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CN100377760C - Electrostatically charged filter media with added active agent - Google Patents

Electrostatically charged filter media with added active agent Download PDF

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CN100377760C
CN100377760C CNB038240815A CN03824081A CN100377760C CN 100377760 C CN100377760 C CN 100377760C CN B038240815 A CNB038240815 A CN B038240815A CN 03824081 A CN03824081 A CN 03824081A CN 100377760 C CN100377760 C CN 100377760C
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protective medium
porous dielectric
dielectric carrier
medium
fiber
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CN1688377A (en
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皮埃尔·梅西尔
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TRIOSYN HOLDING Inc
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Abstract

There is provided a protective media and a method of manufacturing the same. In one aspect, the protective media includes a porous dielectric carrier, an active agent incorporated in the porous dielectric carrier, and an electrostatic charge across at least a portion of the porous dielectric carrier. This innovative media is capable of eradicating microorganisms and/or toxins more efficiently than prior art solutions and can also self sterilize.

Description

加入活性剂的充有静电的过滤介质 Electrostatically charged filter media with added active agent

技术领域 technical field

本申请要求美国临时申请60/411,066,60/434,526和60/458,800的优先权,它们的申请日分别为2002年9月16日,2002年12月19日和2003年3月28日。它们的内容全部作为本申请的参考文献。This application claims priority to US provisional applications 60/411,066, 60/434,526 and 60/458,800, which have their filing dates of September 16, 2002, December 19, 2002 and March 28, 2003, respectively. The contents of these are all taken as reference documents of this application.

本发明涉及充有静电的过滤介质,更具体地说,涉及加入活性剂的充有静电的介质,及其制备方法。This invention relates to electrostatically charged filter media, and more particularly, to electrostatically charged media incorporating active agents, and methods of making the same.

背景技术 Background technique

现有技术的过滤方法包括例如机械过滤-颗粒的物理保持性要大于过滤介质的孔;静电过滤-将颗粒在不杀灭/减活颗粒的情况下粘附到过滤器内的颗粒上,并按照于1999年11月9日授与本发明人的题目是“使用碘/树脂消毒剂对空气的消毒”的美国专利US5,980,827的教导和要求保护的方式进行过滤。现已确定,当产品加入具有盘旋通路的介质时,在细小薄介质内进行过滤可改善碘化树脂的过滤效果。通过迫使微生物/毒素通过迂回路径,可最终使微生物/毒素被杀灭/减活。提供迂回路径的一种方法是使用无纺介质。Prior art filtration methods include for example mechanical filtration - particles are physically retained larger than the pores of the filter media; electrostatic filtration - particles are adhered to particles within the filter without killing/deactivating them, and Filtration was carried out in the manner taught and claimed in US Patent No. 5,980,827, issued to the present inventor on November 9, 1999, entitled "Disinfection of Air Using Iodine/Resin Disinfectant". It has been determined that filtration in fine, thin media improves the filtration of iodinated resins when the product is added to media with convoluted passages. By forcing the microbes/toxins through a detour, the microbes/toxins can eventually be killed/inactivated. One method of providing a circuitous path is to use nonwoven media.

在公开的题目为“在三维基体结构中对颗粒的固定”的美国专利申请20010045398中,第一次生产出无纺材料,而后,利用酒精和部分溶剂加入一种例如在美国专利5,639,452(‘452专利)中公开的碘化树脂,同时利用脉动真空泵打开过滤孔,使活性剂通过它(“三元合成”树脂)。In published US patent application 20010045398 entitled "Fixation of particles in a three-dimensional matrix structure", a nonwoven material was produced for the first time, and then, using alcohol and some solvents, added a compound such as that described in US patent 5,639,452 (' '452 patent) while using a pulsating vacuum pump to open the filter pores and allow active agents to pass through it ("ternary synthesis" resins).

美国专利US 6,346,125教导,将一种含水抗菌剂加入不充静电的无纺材料中。特别是,‘125专利描述了一种用于将含水抗菌剂加入一种不充静电的无纺材料中的特定方法。然而,在没有静电特性的情况下,无纺材料必须有较大的厚度,以使微生物与用于净化的抗菌剂充分接触。US Patent No. 6,346,125 teaches adding an aqueous antimicrobial agent to a non-static non-woven material. In particular, the '125 patent describes a specific method for incorporating an aqueous antimicrobial agent into a non-statically charged nonwoven material. However, in the absence of electrostatic properties, non-woven materials must have a large thickness to allow sufficient contact between microorganisms and antimicrobial agents for decontamination.

美国专利US 5,952,092教导了一种具有化学活性颗粒的无纺纤维。但在该创新中,该专利没有教导使用静电底层。US Patent US 5,952,092 teaches a nonwoven fiber with chemically active particles. But in this innovation, the patent does not teach the use of an electrostatic underlayer.

无纺驻极体及其制备方法已是现有技术中已知的。例如,美国专利US 5,409,766描述了一种处于驻极体状态的无纺纤维,它由用聚合物组分形成的单丝组成,这些聚合物组分能长时间地在热湿条件下收集灰尘。另外还公开了一种用于生产无纺纤维的方法,以及由这种无纺纤维组成的空气过滤遮挡材料。但这种现有技术系统没有提供抗菌/抗毒特性。因此,对悬浮在无纺纤维中的微生物/毒素不能杀菌和减活。一旦无纺材料的静电特性消失或材料饱和,则微生物/毒素可重新释放回大气中。Nonwoven electrets and methods for their preparation are known in the prior art. For example, US Pat. No. 5,409,766 describes a nonwoven fiber in an electret state consisting of monofilaments formed with polymer components capable of collecting dust under hot and humid conditions for a long time. Also disclosed is a method for producing a nonwoven fiber, and an air filter covering material composed of the nonwoven fiber. But this prior art system does not provide antimicrobial/antiviral properties. Therefore, microbes/toxins suspended in the nonwoven fibers cannot be sterilized and inactivated. Once the electrostatic properties of the nonwoven material are lost or the material is saturated, the microorganisms/toxins can be re-released back into the atmosphere.

现已知,可将充静电的过滤料用于例如面具中。相对于二者,面部密封是一个众所周知的问题,并且人们还试图提出在产业上存在的局限性。问题在于人的身体形态的结构或组织是相互存在差异的,这种差异产生较大范围的几何背离,这就难以产生100%的空气密封。对于面具来说,很难在面部尺寸和形状范围内在皮肤和面具之间形成密封。人们已尝试了各种不同的技术手段,如使用粘性密封、平宽密封和弹性密封。在产业上人们已将注意力转向产生空气密封上,但是,实际上产生的压差迫使在密封件和皮肤之间的间隙中的空气绕流过空气过滤材料。本发明的静电过滤料可用海绵或其它可透气的无纺材料制成,以将压差减到最小,因而可防止空气被迫通过间隙。另外,由于具有低压降(像静电过滤料)的细小过滤料,可有效地利用衬垫在使用者与面具之间形成密封,这种过滤料带来了与其混合的活性剂的优点。It is known to use electrostatically charged filter materials, for example, in masks. With respect to both, face sealing is a well known problem and attempts have been made to address limitations in the industry. The problem is that the structures or tissues of human body shapes are different from each other, and this difference produces a large range of geometric deviations, which makes it difficult to produce 100% air tightness. It is difficult for masks to create a seal between the skin and the mask over a range of facial sizes and shapes. Various techniques have been tried, such as the use of viscous seals, flat width seals and elastic seals. Attention in the industry has turned to creating an air seal, however, the pressure differential that is actually created forces the air in the gap between the seal and the skin to bypass the air filter material. The electrostatic filter material of the present invention can be made of sponge or other breathable nonwoven material to minimize pressure differentials and thus prevent air from being forced through the gaps. In addition, the cushion can be used effectively to form a seal between the user and the mask due to the fine filter material with low pressure drop (like an electrostatic filter material), which brings the benefits of active agents mixed with it.

另一种已知的现有技术教导使用高压降介质,包括HEPA过滤器的机械过滤。但本发明的压力降要比单独使用HEPA过滤器的压力降大约低50%到90%。过滤料还包括在通道中杀灭植物细菌、孢子和病毒的材料。它们被从气流中滤出并被杀灭。此外,本发明是自动消毒的,即它不仅过滤流过它的空气,而且还能杀灭捕获在过滤料中的细菌。因此,这种介质保护了使用者和外部空气。Another known prior art teaches mechanical filtration using high pressure drop media, including HEPA filters. However, the pressure drop of the present invention is about 50% to 90% lower than that of a HEPA filter alone. Filter media also include materials that kill plant bacteria, spores and viruses in the channels. They are filtered out of the air stream and killed. Furthermore, the present invention is self-sterilizing, ie it not only filters the air passing through it, but also kills bacteria trapped in the filter material. Thus, this medium protects the user and the outside air.

由于现有技术存在缺陷,所以最好是使用一种具有优越于现有解决方案的特征的驻极体。本发明的改进包括一种有助于活性剂的底层,即电介质。Due to the deficiencies of the prior art, it would be better to use an electret with characteristics superior to existing solutions. The improvement of the present invention includes a substratum, ie, dielectric, that facilitates the active agent.

发明内容 Contents of the invention

本发明克服了现有技术的上述问题。特别地,按照本发明的一个方面,提供一种可充静电的、其内加入活性剂的无纺介质。这种改进的介质能比现有技术的解决方案更有效地根除微生物和/或毒素,而且还能自动消毒。The present invention overcomes the above-mentioned problems of the prior art. In particular, according to one aspect of the present invention, there is provided an electrostatically chargeable nonwoven medium having an active agent incorporated therein. This improved media eradicates microorganisms and/or toxins more effectively than prior art solutions and is also self-sterilizing.

本发明还提供制备可充静电的、其内加入活性剂的过滤介质的方法。可采用各种方法制备底层;活性剂可按照不同的方法加入;并且也可按不同的方法充静电,所有这些都在这些描述了或是现有技术中已知的。The present invention also provides a method of making an electrostatically chargeable filter medium having an active agent incorporated therein. The bottom layer can be prepared in various ways; the active agent can be added in different ways; and it can be electrostatically charged in different ways, all of which are described in these or are known in the art.

由于对每种过滤料使用非常少的活性剂,所以可在保持有效性的同时降低成本。另外,本发明的强化静电过滤提供了附加的活性剂的性能和静电特性。Because very little active agent is used per filter media, costs can be reduced while maintaining effectiveness. In addition, the enhanced electrostatic filtration of the present invention provides additional active agent performance and electrostatic properties.

除了本发明的上述方面外,在阅读了下面参照附图的描述后,将对其它的方面、特征和优点有更深的理解。In addition to the above-mentioned aspects of the present invention, other aspects, features and advantages will be better understood after reading the following description with reference to the accompanying drawings.

附图说明 Description of drawings

图1是表示按照本发明技术教导的一个典型实施例的外貌图;Fig. 1 is the appearance figure that represents a typical embodiment according to the technical teaching of the present invention;

图2和3表示可充静电的底层的典型实施例;Figures 2 and 3 represent exemplary embodiments of electrostatically chargeable bottom layers;

图4是表示提供一种加入活性剂的无纺介质的典型实施例。Figure 4 is a diagram illustrating an exemplary embodiment for providing an active agent-incorporated nonwoven medium.

具体实施方式 Detailed ways

下面描述本发明的一些典型实施例。本发明所描述的实施例对本领域的专业技术人员来说显然只是为了通过一些实例进行举例说明,而不是限制。在本说明书中公开的所有特征,除非是特意说明,都可用具有相同或相似目的的其它特征取代。因此,属于本发明改型的许多其它实施例都将作为这里所限定的本发明及其等同物而落入本发明的范围内。Some typical embodiments of the present invention are described below. The described embodiments of the present invention are obvious to those skilled in the art for the purpose of illustrating by way of example rather than limitation. All features disclosed in this specification, unless stated otherwise, may be replaced by other features serving the same or a similar purpose. Accordingly, many other embodiments which are modifications of the invention will fall within the scope of the invention as defined herein and equivalents thereof.

本发明提供一种充静电的过滤介质,它包括一种其内加入活性剂的底层。SUMMARY OF THE INVENTION The present invention provides an electrostatically charged filter medium comprising a bottom layer having an active agent incorporated therein.

过滤介质filter media

本发明的过滤介质包括(1)底层,(2)加入的活性剂和(3)静电荷。The filter media of the present invention comprise (1) a bottom layer, (2) an added active agent and (3) an electrostatic charge.

底层bottom layer

底层包括具有电介质特性能强化具有电介质特性的任何材料,并且这些材料内加入活性剂。The bottom layer includes any material having dielectric properties that can be enhanced to have dielectric properties, and the active agent is incorporated into these materials.

在一个特定实施例中,底层可以是具有纤维性基体结构的纤维基材料;它可以是具有开放小室的基体结构的类似海绵的材料;它可以是弹性或非弹性的;等等。In a particular embodiment, the substrate may be a fiber-based material with a fibrous matrix structure; it may be a sponge-like material with an open cell matrix structure; it may be elastic or inelastic; and the like.

如上所述,在一个实施例中,底层是无纺纤维。无纺材料是一种相互粘合在一起的纤维,而不是纺成的和织成的布。它可以是通过摩擦或粘合方法结合起来而制成的定向或随机定向的片、垫,网或絮的纤维;它可采取纤维的形式。图1提供了一个无纺纤维的典型实施例。As noted above, in one embodiment, the substrate is nonwoven fibers. Nonwovens are fibers bonded together rather than spun and woven. It may be an oriented or randomly oriented sheet, mat, web or batt of fibers combined by friction or bonding methods; it may take the form of fibers. Figure 1 provides a typical example of a nonwoven fiber.

在另一个实施例中,底层可以是一种松软度可变的无纺织物,包括聚合物纤维。该聚合物可以是例如尼龙、聚乙烯、聚丙烯、聚酯等,或是任何适合于用作底层的其它聚合物。另外,底层可用非聚合物纤维材料制成。In another embodiment, the substrate may be a variable loft nonwoven fabric comprising polymeric fibers. The polymer can be, for example, nylon, polyethylene, polypropylene, polyester, etc., or any other polymer suitable for use as a backing layer. Alternatively, the bottom layer may be made of non-polymeric fibrous materials.

无纺材料可以是一种适用于高效颗粒空气过滤器(即HEPA过滤器)的材料。适合的无纺材料可从Technol Aix en Provence Cedex 03France(参见加拿大专利1,243,801)获得;另一种适用材料可以从Minnesota Mining&Manufacturing Co.(3M)获得。无纺材料可具有三维结构,这种结构是一种提供能捕集(即用物理方式)所需活性剂的基体。例如,如果无纺材料是基于纤维的材料,则无纺材料的结构纤维是现有的并以提供能捕集所需活性剂的纤维化基体结构的方式分布。无纺材料可具有微观结构。在一个特定实施例中,活性剂具有适合于被所需无纺材料的三维(例如网状)基体结构捕集的粒度。The nonwoven material may be a material suitable for use in a high efficiency particulate air filter (ie, a HEPA filter). A suitable nonwoven material is available from Technol Aix en Provence Cedex 03 France (see Canadian Patent 1,243,801); another suitable material is available from Minnesota Mining & Manufacturing Co. (3M). The nonwoven material can have a three-dimensional structure that provides a matrix capable of trapping (ie, physically) the desired active agent. For example, if the nonwoven material is a fiber-based material, the structural fibers of the nonwoven material are present and distributed in such a way as to provide a fibrous matrix structure capable of trapping the desired active agent. Nonwoven materials can have a microstructure. In a particular embodiment, the active agent has a particle size suitable for entrapment by the three-dimensional (eg, network) matrix structure of the desired nonwoven material.

其它底层还包括玻璃纤维和像纤维素这样的纤维,这种纤维最终形成纸基纤维介质。任何有起活性剂载体作用并具有电介质特性或可使其赋予电介质特性的底层都适合于作为本发明的底层。当使用没有强电介质特性的底层,如玻璃纤维时,还可提供改进的底层电介质特性。本发明不局限于使用无纺材料。其它适用的底层可包括海绵材料或泡沫材料。Other substrates include fiberglass and fibers such as cellulose, which ultimately form the paper-based fibrous media. Any sublayer that acts as an active agent carrier and has dielectric properties or can be made to impart dielectric properties is suitable as the sublayer of the present invention. Improved dielectric properties of the substrate can also be provided when using substrates without strong dielectric properties, such as fiberglass. The invention is not limited to the use of nonwoven materials. Other suitable substrates may include sponge or foam materials.

活性剂active agent

本发明的活性剂可以是例如抗菌剂、抗毒素或类似物质。抗菌剂可以是生物静电剂或生物杀生剂。生物静电剂是抑制所有或某些细菌孢子、病毒、真菌等(具有生物活性的颗粒)生长的材料,而生物杀生剂是一种杀灭所有或某些细菌孢子、病毒、真菌等的材料。生物静电剂最好如上述的专利‘452中所描述的,包括碘化树脂颗粒。其它适用的活性剂包括其上附有抗菌剂的银、铜、沸石,卤化树脂及现有技术中已知的能灭活/减活微生物/毒素剂,包括例如活性碳,其它金属及其它化合物。例如下面将适用的金属和/或化合物非穷举地列出。Active agents of the invention may be, for example, antibacterial agents, antitoxins or similar substances. The antimicrobial agent can be a biostatic agent or a biocide. A biostatic agent is a material that inhibits the growth of all or some bacterial spores, viruses, fungi, etc. (particles with biological activity), while a biocide is a material that kills all or some bacterial spores, viruses, fungi, etc. The biostatic agent is preferably as described in the aforementioned '452 patent, comprising iodinated resin particles. Other suitable active agents include silver, copper, zeolites with antimicrobial agents attached thereto, halogenated resins and agents known in the art to inactivate/deactivate microorganisms/toxins including for example activated carbon, other metals and other compounds . For example, a non-exhaustive list of suitable metals and/or compounds follows.

典型金属typical metal

铝、钡、硼、钙、铬、铜、铁、镁、锰、钼、镍、铅、钾、硅、钠、锶、锌Aluminum, barium, boron, calcium, chromium, copper, iron, magnesium, manganese, molybdenum, nickel, lead, potassium, silicon, sodium, strontium, zinc

典型化合物typical compound

N-甲基哌嗪N-Methylpiperazine

氢氧化钾Potassium hydroxide

氯化锌Zinc chloride

氯化钙calcium chloride

碳酸钠和重碳酸钠的混合物Mixture of Sodium Carbonate and Sodium Bicarbonate

本说明书中所列举的抗菌剂是为了阅读方便,而不是对本发明的限定。The antibacterial agents listed in this specification are for the convenience of reading, rather than limiting the present invention.

静电荷static charge

加入活性剂的过滤介质也充有静电。因此,通过介质表面的势能产生电场,其中电场能吸引和/或排斥引入介质中的带电颗粒,使得在某些情况下可改变带电颗粒的运动路径。Filter media with active agents are also electrostatically charged. Thus, an electric field is generated by the potential energy of the surface of the medium, which can attract and/or repel charged particles introduced into the medium, so that in some cases the path of motion of the charged particles can be altered.

图2-3提供了充有静电的介质的典型表示方法。本发明的充有静电的过滤介质例如可以是单层的或多层的。可对每层单独充电。单层介质可在一侧具有正电荷,在另一侧具有负电荷。多层介质的一个例子是双层介质。最好采用双层介质,其中这种双层介质包括两层,在每层的一侧充正电荷,另一侧充负电荷,其中这两层是被空气空间分离的,并且两层这样定向:两层中的一层的负电侧靠近另一层的正电侧。在这两层的实施例中,该空气空间提高了充静电的过滤介质的净介电常数。Figure 2-3 provides a typical representation of electrostatically charged media. The electrostatically charged filter media according to the invention can be, for example, single-layer or multi-layer. Each layer can be charged separately. A single layer dielectric can have a positive charge on one side and a negative charge on the other. An example of a multi-layer media is a dual-layer media. Preferably, a bilayer dielectric is used, where the bilayer dielectric comprises two layers, one side of each layer is positively charged and the other side is negatively charged, wherein the two layers are separated by an air space, and the two layers are oriented in such a way : The negative side of one of the two layers is close to the positive side of the other. In the two-layer embodiment, this air space increases the net dielectric constant of the electrostatically charged filter media.

最好提供高介电常数,以延长保持电荷的时间:例如当使用上述空气空间时,提供有良好介电常数的空气。因而,本发明即使在潮湿环境中也是非常有效的。It is preferable to provide a high dielectric constant in order to prolong the charge retention time: for example when using the above-mentioned air space, provide air with a good dielectric constant. Thus, the present invention is very effective even in humid environments.

最终的介质是一种其上附有活性剂或其内浸渍活性剂并具有静电荷的绝缘载体。本发明的介质可形成不同的厚度、密度和压力降。这里描述的介质可用于例如衣服、创伤敷料、空气过滤器、遮盖物、内衬和常用的任何过滤材料。The final medium is an insulating carrier with the active agent attached thereto or impregnated with the active agent and electrostatically charged. The media of the present invention can be formed in varying thicknesses, densities and pressure drops. The media described herein can be used, for example, in garments, wound dressings, air filters, coverings, liners, and any filter material commonly used.

制备方法Preparation

本发明还提供制备充静电的、其上加入活性剂的过滤介质的制备方法。底层本身可按照各种已知的方法制备,如熔体喷射(meltblown)、纺时喷射(spun blown)、空气覆盖(air laid)、挤拉(carted)等。The present invention also provides a method of making an electrostatically charged filter medium to which an active agent has been added. The bottom layer itself can be prepared according to various known methods, such as melt blown, spun blown, air laid, carted and the like.

加入活性剂的方法The method of adding the active agent

现有的使用聚丙烯的加入方法需要使用聚丙烯来保持纤维的厚度,从而使固体颗粒长时间地保持,以防止微粒离开纤维。在本发明中,活性剂,例如在‘452中公开的碘化树脂,可用物理方式被捕集在纤维中。因此,活性剂不必粘附到要加入介质的纤维上。Existing methods of incorporation using polypropylene require the use of polypropylene to maintain the thickness of the fibers so that the solid particles are retained for extended periods of time to prevent particulates from leaving the fibers. In the present invention, active agents, such as the iodinated resins disclosed in '452, can be physically entrapped in the fibers. Thus, the active agent does not have to adhere to the fibers to be added to the medium.

在本发明中,活性剂可用不同的方法加入底层。例如采用在高温高压的混合和熔化过程中的熔化时,通过活性剂的乳化,或通过在工艺中挤出无纺纤维后,再喷射活性剂等加入方法。In the present invention, the active agent can be added to the base layer in different ways. For example, when melting during high temperature and high pressure mixing and melting, by emulsifying the active agent, or by extruding the non-woven fiber in the process, and then spraying the active agent and other adding methods.

在图4所示的优选实施例中,将聚合物颗粒,如聚丙烯颗粒通过挤出机挤出;挤出的纤维具有不同的厚度和长度。当纤维被挤出时,它们朝收集网方向下落。所需的活性剂设置在靠近最终纤维的挤出点的位置上的混团(cloud)中,在纤维仍处于半液半固态时,该混团包围着冷却纤维。在一个实施例中,活性剂颗粒可在0.2微米至0.5毫米的范围内。但是,本领域的一个普通专业技术人员可将采用较小和较大颗粒粒径的活性剂。通过对活性剂颗粒的放置和收集,以使它们与收集网上的纤维结合或捕集在纤维上。在其上加入活性剂的纤维落到收集网上后,利用已知的方法使最终的介质形成网。此外,混团可以处于不同的物理状态,包括蒸汽、细干燥粉尘或雾化或烟雾状颗粒。有利地是,混团的结合可在室温下进行,这时颗粒也处于室温。另外,厚度、长度和压力限定了最终介质的机械特性。In the preferred embodiment shown in Figure 4, polymer pellets, such as polypropylene pellets, are extruded through an extruder; the extruded fibers are of varying thickness and length. As the fibers are extruded, they fall towards the collecting web. The desired active agent is disposed in a cloud near the point of extrusion of the final fiber which surrounds the cooled fiber while the fiber is still semi-liquid and semi-solid. In one embodiment, the active agent particles may be in the range of 0.2 microns to 0.5 mm. However, one of ordinary skill in the art will employ both smaller and larger particle sizes of the active agent. By placing and collecting the active agent particles so that they are bound to or trapped on the fibers of the collection net. After the fibers on which the active agent has been added fall onto the collecting wire, the final media is formed into a web using known methods. In addition, agglomerates can be in different physical states, including vapour, fine dry dust, or aerosolized or aerosolized particles. Advantageously, the conjugation of the clumps can take place at room temperature, when the particles are also at room temperature. Additionally, thickness, length and pressure define the mechanical properties of the final media.

用于上述实施例的适合的熔体喷射系统是由新泽西州Hillside的Accurate Products Co.提供的Accuweb。A suitable melt blowing system for use in the above embodiments is Accuweb supplied by Accurate Products Co. of Hillside, NJ.

使活性剂结合到纤维介质上的其它不同方法也适用于本发明。首先,例如使用公开在美国专利申请20010045398A1中的方法。第二,将挤出的发状纤维的管(bail)浸没在活性剂中(并使用酒精来实现浸湿),然后利用压力和温度制成毡。第三,利用由加入挤出漏斗中的活性剂制备的固体聚合物颗粒制成混合,然后挤入细发状管(bail)中。在通过一定温度和压力过程制成毡。第四,挤出的底层,如处于发状替代物的聚合物底层,并在挤出后将活性剂喷射成固态。活性剂可像烟雾一样蒸发。第五,活性剂可被喷射或喷雾成无纺纤维,同时使纤维受压。第六,挤拉(cart)细丝的管(bail)并将最终的介质与活性剂混合,以形成其内加入活性剂的片。第七,将活性剂沉积在无纺介质上,然后用针刺法冲压介质,以使活性剂充满并通过介质。其它方法也可采用。Various other methods of incorporation of the active agent onto the fibrous media are also suitable for use in the present invention. First, for example using the method disclosed in US patent application 20010045398A1. Second, a bail of extruded hair fibers is submerged in the active agent (alcohol is used to achieve wetting) and then felt using pressure and temperature. Third, mixing is made using solid polymer particles prepared from the active agent added to an extrusion funnel, then extruded into a fine hair-like bail. It is made into felt through a certain temperature and pressure process. Fourth, an extruded base layer, such as a polymer base layer in a hair replacement, and injecting the active agent into a solid state after extrusion. The active agent can evaporate like smoke. Fifth, the active agent can be sprayed or sprayed into the nonwoven fibers while the fibers are compressed. Sixth, a bail of filaments is extruded and the final medium is mixed with the active agent to form a tablet into which the active agent is incorporated. Seventh, the active agent is deposited on the nonwoven medium, and the medium is punched by needling to impregnate and pass the active agent through the medium. Other methods can also be used.

在发明的另一个实施例中,将聚合物颗粒放入在挤出之前就形成的粉状活性剂的挤出机的漏斗中。因此,活性剂在熔化之前在漏斗中混合。将这两种成分混合、加热,然后挤出,以形成用于制成毡的细“发”状纤维。在上述实施例的加入活性剂的最终的细发为管(bail)状绒线。根据聚合物的需要,底层可以是透明的。因此,其上加入活性剂的聚合物纤维可用压力水进行处理,然后加热形成毡。在其它实施例中,其上加入活性剂的最终的聚合物纤维可以是气流法(air laid)、真空法(vacuum laid)、水法(water laid)等制成的。In another embodiment of the invention, the polymer particles are placed in the funnel of the extruder of the powdered active agent formed prior to extrusion. Therefore, the active agents are mixed in the funnel before being melted. The two ingredients are mixed, heated, and extruded to form the fine "hair"-like fibers used to make felt. The final fine hair added to the active agent in the above examples was a bail-like flock. Depending on the polymer requirements, the bottom layer can be transparent. Thus, the polymer fibers to which the active agent has been added can be treated with pressurized water and then heated to form a mat. In other embodiments, the final polymeric fibers onto which the active agent is added may be air laid, vacuum laid, water laid, etc.

虽然这里没有特别描述,但其它传统或已知的将活性剂与底层结合的方法也适用于本发明。因此,从这一点上说,底层具有加入其内的活性剂。Although not specifically described herein, other conventional or known methods of combining the active agent with the substrate are also suitable for use in the present invention. Thus, at this point, the bottom layer has the active agent incorporated therein.

静电充电方法Electrostatic charging method

加入活性剂的底层带有静电荷。电荷可通过电晕、针刺法、化学增强法、任何其它已知的感应系统或方法产生,或利用上述方法的结合来产生电荷。针刺法形成高水平的摩擦,所以能增加电荷。The bottom layer to which the active agent is added is electrostatically charged. The charge can be generated by corona, acupuncture, chemical amplification, any other known inductive system or method, or using a combination of the above methods to generate the charge. Needle punching creates a high level of friction and therefore increases the charge.

在一个特定实施例中,为了将形成介质,例如毡的充有静电的无纺纤维旋转到大约25Kv的电晕系统中,使其缓慢通过直到完全充电。最终的材料能在约6个月至2年间保持其电荷。In one particular embodiment, to spin the forming medium, eg statically charged non-woven fibers of felt, into a corona system of about 25Kv, it is passed slowly until fully charged. The final material retains its charge for about 6 months to 2 years.

静电过滤介质的工作过程Working process of electrostatic filter media

在工作中,将污染的空气或液体流引导到本发明的使用充有静电的过滤介质的过滤器,利用压力梯度强迫或抽吸空气/流体流,使其通过过滤介质。该流可包含要通过过滤元件去除或处理的各种粒径的污染的颗粒。当该流接近过滤介质时,它被引导通过过滤介质,使污染的颗粒与过滤介质接触,并利用按本申请其它地方所描述的活性剂从该流中去除或处理污染的颗粒。利用使颗粒经旋绕的路径通过过滤介质的过滤器特性可实现上述处理,从而延长了污染物与活性剂的接触时间。在处理该流中的颗粒时,接触时间的延长提高了活性剂的效率。In operation, a contaminated air or liquid stream is directed to the filter of the present invention using an electrostatically charged filter media, and a pressure gradient is used to force or draw the air/fluid stream through the filter media. The stream may contain contaminating particles of various sizes to be removed or treated by the filter element. As the stream approaches the filter media, it is directed through the filter media, contacting the contaminating particles with the filter media, and removing or treating the contaminating particles from the stream using active agents as described elsewhere in this application. This is accomplished by utilizing the filter properties of the filter media to take particles through a convoluted path, thereby prolonging the contact time of the contaminants with the active agent. The extended contact time increases the effectiveness of the active agent when processing the particles in this stream.

颗粒通过盘绕路径可使其增加过滤元件底层的静电特性和无纺特性。对于过滤元件的静电特性来说,污染颗粒的盘绕路径可归因于颗粒的极性。极性分子是中性的,并具有较大尺寸。由于尺寸较大,所以当受电场控制而使污染颗粒从其路径上转向时,污染物具有磁矩。The convoluted path of the particles allows them to increase the electrostatic and nonwoven properties of the underlying filter element. With respect to the electrostatic properties of filter elements, the convoluted path of contamination particles can be attributed to the polarity of the particles. Polar molecules are neutral and have a larger size. Due to their large size, pollutants have a magnetic moment when they are deflected from their path by an electric field.

此外,污染颗粒的盘绕路径归因于过滤底层的无纺特性。这是由于无纺底层不具有要通过的流体流的直接和连续的路径来实现的。而由于无纺特性,底层由多孔材料构成,其中不会由单孔材料形成通过底层的连续路径。因此,流体流和由流体流携带的颗粒连续转向地通过底层。这样就延长了通过过滤器的时间,暴露于活性剂的程度增强了。Furthermore, the coiled path of the pollution particles is attributed to the non-woven nature of the filter substrate. This is achieved by the fact that the nonwoven base layer does not have a direct and continuous path for fluid flow to pass through. Instead, due to the nonwoven nature, the bottom layer is composed of a porous material, wherein no continuous path through the bottom layer is formed by a single porous material. Thus, the fluid flow and the particles carried by the fluid flow are continuously diverted through the bottom layer. This prolongs the time through the filter and the exposure to the active agent is enhanced.

附加用途Additional use

本发明还可采用与现有的无纺纤维兼容的方式。使用各种物品,包括耐用和一次性物品。例如,无纺材料可用于如下产品,如尿布、卫生巾、成人失禁巾,抹布、床内衬、汽车产品、面具、空气过滤、水过滤、生物流体过滤、家庭陈设和地面织物。这里所述的介质可用于,例如布、创伤敷料、空气过滤器、遮盖物、内衬。其它用途包括在现有技术中已知的静电过滤器和抗菌剂或抗毒素过滤器。The present invention can also be used in a manner compatible with existing nonwoven fibers. Use a variety of items, both durable and disposable. For example, nonwoven materials can be used in products such as diapers, sanitary napkins, adult incontinence napkins, wipes, bed liners, automotive products, masks, air filtration, water filtration, biological fluid filtration, home furnishings, and floor coverings. The media described herein can be used, for example, in cloths, wound dressings, air filters, coverings, liners. Other uses include electrostatic filters and antimicrobial or antitoxin filters known in the art.

在一个特定实施例中,本发明的具有或不具有活性剂的过滤介质可用作一个封闭物,或使如面具和HVAC等产品的过滤空气的过滤封闭物。按照本发明,提供一种用具有静电特性的底层和加入活性剂的静电材料构成的封闭材料,这种材料是一种三维结构的高伸缩性(在一个实施例中,厚度为1”)可透气材料,它放置在面具或空气过滤器周围,以便不形成所谓的气密连接,而取而代之的是形成可透气密封,它实际上覆盖所有具有不同几何表面的外形,以提供具有过滤特性的可透气密封。该方法将封闭物放入过滤器,从而使旁流过由于不完善配合形成的间隙的空气再流过密封物并被过滤。此外,与“弹性密封”相反,在气密方法中有害的压差在我们的方法中则无害,这是由于通过最小阻力的空气将通过面具的过滤材料的缘故。封闭面具或其它过滤器种类的这种方法可通过替换具有相同特性的可透气泡沫的无纺过滤元件来实现。因此,现有技术的面具试图阻止空气在密封处流动,而本发明的面具起密封垫的作用,它使空气通过并杀灭进入气流的孢子、病毒、细菌、真菌等,该气流中含有有效的活性剂,如公开在上述‘452专利中的碘化树脂。因此,使用一些带子将面具固定在适当位置,以压缩本发明的密封垫,以便基本上与整个脸配合。In a particular embodiment, the filter media of the present invention, with or without active agent, can be used as an enclosure, or filter enclosure for filtering air in products such as masks and HVAC. In accordance with the present invention, there is provided a closure material comprising a bottom layer having electrostatic properties and an active agent-added electrostatic material which is a three-dimensional structure of highly stretchable (in one embodiment, a thickness of 1") scalable Breathable material, which is placed around the mask or air filter so that it does not form a so-called airtight connection, but instead forms a breathable seal, which actually covers all shapes with different geometric surfaces to provide a breathable Air-permeable seal. This method places the closure in a filter so that air that bypasses the gap formed by the imperfect Harmful pressure differentials are harmless in our approach, as the air passing through the least resistance will pass through the filter material of the mask. This method of closing a mask or other filter type can be achieved by replacing a breathable The non-woven filter element of the foam is realized.Therefore, the mask of the prior art tries to prevent the flow of air in the seal, while the mask of the present invention acts as a sealing gasket, which allows the air to pass through and kills spores, viruses, bacteria entering the airflow , fungus, etc., the air stream contains effective active agents such as the iodinated resins disclosed in the aforementioned '452 patent. Therefore, some straps are used to hold the mask in place to compress the gasket of the present invention so that it is substantially compatible with Fits the entire face.

试验数据Test Data

将本发明的过滤介质的一个特定实施例与现有的静电过滤器相比进行试验测试。每测试都是在处理具有不同污染物的空气的相同环境下进行的。在这些测试过程中,收集所提供的试验数据。在每一测试中,将一种污染物以可控制的量引入一个腔内,并送入四条线路中。两条线路包括本发明的过滤器,该过滤器包括加入‘452专利的碘化树脂的充有静电的过滤器。第三条线路包括被称为Transweb的充有静电的过滤器。这种过滤器没有抗菌特性或加入活性剂的任何其它种类的特性。并提供用于控制的第四条线路,它没有过滤器,用于确定进入控制腔中的污染物的量是否等于排出控制腔中的污染物的量。A specific embodiment of the filter media of the present invention was experimentally tested in comparison to existing electrostatic filters. Each test was performed under the same environment treating air with different pollutants. During these tests, the provided experimental data was collected. In each test, a controlled amount of a contaminant was introduced into a chamber and fed into four lines. Both lines included filters of the present invention comprising electrostatically charged filters incorporating the iodinated resin of the '452 patent. The third line includes static-charged filters known as Transweb. This filter has no antimicrobial properties or any other kind of properties with active agents added. And a fourth line is provided for the control, which has no filter, and is used to determine whether the amount of contamination entering the control chamber is equal to the amount of contamination exiting the control chamber.

表A列出了表示本发明一些典型实施例的某些特性。试验号AF276描述了不同的过滤膜对于GB孢子过滤30,60,120,180,240,300和360分钟的性能。BG孢子必须具有约8000至30000孢子的量,这是使普通人致病的量。从表A中可以看出,对于30,60,120,180,240,300和360分钟测试的每次测试,本发明的过滤器100%地减少了气流中的BG孢子量。Table A lists certain characteristics representative of some exemplary embodiments of the invention. Test No. AF276 describes the performance of different filter membranes for GB spore filtration for 30, 60, 120, 180, 240, 300 and 360 minutes. BG spores must have an amount of about 8,000 to 30,000 spores, which is the amount that makes the average human sick. As can be seen from Table A, for each of the 30, 60, 120, 180, 240, 300 and 360 minute tests, the filter of the present invention reduced the amount of BG spores in the air stream by 100%.

正如从表A中看出的,在这些试验中,本发明的静电过滤器基本上达到了与Transweb相同或相似的净效应。但是,本发明个有一个重要优点,即本发明杀灭了孢子,而不是仅仅将它们保存在过滤器中。因此,与本发明不同,如果Transweb由使用者处理或与皮肤接触,则可能发生污染。本发明可保持过滤器的卫生。As can be seen from Table A, the electrostatic filter of the present invention achieved substantially the same or similar net effect as Transweb in these tests. However, the present invention has an important advantage in that it kills the spores rather than just keeping them in the filter. Therefore, unlike the present invention, contamination may occur if the Transweb is handled by the user or comes into contact with the skin. The invention can keep the filter hygienic.

现在来看表B,试验号AF270的结果显示了不同的过滤膜对于MS2病毒过滤30,60,120,180,240,300和360分钟的性能的测试结果。从1至1000范围的病毒量将使普通人致病。因此,即使一个病毒也能使人致病。正如从表B中看出的,对于30,60,120,180,240,300和360分钟的测试,本发明的过滤器可100%地减少气流中的MS2病毒。但Transweb不能达到100%地减少MS2病毒,并在流出的气流中发现1000至10000个病毒单位。用Transweb对付被MS2病毒污染的空气不能达到理想的效果。因此,从表B中可以看出,相对于表A来说,除上述消毒特性的优点外,随着时间的过去,本发明能更有效地抵御MS2这样的病毒。由于只有小量的病毒污染人类(1至1000个病毒),所以与本发明不同,Transweb不能有效地保护使用者被这些病毒侵害。Turning now to Table B, the results of Test No. AF270 show the performance of different filter membranes for MS2 virus filtration for 30, 60, 120, 180, 240, 300 and 360 minutes. Viral loads ranging from 1 to 1000 will make the average person sick. Therefore, even a single virus can make a person sick. As can be seen from Table B, for the 30, 60, 120, 180, 240, 300 and 360 minute tests, the filter of the present invention reduced the MS2 virus in the gas stream by 100%. But Transweb could not achieve 100% reduction of MS2 virus and found 1000 to 10000 virus units in the outgoing air stream. Using Transweb to deal with the air polluted by the MS2 virus cannot achieve the desired effect. Thus, it can be seen from Table B that, relative to Table A, the present invention is more effective over time against viruses such as MS2, in addition to the advantages of the disinfection properties described above. Since only a small number of viruses contaminate humans (1 to 1000 viruses), Transweb, unlike the present invention, cannot effectively protect users from these viruses.

结论in conclusion

现已描述了本发明的一个或多个典型实施例,显然,对于本领域的专业人员来说,上述的描述只是为了通过实例进行举例说明,而不是限制,除了特别说明的外,在本说明书(包括所有权利要求,摘要和附图)中描述的所有特征都可用具有相同目的、等同物或类似目的的其它特征替代。因此,附加的和变换的许多其它实施例都将落入由权利要求书及等同物限定的本发明的范围内。Now that one or more exemplary embodiments of the present invention have been described, it will be apparent to those skilled in the art that the foregoing description is for illustration by way of example only, rather than limitation. All the features described in (including all claims, abstract and drawings) may be replaced by other features serving the same, equivalent or similar purpose. Accordingly, many other embodiments of additions and alterations would fall within the scope of the invention as defined by the claims and their equivalents.

Claims (28)

1. protective medium comprises:
A porous dielectric carrier;
A kind of activating agent that is added in the porous dielectric carrier, described activating agent is a halogenated resin; And
Electrostatic charge at least a portion of described porous dielectric carrier.
2. according to the protective medium of claim 1, wherein said porous dielectric carrier is a non-woven material.
3. according to the protective medium of claim 1, wherein said porous dielectric carrier is the fiber-based material with fibrous matrix structure.
4. according to the protective medium of claim 1, wherein said porous dielectric carrier is the sponge kind material with perforate cell basal body structure.
5. according to the protective medium of claim 2, wherein said non-woven material is a three-dimensional structure, in order to the matrix that can capture described halogenated resin with physics mode to be provided.
6. according to the protective medium of claim 5, wherein said halogenated resin is made up of the suitable particle of the particle diameter that is captured by described matrix.
7. according to the protective medium of claim 1, wherein said halogenated resin is an iodinated resin.
8. according to the protective medium of claim 7, wherein said porous dielectric carrier is a non-woven material.
9. according to the protective medium of claim 7, wherein said porous dielectric carrier is the fiber-based material with fibrous matrix structure.
10. according to the protective medium of claim 7, wherein said porous dielectric carrier is the sponge kind material with perforate cell basal body structure.
11. protective medium according to Claim 8, wherein said non-woven material is a three-dimensional structure, in order to the matrix that can capture described iodinated resin with physics mode to be provided.
12. according to the protective medium of claim 11, wherein said iodinated resin is made up of the suitable particle of the particle diameter that is captured by described matrix.
13. protective medium according to claim 1 also comprises:
Another one porous dielectric carrier;
Be added in the another one activating agent in the described another one porous dielectric carrier; And
Other electrostatic charge at least a portion of described another one porous dielectric carrier;
14. according to the protective medium of claim 13, wherein said other activating agent is a halogenated resin.
15. according to the protective medium of claim 13, wherein the air gap separates described porous dielectric carrier and described other porous dielectric carrier.
16. according to the protective medium of claim 15, wherein said other porous dielectric carrier is a non-woven material.
17. according to the protective medium of claim 15, wherein said other porous dielectric carrier is the fiber-based material with fibrous matrix structure.
18. according to the protective medium of claim 15, wherein said porous dielectric carrier and other porous dielectric carrier are the sponge kind materials with perforate cell basal body structure.
19. according to the protective medium of claim 17, wherein said non-woven material is a three-dimensional structure, in order to the matrix that can capture described activating agent and other activating agent with physics mode to be provided.
20. according to the protective medium of claim 19, wherein said other activating agent is made up of the suitable particle of the particle diameter that is captured by described matrix.
21. a method for preparing protective medium as claimed in claim 1 comprises:
A kind of extruder with outlet is provided;
A collecting net that is positioned at described outlet of extruder below is provided;
A kind of extrudable hot melt material is provided;
Utilize described extruder to extrude described extrudable material, make extruding fiber flow and falling of cooling towards described collecting net; And
The mixed group of halogenated resin is provided in the position near the described exit of described extruder, so that described mixed group surrounds cooled fibers, described fiber is still consolidated state at half liquid half simultaneously, thereby described halogenated resin is fixed and collects, and mutually combine or be captured on the collecting net that forms medium by described fiber.
22., also comprise described medium made net according to the method for preparing protective medium of claim 1.
23. according to the method for preparing protective medium of claim 1, wherein said mixed group is in physical state, it is selected from the group of being made up of following material: steam, thin dried dust, atomizing particle and aerosolised particles.
24. the method for preparing protective medium according to claim 1 also comprises the step that electric charge is applied to whole described net.
25. a method for preparing protective medium as claimed in claim 1 comprises:
A kind of extruder with outlet is provided;
A collecting net that is positioned at described outlet of extruder below is provided;
But provide the storage bin of an extruded material;
Utilize described extruder to extrude described extrudable material, make and extrude fiber flow and fall towards described collecting net; With
The mixed group of halogenated resin is provided in the position near the described exit of described extruder, so that described mixed group surrounds fiber, simultaneously described fiber falls, thereby described halogenated resin is fixed and collects, and mutually combines or be captured on the collecting net that forms medium by described fiber.
26., also comprise described medium made net according to the method for preparing protective medium of claim 1.
27. according to the method for preparing protective medium of claim 1, wherein wherein said mixed group is in physical state, it is selected from the group of being made up of following material: steam, thin dried dust, atomizing particle and aerosolised particles.
28. the method according to the protective medium of claim 1 wherein also comprises the step that electric charge is applied to whole described net.
CNB038240815A 2002-09-16 2003-09-08 Electrostatically charged filter media with added active agent Expired - Fee Related CN100377760C (en)

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US41100602P 2002-09-16 2002-09-16
US60/411,006 2002-09-16
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US60/458,800 2003-03-28

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WO2008010137A2 (en) * 2006-07-19 2008-01-24 Koninklijke Philips Electronics N.V. Electrostatic particle filter
JP4581027B1 (en) * 2009-10-19 2010-11-17 コデラカプロン株式会社 Mask filter and manufacturing method thereof, mask filter pocket and mask
DE102011051902A1 (en) * 2011-07-18 2013-01-24 Haomin Ding Filter, in particular breathing air filter
CN110545894B (en) * 2017-02-21 2022-10-28 霍林斯沃思和沃斯有限公司 Electret-containing filter media
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US5582865A (en) * 1988-12-12 1996-12-10 Extraction Systems, Inc. Non-woven filter composite

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