙烯)和聚氯乙烯；二烯聚合物，如1，2-聚-1，3-丁二烯、1，4-聚-1，3-丁二烯、聚异戊二烯和聚氯丁二烯；聚苯乙烯；和上文物质的共聚物，如丙烯腈-丁二烯-苯乙烯(ABS)共聚物。可以使用的聚烯烃包括聚乙烯、线性低密度聚乙烯、聚丙烯、聚(1-丁烯)、聚(2-丁烯)、聚(1-戊烯)、聚(2-戊烯)、聚(3-甲基-1-戊烯)和聚(4-甲基-1-戊烯)等。
适合的粘结剂的实例是MICROTHENE
Figure G05823181920070111D000051
F(由Quantum ChemicalCompany，Cincinnati，Ohio生产的微细聚烯烃粉末)，例如以商品名FN-510销售的它们的低密度聚乙烯和以商品名FE-532销售的它们的乙烯-乙酸乙烯酯共聚物。优选地，粘结剂以这样的量存在，该量足以有效地使膨体纤维和活性颗粒彼此地接合并将它们与底层基材接合，而不会妨碍活性颗粒的吸附或吸收容量。在具有大约370到大约450克/米2的铺列量的复合材料中，基于干燥混合物的总重量，粘结剂以大约7wt％到9wt％的量存在。
本发明的复合材料优选使用干法成网的连续方法(如美国专利No.5,792,513中公开的方法)来制备。通常，供应辊提供待处理的基材。在基材供应辊下游是滚花辊，它被设置用来接收来自加料斗的活性颗粒、膨体纤维和粘结剂颗粒的干燥混合物和将该干燥混合物施加到基材的上表面上。
优选通过将活性颗粒例如活性炭与该膨体纤维混合来制备干燥混合物。通过将该活性颗粒和膨体纤维一起混合而没有粘结剂颗粒，可以在该活性颗粒内获得纤维的更好分散，因为该活性颗粒的重量和结构驱散该纤维上的静电荷。为进一步改进纤维分散，则优选该纤维具有低的含湿量，例如小于或等于5wt％的水分。当使用活性炭时，应该小心以免在混合期间压裂或剪切该活性炭。例如，可以使用条带式掺混机，例如可从Forberg International AS，Larvik，Norway获得的Forberg条带式混合机，来混合该活性颗粒和膨体纤维。然后将粘结剂添加到活性颗粒和膨体纤维的混合物中。
该滚花辊的表面可以设计用来提供基本上连续的涂层，或者，也可以是特殊设计的涂层例如基材表面上的条纹。可以使用刷子或其它的设备以帮助将干燥混合物从滚花辊上除去。此后，在加热下让基材穿过导辊和传动辊之间的辊隙。可以将导辊和传动辊中的一个加热或两者都加热。通过杆将气压缸连接到该导辊的轴上以在辊隙内的网幅上维持所需压力。该导辊和传动辊之间的间隙可以调到该复合材料的所需厚度以保持由纤维提供的膨松质量。
在穿过一个或多个加热辊的表面的过程中，当复合材料进入导辊和传动辊之间的辊隙时，将复合材料加热到等于或略高于粘结剂颗粒的软化温度的温度。在该辊隙内，在最小压力下粘结剂材料与活性材料和网幅的材料熔合。或者，可以通过将该复合材料输送通过层压机而将粘结剂加热。此类层压机在本领域中是熟知的。
通过将粘结剂加热到其软化温度，该粘结剂颗粒变得发粘而不会流入或污染活性颗粒的活性表面，也不会阻碍纤维在干燥混合物中的膨松效果。将复合材料加热到明显高于该粘结剂软化温度的温度可能会不利地影响该膨体纤维，使该纤维软化或变形。该膨体纤维优选保持完整和基本上呈棒状。
可以将具有与底层基材的材料相同或不同材料的第二基材作为顶板添加到该复合材料上。从另一个供应辊供给该第二基材，并且让该第二基材也在辊的辊隙之间穿过并送到它将要熔合到其上的干燥混合物的顶部，或如果使用层压机的话，在进入该层压机之前，将第二基材供给到复合材料的顶部上。因此，离开辊或层压机的所得复合材料具有顶部和底部的板、薄膜、或无纺层，使得该干燥混合物夹在它们中间。离开辊隙后，该粘结剂颗粒冷却并硬化，从而形成所需复合材料。加热到更高的温度会不利地影响底层基材。
可以将该复合材料送到卷取辊上以作为卷材商品销售，或随后切割或冲压到所需尺寸、和/或打褶。当将该复合材料打褶时，取决于具体应用，使用具有较高基重，例如大约30到35克/码2或更高的基材可能是合乎需要的。然而，基材的较高基重可能降低所得复合材料的透气性。本领域技术人员可以测定透气性的降低对具体应用是否是重要的。
本发明的复合材料适用于流体过滤应用，尤其是空气过滤应用，其中需要高透气性而不会牺牲或减弱该活性颗粒的动力学性能，并且具有增加的活性颗粒的负载量。
实施例/测试
提供以下实施例来举例说明本发明，并且不应该认为是限制本发明的范围。
使用可得自Air Techniques，International of Owings Mill，Maryland的Model TDA-100P来进行气溶胶拦截和气流阻力测量。让直径为5.3英寸的圆形样品经受合成脂族烃油的0.18微米颗粒的单分散体的处理，和其在研究中以32scfm的流速使用。
将大约6wt％的长度大约为3.175毫米和旦尼尔大约为45的聚酯纤维、85wt％的为20×50目的椰壳炭(coconut carbon)、和9wt％的包含MICROTHENE
Figure G05823181920070111D000081
FN-510的粘结剂颗粒的干燥混合物以大约370克/米2的铺列量负载到基材上。顶部和底部基材都是得自AmericanNonwovens Corp.(Columbus，Missouri)并以商品名SRF5037B销售的湿法成网无纺材料。基重为21克/码2。该复合材料具有平均0.23毫米H2O的空气阻力。比较起来，具有相同铺列量、用相同椰壳炭和9wt％粘结剂制成、具有REEMAYTM 2275的底部基材和REEMAYTM 2004的顶部基材(两者均由BBA Nonwovens Reemay，Inc.，Old Hickory，Tennessee获得)的复合材料具有平均0.34毫米H2O的空气阻力。通过将膨体纤维引入干燥混合物，通过本发明复合材料的空气阻力减少大约30％。当添加纤维时，该复合材料的效率也提高了，使得该含纤维的复合材料具有平均17.28％的效率，而对比复合材料具有平均14.20％的效率。
当使用450克/米2的铺列量制备本发明的复合材料时，引入膨体纤维的本发明复合材料具有平均0.38毫米H2O的空气阻力，而没有膨体纤维的复合材料具有平均0.43毫米H2O的空气阻力。以这一更高的铺列量，膨体纤维提供大约12％的空气阻力的降低。当添加纤维时，该复合材料的效率也提高了，使得该含纤维的复合材料具有平均19.02％的效率，而对比复合材料具有平均17.78％的效率。
在0.5英寸(12.7毫米)水柱的压力下，使用由Frazier PrecisionInstruments Company，Hagarstown，Maryland制造的织物渗透机器来进行透气性研究。对于其中膨体纤维具有370克/米2的铺列量的本发明复合材料来说，该Frazier透气性高于大约200scfm，而没有纤维的对比复合材料为大约155到大约175scfm。
虽然已经结合特定的优选实施方案具体地描述了本发明，但是显然根据上文描述，许多替换、修改和变化对本领域技术人员来说是显而易见的。因此，认为所附权利要求书将涵盖落入本发明真实范围和精神内的任何这些替换、修改和变化。

Claims (15)

1.复合材料，包含：
具有第一表面的离散基材，
沉积在所述基材第一表面上的干燥混合物，所述干燥混合物包含活性颗粒、粘结剂颗粒和旦尼尔高于20的膨体纤维，
其中将所述复合材料加热到该粘结剂颗粒的软化温度，但该温度小于该活性颗粒和膨体纤维的熔化温度，使得该软化的粘结剂颗粒将该活性颗粒和膨体纤维彼此地接合并将它们与所述基材接合，和该膨体纤维基本上保持直且呈棒状的形状而不会围绕该活性颗粒弯曲，从而增加了该活性颗粒周围的气流。
2.权利要求1的复合材料，其中所述基材包含透气性高于600scfm的无纺层。
3.权利要求1的复合材料，其中所述基材包含透气性高于800scfm的无纺层。
4.权利要求1的复合材料，其中所述基材包含进一步包括胶乳粘结剂的湿法成网无纺层。
5.权利要求1的复合材料，其中该活性颗粒包括吸附剂、吸收剂或它们的结合物。
6.权利要求1的复合材料，其中该活性颗粒包含平均粒度为20x50目的活性炭。
7.权利要求1的复合材料，其中该膨体纤维具有高于30的旦尼尔。
8.权利要求1的复合材料，其中该膨体纤维具有高于45的旦尼尔。
9.权利要求1的复合材料，其中基于该干燥混合物的总重量，该膨体纤维以3到12wt％的量存在。
10.权利要求1的复合材料，其中该膨体纤维包括聚合物、金属、玻璃或它们的结合物。
11.权利要求1的复合材料，其中该膨体纤维包括旦尼尔为45的聚酯。
12.权利要求1的复合材料，其中所述复合材料具有高于200scfm的透气性。
13.权利要求1的复合材料，其中该膨体纤维包括离子交换树脂。
14.权利要求1的复合材料，其中该膨体纤维包括工程树脂。
15.包含权利要求1的复合材料的流体过滤系统。
CN2005800231819A 2004-07-30 2005-07-27 具有增强透气性的膨体复合材料 Active CN101341283B (zh)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US59273304P 2004-07-30 2004-07-30
US60/592,733 2004-07-30
US11/189,686 2005-07-26
US11/189,686 US7407701B2 (en) 2004-07-30 2005-07-26 Lofted composite with enhanced air permeability
PCT/US2005/026451 WO2006014932A2 (en) 2004-07-30 2005-07-27 Lofted composite with enhanced air permeability

Publications (2)

Publication Number Publication Date
CN101341283A CN101341283A (zh) 2009-01-07
CN101341283B true CN101341283B (zh) 2012-06-20

Family

ID=35732603

Family Applications (1)

Application Number Title Priority Date Filing Date
CN2005800231819A Active CN101341283B (zh) 2004-07-30 2005-07-27 具有增强透气性的膨体复合材料

Country Status (5)

Country Link
US (1) US7407701B2 (zh)
EP (1) EP1771616B1 (zh)
JP (1) JP2008508092A (zh)
CN (1) CN101341283B (zh)
WO (1) WO2006014932A2 (zh)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7407701B2 (en) * 2004-07-30 2008-08-05 Kx Technologies Llc Lofted composite with enhanced air permeability
US20060292947A1 (en) * 2005-06-24 2006-12-28 Lavietes Daniel Polyester fiber scrim and method for making same
EP2206544B1 (en) * 2007-09-28 2016-07-20 Toray Industries, Inc. Filtering medium
CA2931618C (en) * 2013-11-26 2021-11-23 Dri-Steem Corporation Steam dispersion system
US10547044B2 (en) * 2015-09-01 2020-01-28 Worcester Polytechnic Institute Dry powder based electrode additive manufacturing
CN109126397A (zh) * 2018-09-29 2019-01-04 杭州超通科技有限公司 一种分子筛干燥过滤芯的制备方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5272000A (en) * 1987-05-22 1993-12-21 Guardian Industries Corp. Non-woven fibrous product containing natural fibers
US5792513A (en) * 1997-03-07 1998-08-11 Koslow Technologies Corporation Continuous solid state web coating process

Family Cites Families (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5322177A (en) * 1973-10-29 1978-03-01 Kuraray Co Ltd Production of filter medium
JPS5150467U (zh) * 1974-10-16 1976-04-16
US4540625A (en) * 1984-01-09 1985-09-10 Hughes Aircraft Company Flexible air permeable non-woven fabric filters
JPH0751142B2 (ja) * 1985-07-31 1995-06-05 メ−ルンリユ−ケ・ア−ベ− おむつ、衛生ナプキン等の如き使い捨て物品用吸収体
US4699823A (en) * 1985-08-21 1987-10-13 Kimberly-Clark Corporation Non-layered absorbent insert having Z-directional superabsorbent concentration gradient
US4868032A (en) * 1986-08-22 1989-09-19 Minnesota Mining And Manufacturing Company Durable melt-blown particle-loaded sheet material
DE3720031A1 (de) * 1987-06-16 1989-01-05 Freudenberg Carl Fa Saugkoerper aus vliesstoff und verfahren zu seiner herstellung
GB8717729D0 (en) * 1987-07-27 1987-09-03 Bonar Carelle Ltd Non-woven materials
US4950531A (en) * 1988-03-18 1990-08-21 Kimberly-Clark Corporation Nonwoven hydraulically entangled non-elastic web and method of formation thereof
CA1316804C (en) * 1988-11-22 1993-04-27 Sylvie Boisse Absorbent liner for impermeable clothing
US5230959A (en) * 1989-03-20 1993-07-27 Weyerhaeuser Company Coated fiber product with adhered super absorbent particles
JPH0330817A (ja) * 1989-06-29 1991-02-08 Japan Tobacco Inc エアコンディショナ用脱臭フィルタ
US5128082A (en) * 1990-04-20 1992-07-07 James River Corporation Method of making an absorbant structure
US5135787A (en) * 1990-08-14 1992-08-04 E. I. Du Pont De Nemours And Company Iced food shipping container with aqueous liquid absorbing pad
EP0825286A3 (en) * 1992-11-18 2000-11-02 AQF Technologies LLC Fibrous structure containing immobilized particulate matter and process therefor
US5662728A (en) * 1992-12-31 1997-09-02 Hoechst Celanese Corporation Particulate filter structure
US5580459A (en) * 1992-12-31 1996-12-03 Hoechst Celanese Corporation Filtration structures of wet laid, bicomponent fiber
US5597645A (en) * 1994-08-30 1997-01-28 Kimberly-Clark Corporation Nonwoven filter media for gas
US5906743A (en) * 1995-05-24 1999-05-25 Kimberly Clark Worldwide, Inc. Filter with zeolitic adsorbent attached to individual exposed surfaces of an electret-treated fibrous matrix
JPH0910539A (ja) * 1995-06-27 1997-01-14 Shimizu Corp ガス状物質除去フィルタ
US5681361A (en) * 1996-01-11 1997-10-28 Minnesota Mining And Manufacturing Company Method of making an abrasive article and abrasive article produced thereby
US6102039A (en) * 1997-12-01 2000-08-15 3M Innovative Properties Company Molded respirator containing sorbent particles
JPH11300126A (ja) * 1998-04-16 1999-11-02 Tennex Corp 脱臭フィルターおよびその使用方法ならびにフィルターエレメント
US6479415B1 (en) * 1998-06-08 2002-11-12 Bki Holding Corporation Absorbent structures having fluid acquisition and distribution layer
US6562742B2 (en) * 1999-01-11 2003-05-13 Bki Holding Corporation High-performance absorbent structure
US6723428B1 (en) * 1999-05-27 2004-04-20 Foss Manufacturing Co., Inc. Anti-microbial fiber and fibrous products
JP2002017832A (ja) * 2000-07-03 2002-01-22 Tennex Corp 脱臭フィルターおよびその製造方法
JP2002292277A (ja) * 2001-03-29 2002-10-08 Mahle Tennex Corp 吸着シート
JP2003320209A (ja) * 2002-05-01 2003-11-11 Mahle Tennex Corp 脱臭濾材および脱臭フィルタ
JP2003334410A (ja) * 2002-05-16 2003-11-25 Toray Ind Inc エアフィルタ用濾材およびその製造方法
US6770204B1 (en) * 2003-03-15 2004-08-03 Koslow Technologies Corporation Filter media with enhanced microbiological interception capability
US7407701B2 (en) * 2004-07-30 2008-08-05 Kx Technologies Llc Lofted composite with enhanced air permeability

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5272000A (en) * 1987-05-22 1993-12-21 Guardian Industries Corp. Non-woven fibrous product containing natural fibers
US5792513A (en) * 1997-03-07 1998-08-11 Koslow Technologies Corporation Continuous solid state web coating process

Also Published As

Publication number Publication date
WO2006014932A3 (en) 2006-12-07
US7407701B2 (en) 2008-08-05
EP1771616A4 (en) 2010-09-29
CN101341283A (zh) 2009-01-07
EP1771616B1 (en) 2013-09-11
US20060024484A1 (en) 2006-02-02
JP2008508092A (ja) 2008-03-21
EP1771616A2 (en) 2007-04-11
WO2006014932A2 (en) 2006-02-09

Similar Documents

Publication Publication Date Title
EP2235245B1 (en) Composite non-woven fibrous webs having continuous particulate phase and methods of making and using the same
EP2726659B1 (en) Non-woven electret fibrous webs and methods of making same
EP2242726B1 (en) Fluid filtration articles and methods of making and using the same
CN102859058B (zh) 含有化学活性颗粒的非织造纤维网以及制造和使用所述非织造纤维网的方法
CN102859060B (zh) 含有化学活性颗粒的非织造纳米纤维幅材以及制造和使用非织造纳米纤维幅材的方法
JP6542787B2 (ja) 寸法安定性メルトブローン不織布繊維構造とその製造方法及び製造装置
JP6054865B2 (ja) パターン付きエアレイド不織布繊維ウェブ、並びにこれらの製造及び使用方法
CN103781956B (zh) 非织造驻极体纤维网及其制备方法
TWI486497B (zh) 非織材料及製造該材料之方法
CN101341283B (zh) 具有增强透气性的膨体复合材料
TWI475138B (zh) 非織材料及製造該材料之方法
CN100491620C (zh) 一种功能微粒改性熔喷非织造布的制备方法及制造设备
JP2818693B2 (ja) 固定された粒子物質を含有する繊維状構造物およびその製造方法
CN111819245A (zh) 包含阻燃聚合物的陶瓷涂覆的纤维以及制备非织造结构的方法
CN110945165A (zh) 包含结晶聚烯烃和烃增粘剂树脂的纤维及其制备方法
JP2019166513A (ja) 集塵脱臭濾材及び集塵脱臭フィルター
WO2019025942A1 (en) MULTI-CONSTITUENT FIBERS COMPRISING A CRYSTALLINE POLYOLEFIN AND A HYDROCARBON TACKIFYING RESIN, AND METHOD FOR THE PRODUCTION THEREOF
JP4178997B2 (ja) 機能性繊維集合体及びそれを用いた成形体
WO2019025943A2 (en) SEMICONTINUOUS FILAMENTS COMPRISING A CRYSTALLINE POLYOLEFIN AND A HYDROCARBON TACKIFYING RESIN, AND PROCESS FOR THE PRODUCTION THEREOF

Legal Events

Date Code Title Description
C06 Publication
PB01 Publication
C10 Entry into substantive examination
SE01 Entry into force of request for substantive examination
C14 Grant of patent or utility model
GR01 Patent grant