CN101784322B

CN101784322B - Liquid filtration systems

Info

Publication number: CN101784322B
Application number: CN200880102197.2A
Authority: CN
Inventors: 布拉德利·M·伊顿; 威廉·J·法伊尔三世; 托伦斯·B·斯塔尔; 图恩德·Y·瓦特; 马克·W·斯希梅尔
Original assignee: 3M Innovative Properties Co
Current assignee: Shuwanuo Intellectual Property Co
Priority date: 2007-08-07
Filing date: 2008-08-06
Publication date: 2014-03-12
Anticipated expiration: 2028-08-06
Also published as: JP2010535621A; BRPI0813597A2; EP2188030A2; AU2008283876A1; JP5805950B2; WO2009021028A2; AU2008283876B2; CN101784322A; WO2009021028A3; EP2188030A4; KR20100059839A

Abstract

Provided are filter elements and methods of making and using the same where the filter elements are suitable for liquid filtration and contain a particle- loaded meltblown fiber web. A filter element comprises: a porous article comprising a web of self-supporting nonwoven polymeric fibers and a plurality of sorbent particles enmeshed in the web, the article comprising a first surface and a second surface; a liquid- impermeable housing surrounding the porous article; an inlet in fluid communication with the first surface; and an outlet in fluid communication with the second surface. A plurality of layers of the web of self-supporting nonwoven polymeric fibers may be used to the porous article. Spiral-wound webs, web-covered blocks, and stacked disks of webs are also provided.

Description

Fluid filter system

Technical field

The present invention relates to fluid filter system and filter medium, wherein filter medium contains (for example) polymeric web, contains sorption composition in described net.

Background technology

There is polytype fluid filter system (as filtered for service water) to be commercially available.Traditionally, with the bed of loose carbon granule, from water, remove metal and/or organic substance.Can prepare composite block from the combination of sorbent material (as adsorbing active carbon) and polymeric binder (as polyethylene), described combination is sintered together under the condition of heat and pressure, can be used for water filter technology.It is suitable with expanded bed carbon granule functional that charcoal piece technology (for example) can provide, and particle can not come off or occupy too many space.For charcoal piece technology, because sorbent material is as the amount increase of active carbon, the pressure drop meeting on whole charcoal piece increases.In addition, the heat of charcoal piece and pressure exposure can limit the type of the material that is available for charcoal piece.For example, charcoal piece technology can not be used the material to thermal degradation sensitivity conventionally, as ion exchange resin.

Continuation need to be put forward compact water filtration system for household use.Also need to provide active material heap(ed) capacity high and don't can increase the system of the pressure drop in whole system.Also it is desirable to make the degradation to filter medium in process to minimize.In addition, lasting needs provide the system with improved service life.

Summary of the invention

The invention provides filter cell and preparation and application thereof, wherein said filter cell is applicable to liquid filtering, and contains the meltblown fiber web that loads particle.

In one aspect, provide filter cell, it comprises: comprise self support type non-woven polymeric webs and a plurality of porous article that is embedded in the adsorber particles in described net, described goods comprise first surface and second surface; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.

Comprise on the other hand the fluid filter system that comprises fluid source and filter cell, described filter cell comprises: comprise self support type non-woven polymeric webs and a plurality of porous article that is embedded in the adsorber particles in described net, described porous article comprises first surface and second surface; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.

Aspect another, filter cell is provided, it comprises: the block composite of charcoal that comprises active medium and binding agent, for the weight of the block composite of described charcoal, the scope of the content of described active medium is 10 to 90 % by weight, and the scope of the content of described binding agent is 10 to 90 % by weight; Around the net of the block composite of described charcoal, described net comprises self support type non-woven polypropylene fiber and a plurality of adsorber particles being embedded in described net, and for the weight of described net, the scope of the content of described adsorber particles is 50 to 97 % by weight.

On the other hand, provide and comprised a plurality of filter cells that are attached to mutually disc together, described disc comprises self support type non-woven polypropylene fiber and a plurality of adsorber particles being embedded in described fiber.

Other aspect comprises the method for filtering fluid.Described method comprises makes filter cell and fluid contact, described filter cell comprises and comprises self support type non-woven polymeric webs and a plurality of porous article that is embedded in the adsorber particles in described net, and described porous article comprises first surface and second surface; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.

Aspect more, the method that forms filter cell is provided, described method comprises: molten polymer is flowed by a plurality of apertures to form precursor; Described precursor is refined as to fiber; Adsorber particles stream is guided in the middle of described precursor or fiber; Described fiber and adsorber particles are collected to form porous article as nonwoven web; With described porous article is arranged in liquid impermeability housing.

The filtration article of direct forming is also provided, and prepares described goods and use described goods to carry out the method for fluid purification, wherein said goods utilization loads the meltblown fibers web frame of particle.

In one aspect, provide filter cell, it comprises: a plurality of coilings form the porous layer of porous article, and wherein said porous layer comprises self support type non-woven polymeric webs and a plurality of adsorber particles being embedded in described net; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.

Filter cell is provided on the other hand, and it comprises: reel for more than first and form the porous layer of porous article, wherein said porous layer comprises the first net and a plurality of carbon granule being embedded in described the first net of self support type non-woven polypropylene fiber; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.

Another aspect provides the method for filtering fluid, described method comprises makes filter cell and fluid contact, a plurality of porous layers are reeled and are formed porous article, and wherein said porous layer comprises self support type non-woven polymeric webs and a plurality of adsorber particles being embedded in described net; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.

Be the method that forms filter cell on the other hand, described method comprises: molten polymer is flowed by a plurality of apertures to form precursor; Described precursor is refined as to fiber; Adsorber particles stream is guided in the middle of described precursor or fiber; Described fiber and adsorber particles are collected on mandrel to form porous article as nonwoven web; With described porous article is arranged in liquid impermeability housing.

Accompanying drawing explanation

Fig. 1 is the schematic sectional view of porous article;

Fig. 2 is arranged on the sectional view of the porous article in housing;

Fig. 3 is the schematic diagram of housing;

Fig. 4 is arranged on the sectional view of the screw winding porous article in housing;

Fig. 5 is arranged on the sectional view of the stacked disk piece filter in housing;

Fig. 6 loads the schematic diagram of the schematic part of porous article for generation of the particle of direct forming.

Fig. 7 is the schematic diagram of porous article.

Fig. 8 is the sectional view of porous article; And

Fig. 9 is the sectional view of porous article.

Before describing some exemplary embodiments of the present invention, should be appreciated that the present invention is not limited to the details of structure or processing step mentioned in following description.The present invention allows other embodiment, and can implement in every way or carry out.

The specific embodiment

The invention provides liquid purifying filtration article, it adopts the meltblown web (or blowing microfibre (BMF) net) that loads particle to form liquid-treatment unit in conjunction with substrate.These BMF nets that load particles are to make the refinement of polymer meltblown fibers and the air-flow to collector forms by these fiber conveyings by the sorbent material of particle, particle and/or agglomerate or their blend is added to.Along with the particle in fiber contact mixed airflow and be collected and form net, particle is embedded in meltblown fibers matrix.High particle LOADING RATES (being up to for example approximately 97 % by weight) is possible.Sorbent material includes, but is not limited to change the physics of fluid or the material type of chemical property, as absorbing material and sorbing material and have surface-active material.The example of adsorbent can include, but is not limited to granular and powdered active carbon; Ion exchange resin; Exchanging zeolite with metallic ion adsorbent, as Engelhard ' sATS; Activated alumina, as Selecto Scientific ' s Alusil; Antimicrobe compound, for example silver-based material, zinc-base material and halogen radical material; Acid gas adsorbent; Arsenic reducing material; Iodinated resin; And diatomite.

According to the filter medium of the embodiment of the present invention, comprise net (not rolling) and compact/fine and close net (calendering) loading that loads particle.These media show to have low fluid flow resistance, aspect for example gravity current, filtration applications, with respect to commercially available prod, have significant improvement.In the application that requires high flow rate, also there is extra advantage.These opening, porous character that load net can obviously not increase the resistance that flows through filter and housing.Low pressure drop on this whole medium makes to apply for high flow rate (as full family formula is filtered) and can also be for requiring the application of gravity flow filtration.Confirmed to surpass the active carbon LOADING RATES of 90 % by weight.LOADING RATES can be also at least 40,50,60,70 or even 80%.When using thermo-responsive particle as some ion exchange resin, loading netting gear has the extra advantage that is better than into piece technology.Particle can not be exposed to the high temperature seen in piece molding or expressing technique process.This has reduced the misgivings of the thermal instability that relates to particle (ion exchange resin) degraded.Structure open, porous is also an advantage in high sediment situation.The structure of high opening has retained many potential passages for fluid contact particle.In full family formula is filtered, require large sediment particle to be trapped in medium, and allow less sediment particle through medium.This can make medium can not silt up too early and occur too early excessive pressure drops, thereby contributes to increase the service life.

In a detailed embodiment, adsorber particles comprises active carbon, diatomite, ion exchange resin, metal ion exchanged adsorbent, activated alumina, Antimicrobe compound, acid gas adsorbent, arsenic reducing material, iodinated resin or their combination.

In another embodiment, the Gurley time of described net is no more than 2 seconds (or being no more than in other embodiments 1 second or even 0.5 second).Other embodiment provides, and under environmental condition, under the 5.3cm/ even air surface speed of second, the pressure drop of described filter is no more than 150mm water column (or be no more than in other embodiments 75 or 30mm water column even).In certain embodiments, the particle mean size of adsorber particles is no more than 250 μ m (or 200,150,100 or even 60 μ m).A detailed embodiment provides, and the average fill rate of described filter is less than 10 minutes/gallon.

In one embodiment, described net volume is around forming described goods.In another embodiment, described goods are to be formed by a plurality of nets adjacent one another are.A detailed embodiment provides, and the first fleece contains the first adsorbent, and the second fleece contains the second adsorbent.Another embodiment provides, the particle that the first fleece comprises the first particle mean size, and the particle that the second net comprises the second particle mean size.

In yet another embodiment, described net is substantially round core.Described core can comprise charcoal piece.Other embodiment comprises that base net weight range is the net of 10-1000 (or 20-300 or even 25-100) gram/m.In another embodiment, the adsorber particles density of described net is in the scope of 0.200.5g/cc.

In one or more embodiments, polymer fiber comprises polypropylene.In certain embodiments, the polyolefin that polymer fiber comprises metallocene catalysis.In detailed embodiment, polyacrylic polymer melt flow index is in the scope of 30-1500 (or 75-750 or even 200-500).

Another embodiment provides, and described net is compressed by rolling, heat or exerting pressure.Other embodiment comprises the filter cell with adsorbent density gradient.

In one embodiment, by described net volume around to form porous article.In another embodiment, porous article is to be formed by a plurality of nets adjacent one another are.In yet another embodiment, described net is substantially around charcoal piece.

On the other hand, provide and comprised a plurality of filter cells that are attached to mutually disc together, described disc comprises self support type non-woven polypropylene fiber and a plurality of adsorber particles being embedded in described fiber.A detailed embodiment provides, more than first the first adsorber particles that disc comprises active carbon, and more than second the second adsorber particles that disc comprises ion exchange resin.

Aspect more, the method that forms filter cell is provided, described method comprises: molten polymer is flowed by a plurality of apertures to form precursor; Described precursor is refined as to fiber; Adsorber particles stream is guided in the middle of described precursor or fiber; Described fiber and adsorber particles are collected to form porous article as nonwoven web; With described porous article is arranged in liquid impermeability housing.In one embodiment, described method also comprises by calendering, heats or exert pressure to compress described nonwoven web, the compressed web that is no more than 2 seconds to form the Gurley time.On the other hand, described method also comprises a plurality of nonwoven webs that are adjacent to each other attached to form described porous article.Another embodiment provides, and described method also comprises and will after described nonwoven web coiling, more described nonwoven web be placed in housing.Other embodiment comprises the rheological characteristic of controlling fiber.

Also provide directly by collect melting and spraying or liquid purifying filtration article that blowing microfibre (BMF) precursor forms of the particle, particle or the agglomerate that contain adsorbent on rotary footstalk collector.These particles are out and being sent to the process of rotary footstalk collector to be loaded in BMF precursor stream from mould at BMF precursor stream.The adding of sorbent material make it possible to from water source to be purified or fluid supply is removed extra unwanted chemical substance and pollutant.In the process that this processing forms at filter cell, set up from level to level filter diameter.In certain embodiments, filter cell transverse reciprocating moves.

Designed some without any the BMF protofilament of sorbent material, to remove degranulation and sediment from water source of supply.The representative example of this technique is described to some extent in U.S. Patent Application Publication No. 2004/0245171 and 2007/0175819 (Schimmel), and the disclosure of described patent application is incorporated herein by reference.

When BMF net is by the sorbent material of particle, particle and/or agglomerate or their blend being added to when making the refinement of polymer meltblown fibers and these fiber conveyings to the air-flow of collector being formed, along with the particle in fiber contact mixed airflow and be collected and form net, particle is embedded in meltblown fibers matrix.High particle LOADING RATES (up to for example approximately 97 % by weight) is possible.Sorbent material includes, but is not limited to change the physics of fluid or the material type of chemical characteristic, as absorbing material and sorbing material.The example of adsorbent can include, but is not limited to granular and powdered active carbon; Ion exchange resin; Exchanging zeolite with metallic ion adsorbent, as Engelhard ' s ATS; Activated alumina, as Selecto Scientific ' s Alusil; Antimicrobe compound, for example silver-based material, zinc-base material and halogen radical material; Acid gas adsorbent; Arsenic reducing material; And iodinated resin.

The filter cell of direct forming can comprise by melting and spraying precursor, load particle or both adjust the gradient density realizing.In one or more embodiments, to melting and spraying precursor air-flow, regulate to produce various effects.By two or more independent moulds of the lower operation of the target effective fibre diameter from different (EffectiveFiber Diameters, EFD) fibrous airstream is out mixed, can form the precursor Size Distribution of mixing.As U.S. Patent Application Serial 11/461, described in 136, by use mixing blowing or fiber die head (alternatingfiber die tips) alternately, can obtain similar effect, the disclosure of this patent application is incorporated herein by reference.Mixing blow moiding method is also used in and on whole die surface, produces the region with different size fiber or fiber size gradient.Do like this and just can make the structure of each layer of filter adapt to for for example deep filter.Particle, particle, agglomerate, other rules, shape or their mixture irregular or hollow can be added in one or more these precursor streams, and collect on rotary footstalk or protrusive collection footstalk, to form filter cell.

Be to make the operation in the layer separating of two or more moulds on the other hand, rather than there is the precursor air-flow of mixing.Each mould also can parallel operation, when element is rotated on rotary footstalk, produces unique layered effect.In one or more moulds, use different polymer or multicomponent fibre, also can make other change to performance.

Can use protrusive collector footstalk, by particle only being added to particle loader to the target area of net, form in gradient or the filter cell of layering even.This can be by narrow particle loader is combined with to realize with wider mould, or realize by the feed roller with patterning in particle loader.The pothole that feed roller utilization forms through machining is controlled volume feed rate at roller facing in doctor rotation process.By changing the volume of the lip-deep pothole of whole feed roller, can control the local charging of particle, and then control the part of particle in gained net and add weight.

Other method is in particle loader, to use the hopper of segmentation.Particle is only added to the sectional area that you want to carry out feed.This method also makes in each sectional area, to use different particles, so that can use two kinds of particle sizes, or the control that can carry out treated adsorbent or have an adsorbent of property is added.Can change with a plurality of particle loaders quantity or the type of the particle that is loaded on target area.

By using these methods, can form direct forming, customization is for the filter cell of concrete application.For example, can be close to footstalk core and directly form tiny polypropylene fibre internal layer, it contributes to minimizing come off and slough off phenomenon.Can be close to the particle loading net intermediate layer that internal layer is provided for primary separation.In addition, can on intermediate layer, form the skin with desired function, for example, described skin can have larger aperture and serve as extra pre-filtering layer to remove larger pollutant and/or to have larger-diameter fiber before arriving primary separation layer.Those skilled in the art also can propose many other feasible arrangements, and these arrangements are also thought and fallen in scope of the present invention.

In one aspect, provide filter cell, it comprises: a plurality of coilings form the porous layer of porous article, and wherein said porous layer comprises self support type non-woven polymeric webs and a plurality of adsorber particles being embedded in described net; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.In one embodiment, described a plurality of porous layer by consolidation together.In another embodiment, described a plurality of porous layer is discrete composite bed.In a detailed embodiment, adsorber particles comprises active carbon, diatomite, ion exchange resin, metal ion exchanged adsorbent, activated alumina, Antimicrobe compound, acid gas adsorbent, arsenic reducing material, iodinated resin or their combination.

In certain embodiments, described filter cell also comprise by described net around core.Other embodiment provides, and the density range of the adsorber particles of described net is 0.20-0.5g/cc.

In one or more embodiment, described polymer fiber comprises polypropylene.Some embodiment provide, the polyolefin that described polymer fiber comprises metallocene catalysis.In one embodiment, the polyolefin of metallocene catalysis comprises polypropylene.In another embodiment, polyacrylic polymer melt flow index is in the scope of 30-1500.

In one embodiment, more than first layer comprises the polymer fiber with the first effective fiber diameter, and more than second layer comprises the polymer fiber with the second effective fiber diameter.In another embodiment, described polymer fiber comprises the effective fiber diameter of mixing.

In yet another embodiment, described adsorber particles is present in more than first layer with the first density, and is present in more than second layer with the second density.Other embodiment is included, and more than first layer comprises the first adsorbent, and more than second layer comprises the second adsorbent.In more embodiment, more than first layer comprises the particle with the first average grain diameter, and more than second layer comprises the particle with the second average grain diameter.

A detailed embodiment provides, and filter cell has the adsorbent density gradient of axial mode.Another detailed embodiment provides, and filter cell has the adsorbent density gradient of radial mode.

In one embodiment, filter cell also comprises the layer that a plurality of the second nets by self support type non-woven polymer fiber form, and described fiber there is no adsorber particles.

Filter cell is provided on the other hand, and it comprises: reel for more than first and form the porous layer of porous article, wherein said porous layer comprises the first net and a plurality of carbon granule being embedded in described the first fleece of self support type non-woven polypropylene fiber; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid.In one embodiment, described porous article also comprises more than second porous layer, and wherein said porous layer comprises the second net and a plurality of ion exchange resin being embedded in described the second fleece of self support type non-woven polypropylene fiber.

Be the method that forms filter cell on the other hand, described method comprises: molten polymer is flowed by a plurality of apertures to form precursor; Described precursor is refined as to fiber; Adsorber particles stream is guided in the middle of described precursor or fiber; Described fiber and adsorber particles are collected on axle to form porous article as nonwoven web; With described porous article is arranged in liquid impermeability housing.

In one embodiment, described method also comprises more than second layers that form more than first layers that comprise the polymer fiber with the first effective fiber diameter and comprise the polymer fiber with the second effective fiber diameter.Another embodiment provides, and described method also comprises to be provided described adsorber particles more than first layer neutralization and with the second density, provide in more than second layer with the first density.In another embodiment, described method also comprises provides more than first layers with the first adsorbent and more than second layers with the second adsorbent.In yet another embodiment, described method also comprises the rheological characteristic of controlling fiber.

So-called " loading the melt blown media of particle " or " net " comprise that the open structure of fiber (for example microfibre) is wound around agglomerate filter medium, described fiber contains the particle being embedded in the middle of fiber, and described particle is in order to reduce or to remove the adsorbent of the material such as chemical pollutant, chlorine and sediment from water.

So-called " collection embedding " refers to that particle disperses and physically remains in the fiber of described net.Conventionally, between fiber and particle, exist some contact to contact with line, make the almost all surfaces of particle amass all and can supply and fluid interaction.

So-called " adsorbent density gradient " refers to that the amount of every quadrature sorbent material on whole filter needs not to be uniformly, and this amount variable provides more material and provides less material in other regions with some region at filter.For example, the adsorbent density gradient of axial mode means, and along the middle part of filter, between the quantity of sorbent that every quadrature is located in one end of filter and other end place and two ends, amount is everywhere different, but this amount is not changing in the radial direction from middle part.On the other hand, the adsorbent density gradient of radial mode means, and from the middle part of filter, has different quantity of sorbent from the outer surface of the filter core region of comparing.It is linear that the variation of density needs not to be, but can change as required.For example, density can the variation of single step, the mode such as repeatedly step variation, sinusoidal manner variation changes.

So-called " fluid processing unit " or " fluid filter system " comprise the system that contains filter medium with by original fluid (as the untreated water) method separated with the fluid of processing.This generally includes for the filter housings of filter cell with in order to by the fluid of the processing outlet of discharge filter housing in a suitable manner.

These two terms of particle and particle can be used substantially mutually.In general, particle is fritter or single part.Particle belongs to particle or consists of particle.It is separated that the particle using in the embodiment of the present invention can keep, or can conglomeration, physically interweave mutually, on static in conjunction with or otherwise in conjunction with to form particle.In some cases, can form intentionally agglomerate, as U.S. Patent No. 5,332, those agglomerates described in 426 (people such as Tang).

So-called " calendering " comprises makes product (as the net of loadable polymer absorbent) process roller to obtain the process of compression material.Roller can optionally heat.

Term " Gurley time " refers to 124mm (4.88 inches) H ₂50cc air under O pressure is amassed and is approximately 645mm by circular cross section ²net sample institute's time spent of (1 square inch).For making to measure unanimously, maintain the temperature of about 23-24 ℃ (74-76 °F) and 50% relative humidity." Gurley " time can be used W. & L.E.Gurley (Troy, the densitometer of that type of N.Y.) selling with trade name " Model4110 " densitometer is measured, and Gurley-Teledyne sensitivity meter for this densitometer (catalog number (Cat.No.) 4134/4135) is calibrated and operated.The Gurley time is inversely proportional to the voidage that loads the net of particle.The Gurley time is also inversely proportional to the average pore size that loads the net of particle.

Term " melt flow index " or " MFI ", also referred to as " MFR " or " melt flow rate (MFR) ", are to be defined by test method ASTM 1238.Polyacrylic polymer is measured with ASTM 1238 test methods " method B " version.

Term " melt-blown process " refers to that the mould by thermoplastic polymer is extruded through being comprised of one or more holes prepares fiber fines.Along with fiber from mould out, they are by air stream refinement, described air stream almost flows abreast with fiber out, or flows with fiber tangentially out.

Term " voidage " refers to the percentage calculating like this: measure the weight and volume of filter, then this filter weight is compared with the theoretical weight of the solid integral body of the same composition material of this same volume.

Term " thermal degradation " refers to the effect of heat to material.For example, some adsorber particles that forms block compound or load net, in the processing procedure of for example sintering or calendering, may be easy to become physically unstable.For the polymer such as polypropylene, with the independent processing of heat or the processing polymer that combines with mechanism, can cause polymer chain break, crosslinked and/or chemical change.

Term " control degradation " comprise by controlled method reduce polymer molecular weight and the molecular weight distribution of polymer is narrowed, for example, by specific heat and/or shear input rate, or by introduce energy decomposing copolymer chain and because of the quantity with polymer proportional can be in degradation reaction used up material.

Term " porosity " is measuring of void space in material.The size in hole and space, frequency, quantity and/or interconnecting property all have contribution to the porosity of material.

Term " control rheological characteristic " may be defined as and uses radiation, peroxide or other free radical agents, to adjust the rheological properties (as viscosity and molecular weight distribution) of some polyolefin (as polypropylene) by degraded.

Term " densified " refers to such process, by this process, directly or indirectly be placed on the fiber compressed (before or after described placement) on filter winding mandrels or footstalk, and be prepared to and form all sidedly or partly the region compared with low-porosity, be no matter to form by designing, or the typical product of processing technique in forming or established filter as certain form.Densified also comprising the process of net calendering.

particle loading process

Particle loading process is the additional process of the common disclosed standard meltblown fibers of U.S. Patent Publication No. 2006/0096911 (incorporated herein by reference) manufacturing process of transferring the possession of for example.Blowing microfibre (BMF) is that fluid is distributed in mold cavity on whole die width, and polymer is flowed out and becomes precursor from mould by a series of aperture by entering and flowing through the melt polymerization deposits yields of mould.In one embodiment, flow through air manifold and the contiguous air knife assembly that forms a series of polymer aperture of mould outlet (die head) of the air stream of heating.Can flow to trip temperature and speed to this heated air and regulate, with by polymer precursor refinement (drawing-down) to required fibre diameter.BMF fiber is sent to surface of revolution in this turbulent air flow, and they form net at this surface aggregation.

The required particle (as adsorber particles) of for example activated carbon particles or ion-exchange resin bead grain and so on is loaded in particle hopper, and in hopper, particle can be filled into the pothole in material roller quantitatively.With the rigidity of segmentation adjustment region or semi-rigid doctor with respect to feed roller formation control gap, to limit the outflow of hopper.Doctor is adjusted to the surface of contact feed roller conventionally, so that grain flow is defined as the pothole volume of feed roller.Then can control feed rate by adjusting feed roller velocity of rotation.After feed roller, there is brush roll in running, to remove any residual particles from pothole.Particle falls into the chamber of available compressed air or the pressurization of other pressure gas source.This chamber is designed to produce an air stream, and this air stream can transmit particle and cause particle and mixed from air stream refinement out of meltblown die and the meltblown fibers of transmission.

By adjusting the pressure in forced ventilation grain flow, the VELOCITY DISTRIBUTION of particle is changed.When using low-down particle rapidity, particle can be turned to by mould air stream and not mix with fiber.Under low particle rapidity, particle is only trapped on the top surface of net.Along with the increase of particle rapidity, particle starts to mix with the fiber melting and spraying in air stream more up hill and dale, can in the net of collecting, form uniformly and distribute.Along with particle rapidity continues to increase, particle partly passes and melts and sprays air stream, and is trapped in the bottom of the net of collection.Under higher particle rapidity, particle can pass completely through and melts and sprays air stream and be not trapped in the net of collection.

In another embodiment, by use two substantially vertical, be in tilted layout to the collector projection mould of relative precursor stream roughly, particle is mixed between two precursor air streams.Meanwhile, adsorber particles enters the first skewed slot by hopper.Particle is entered in precursor stream by gravity supply.The mixture of particle and fiber drops on collector, and forms the nonwoven web of the non-woven loading particle of self support type.

In other embodiments, by oscillating feeder, injector or other technologies well known by persons skilled in the art, provide particle.

In many application, particle need to be evenly distributed in whole net substantially.Situation about also having is that non-uniform Distribution is favourable.Gradient along the depth direction of netting can make pore-size distribution change, and this can be used for depth-type filtration.The net that surface can be loaded with to particle forms filter, and in this filter, fluid is early exposed to particle in fluid passage, and the remainder of net provides carrier structure and the means that prevent that particle from coming off.Also fluid passage can be reversed, make meltblown web can serve as prefilter, to remove some pollutants before the active surface at fluid arrival particle.

In yet another embodiment, collector also comprises cylinder coiling mechanism (cartridge windingmechanism), its effect is that each single filter is formed on winding mandrels or on hinged cantilever axle, described hinged cantilever axle is equipped with certain filter cylinder withdrawing device, and this device is designed to substantially continuously the filter cylinder of formation be pulled out/released from rotating shaft.

polymer rheology is controlled

Controlling rheological characteristic for the polymer of meltblown fibers can make net be customized to have desirable characteristics.The common U.S. Patent Application Publication No. 2004/0245171 and 2007/0175819 (Schimmel) of transferring the possession of (incorporated herein by reference in full) is discussed to some extent to this.For example, adjust the intensity that (for example) polyacrylic viscosity can increase net.The fiber of height-fiber bonds and expects, making filter can be useful shape by machine shape, as the cylinder with groove, keeps good flow behavior and high voidage simultaneously.

For polypropylene, control and take the degraded of the pp material that low MFI (HMW) be feature and can cause producing and have for making the modified polypropene of the ideal characterisitics of particle loading meltblown web.

In one embodiment, utilize control degradation to provide to show and have approximately 30 to approximately 1500 the material of the melt flow index of (or in other embodiments, be 75 to 750, or even 200 to 500), thereby can make net with polyacrylic polymer.

In another exemplary embodiment of the present invention, in order to produce the polyacrylic polymer that shows the melt flow index with approximately 35 to approximately 350, carry out as follows control degradation: pass through mode of heating, use or do not use simultaneously oxygen, by radiation, or by the effect of one or more free radicals that produced when being heated in plurality of reagents (as peroxide).Therefore,, by the control degradation of polymer, realized the favourable modification to polyacrylic rheological characteristic and physical characteristic.

Referring to Fig. 1, schematically show the cross section of porous article 10.Goods 10 have length and the width of thickness T and any required size.Goods 10 are the polymer fiber 12 that contains winding and the nonwoven web that is embedded in the adsorber particles 14 in net.Little connection hole (not shown in figure 1) in goods 10 makes water or other fluids can pass the gauge of (for example flowing through) goods 10.14 pairs of fluids that pass of particle are modified, for example absorption and sorption or otherwise modify pollutant and the particle existing in this fluid.

Fig. 2 is the sectional view that the housing 20 of filter cell is housed, and this filter cell comprises the porous web goods 24 that are arranged on multi-hole center 22.End cap 26 for example, is fixed to net 24 (not shown) with () adhesive.The entrance 28 of housing 20 is by fluid as water guiding net 24, and in net, fluid contact is embedded in adsorber particles in net and processed.The fluid of processing flows to the groove 27 that core 22 limits.Right reprocessed fluid flows out from housing by going out 29.

Fig. 3 shows the schematic diagram of the housing 30 with entrance 38 and outlet 39.This housing is applicable to the filter cell that the present invention comprises.

Fig. 4 shows the sectional view of the housing that filter cell is housed 40 with wall 41, and described filter cell comprises the screw winding porous web goods 44 with groove 47.End cap 46 for example, is fixed to net 44 (not shown) with () adhesive.Fluid enters net 44 as water, and touches the adsorber particles that is embedded in net and processed.The fluid of processing flows to the groove 47 that core 22 limits.

Fig. 5 shows the sectional view of the stacked disc 54 of Web materials that is arranged in housing 50, and described housing has the entrance 58 that arrives disc.The stacked disc 54 of fluid contact, reservoir 59 is the fluid of collection and treatment.

Referring to Fig. 6, provide the schematic diagram of example components that loads the system of porous article for generation of the particle of direct forming.Show collector assembly 114, it comprises the rotation footstalk 122 with inner 124, and this rotation footstalk is rotatably installed in a usual manner by the bearing (not shown) on bearing.Footstalk 122 also has open distal end 116, inner surface 120 and outer peripheral surface 126.Meltblown die 112 is transported to collector assembly 114 for the web frame that forms direct forming by non-woven particle load fibers 110,110a, 110b, 110c, 110d and 110e.

In Fig. 7 and 8, show respectively schematic diagram and the sectional view of the porous article 130 being formed by each layer 138 that comprises the nonwoven web 132 of particle 134.Pending fluid enters each layer 138, and the fluid of processing flows through groove 136.In this embodiment, goods particle density is everywhere substantially the same.Another sectional view that porous article is provided in Fig. 9, wherein shows particle density gradient.In section 142, the population ratio region more than 144 of per unit area, the latter has more per unit area population than section 146 again.

Except as otherwise noted, otherwise the numeral of the quantity of all expression compositions that use in description and claims, characteristic (as molecular weight), reaction condition etc. is all interpreted as all by term " about ", being modified in all cases.Therefore, unless the contrary indication, otherwise the digital parameters providing in following description and appended claims is approximation, desirable characteristics that can the acquisition of pursuing according to the present invention and becoming.Show no sign of the meaning of the scope that the application restric-tion of doctrine of equivalents is protected in claim, at least should explain each numerical parameter according to the number of reported significant digit and by the usual technology of rounding off.

Although number range and the parameter of setting forth broad scope of the present invention are approximations, numerical value listed in specific embodiment is as far as possible accurately reported.But any numerical value all contains some inevitable existing standard deviation in its experimental measurement separately and the error that causes inherently.

example

example 1

Carried out a series of screening experiment, to characterize the performance that loads meltblown web for the particle of desalt application.Used the base resin of two types: 350MFI polypropylene, with trade name Type3960, sell (can derive from Total Petrochemicals) and 80MFI metallocene catalysis polypropylene, with trade name Vistamaxx 2125, sell (can derive from ExxonMobil).Assessed the activated coco nut charcoal of several grain size categories, these active carbons are sold (can derive from PICA) with trade name NC506.For specific test, also comprised extra example net, these nets have been used: with trade name Nuchar Aquaguard sell (can derive from Mead Westvaco) wooden base charcoal, with trade name ATC N60260 sell (can derive from Calgon) the palm shell charcoal with titanium silicate coating, with trade name YPC 100MD, sell the palm shell charcoal of (can derive from Kuraray) and with trade name DowexHCR-S, sell the cationic ion-exchange resin of (can derive from Dow Chemical).

Collect under the following conditions the short code winding article (short yardage roll) of about 10 inches of (25.4cm) wide loading nets.By polymer-extruded 10 inches (25.4cm) the wide hole drilling die (DOD) that passes, for polypropylene base net extruded velocity, be 8lb/hr (3.6kg/hr), for metallocene catalysis polypropylene base net, be 6.5lb/hr (3.0kg/hr).Mould is 12 inches (31.0cm) to the distance of collector.With target basis weight, collect the sample of base net (not loading particle), according to Davies, C.N., " The Separation of Airborne Dust and Particles; " Institution of Mechanical Engineers, London Proceedings 1B, the method proposing in 1952 assessment effective fiber diameter (EFD).Regulate air themperature and speed to reach target effective fibre diameter.To each sample record melt temperature.

Regulate base net condition to reach after target basis weight and effective fiber diameter, particle is added to particle loader hopper, adjust feed roller speed to send the adsorbent (charcoal or ion exchange resin) of required heap(ed) capacity.Enter the air pressure settings of particle loader chamber between 0.5 to 2psig (being respectively 3.4kPa and 13.8kPa).Regulate setting value to be uniformly distributed in net to realize particle.Basic weight is with gram/m (gsm) report.Base net refers to the weight of every square metre of meltblown fiber web (not loading).Load net and refer to every square metre of weight that has loaded the meltblown fiber web of insulating particles.

table 1

Sample	Medium granularity	Polymer	Melt temperature ℃	Effective fiber diameter (micron)	The basic weight (gsm) of base net/loading net
						1	Palm shell charcoal 20 * 50	Metallocene polypropylene	261	18.8	50/564
2	Palm shell charcoal 20 * 50	Metallocene polypropylene	260	18.8	50/390
						3	Palm shell charcoal 60 * 100	Metallocene polypropylene	261	18.8	50/527
4	Palm shell charcoal 60 * 100	Metallocene polypropylene	261	18.8	50/400
						5	Palm shell charcoal 60 * 140	Polypropylene	310	8.7	52/360
6	Palm shell charcoal 60 * 140	Polypropylene	310	8.7	52/525
						7	Palm shell charcoal 60 * 140	Polypropylene	267	12.9	47/532
8	Palm shell charcoal 60 * 140	Polypropylene	265	12.9	47/365
						9	Palm shell charcoal 60 * 140	Polypropylene	238	17.9	51/354
10	Palm shell charcoal 60 * 140	Polypropylene	238	17.9	51/558
						11	Palm shell charcoal 60 * 140	Metallocene polypropylene	267	15.4	54/562
12	Palm shell charcoal 60 * 140	Metallocene polypropylene	267	15.4	54/363
						13	Palm shell charcoal 80 * 325	Polypropylene	310	8.7	52/361
14	Palm shell charcoal 80 * 325	Polypropylene	310	8.7	52/568
						15	Palm shell charcoal 80 * 325	Polypropylene	266	12.9	47/367
16	Palm shell charcoal 80 * 325	Polypropylene	239	17.9	51/325
						17	Palm shell charcoal 80 * 325	Metallocene polypropylene	267	15.4	54/521
18	Palm shell charcoal 80 * 325	Metallocene polypropylene	266	15.4	54/361
						19	Palm shell charcoal 60 * 100	Metallocene polypropylene	*	14.4	52/509

20	Palm shell charcoal 60 * 140	Metallocene polypropylene	*	14.4	52/475
						21	Palm shell charcoal 50 * 200	Metallocene polypropylene	*	14.4	52/460
22	Palm shell charcoal 60 * 140	Polypropylene	*	8.7	52/565
						23	Palm shell charcoal 50 * 200	Polypropylene	*	8.7	52/570
24	Palm shell charcoal 80 * 325	Polypropylene	*	8.7	52/425
						25	Palm shell charcoal band titanium silicate coating 20 * 50	Metallocene polypropylene	265	19.3	50/550
26	Wood base charcoal 80 * 325	Metallocene polypropylene	265	19.3	53/580
						27	Palm shell charcoal 80 * 200	Metallocene polypropylene	265	19.3	53/560
28	Cationic ion-exchange resin	Metallocene polypropylene	263	16.2	52/530

^*estimate 265 ℃.

example 2

Select some net of example 1 to assess the impact of calendering on performance.Used the adjustable calender in gap between polished chrome steel rider.To the calendering pressure of sample, be 60psi (414kPa), the speed of roller is 5 feet per minute clocks (1.5 ms/min).The diameter of roller is 10 inches (25.4cm), has 22 inches of roll surfaces that (56cm) is wide.Every roller is when being filled with heavily approximately 600 pounds (272kg) when controlling temperature oily by Sterlco system.Use the cylinder of internal diameter 5 inches (13cm) to apply nip pressure.

Air-pressure drop to the net through calendering and corresponding input net sample in measurement particle loading net.Air-pressure drop be under room temperature (about 22 ℃) under an atmospheric pressure (101kPa) environmental pressure, with the Air Flow uniform surface speed of 5.3cm/ second, measure.

table 2

Sample	Input net	Calender temperature °F (℃)	Calender gap mil (mm)	Original dimension mil (mm)	Final size mil (mm)	Final basic weight gsm	Air-pressure drop mm H ₂O
								29	3	150(66)	40(1.0)	97.6(2.5)	50.0(1.3)	--	--
30	3	150(66)	29(0.74)	97.6(2.5)	44.0(1.1)	429	3.17
								31	3	150(66)	17(0.43)	97.6(2.5)	30.0(0.8)	--	--

32	3	150(66)	12(0.31)	97.6(2.5)	28.0(0.7)	428	14.00
								33	6	150(66)	29(0.74)	151.0(3.8)	64.0(1.6)	535	7.30
34	14	150(66)	29(0.74)	133.0(3.4)	55.0(1.4)	541	30.20
								35	3	175(79)	29(0.74)	97.6(2.5)	45.0(1.1)	452	3.21
36	3	200(93)	29(0.74)	97.6(2.5)	40.0(1.0)	388	2.10
								37	14	200(93)	29(0.74)	133.0(3.4)	46.0(1.2)	526	24.70
38	20	175(79)	29(0.74)	99.0(2.5)	44.2(1.1)	429	3.55
								39	20	175(79)	12(0.31)	99.0(2.5)	33.1(0.8)	396	15.55
40	24	175(79)	29(0.74)	103.0(2.6)	47.2(1.2)	411	10.03
								41	25	175(79)	29(0.74)	117.0(3.0)	52.5(1.3)	495	1.33
42	26	175(79)	29(0.74)	167.5(4.3)	77.5(2.0)	513	28.05
								43	26	175(79)	12(0.31)	167.5(4.3)	70.5(1.8)	481	25.71
44	27	175(79)	29(0.74)	105.0(2.7)	49.0(1.2)	474	6.12
								45	27	175(79)	12(0.31)	105.0(2.7)	34.0(0.9)	395	16.90
3	3	Untreated	--	97.6(2.5)	97.6(2.5)	506	0.82
								6	6	Untreated	--	151.0(3.8)	151.0(3.8)	580	1.99
14	14	Untreated	--	133.0(3.4)	133.0(3.4)	550	3.58
								20	20	Untreated	--	99.0(2.5)	99.0(2.5)	475	1.07
24	24	Untreated	--	103.0(2.6)	103.0(2.6)	425	2.79
								25	25	Untreated	--	117.0(3.0)	117.0(3.0)	618	0.49
26	26	Untreated	--	167.5(4.3)	167.5(4.3)	570	3.90
								27	27	Untreated	--	105.0(2.7)	105.0(2.7)	569	1.91

Net does not stick on stack under evaluation condition.Net does not increase overall width and may not increase length, especially under higher temperature.With without calendering net compare, improved reticular density.The basic weight that has comprised net, to illustrate the change in size after calendering.

example 3

As follows some samples of example 1 and 2 are assembled into filter.For each sample, from the gained weight of one section of net of about 8 inches of (20cm) W * 12 of size inch (30.5cm), calculate the length that obtains the required net of the filter that contains about 100 grams of media.Obtain the rigidity tube core that size is approximately 1.45 inches of (3.7cm) external diameters and 13.9 inches of (35.3cm) length.On this pipe, there are a plurality of about 0.15 inch of opening that (0.38cm) is square.From 10 inches of (25cm) sample volumes of full duration-nominal, cut the length of the net of the 100 grams of media of transmissibility that calculate.It is about 100 grams that the long net (depending on load condition) of about 3-4 foot (91cm-122cm) causes heap(ed) capacity when being cut into 8 inches of (20cm) length.This net is pasted to the external diameter of this pipe.This net is coiled to suitable length around this pipe.The edge, outside of this net is pasted to the internal layer of this net.This pipe is at one end gone up to the visible good place loading to be cut.The cutting other end is to produce the filter of length about 8 inches (20.3cm).By the two end cap upper end cover of filter.

Filter mean outside diameter is 2.7 inches (6.9cm).The scope of external diameter is at 2.41 inches-2.88 inches (6.1cm-7.3cm).This external diameter causes average medium to be loaded as 106 grams, and scope is at 99-114 gram.Use is 0.20g/cc without the active medium averag density of the net base filter of the net of calendering.

The calendering that charcoal loads net causes finer and close filtration device structure.As a result, the use of calendering net has reduced the volume of the required material of filter, makes to use small filter size.Use the density of the filter that rolls net in the scope of 0.37g/cc to 0.50g/cc.The high density (sample 4) of calendering net causes the active medium of 0.45g/cc.

example 4

test

According to performance test, some filters that form according to example 3 are assessed, comprised initial flush turbidity, clean pressure drop, chlorine minimizing, particle minimizing, gram life test and Gurley value.

For initial flush turbidity, filter is connected to urban water supply, collect and flow through just water of filter.The method is the comparison of the light intensity of light intensity based on sample scattering under definite condition and criterion referenced scattering under the same conditions.The scattered light of higher amount represents that in water, turbidity level is higher.Data are with nephelometric turbidity unit or NTU report.Level lower than 0.5NTU meets NSF/ANSI drinking water standard.Collect the first up-flow and go out current.Measure and record turbidity.Then allow sample flow with 0.75gpm (2.8 liters/min), when 1 gallon (3.8 liters), 5 gallons (19 liters) and 10 gallons (38 liters), collect extra sample, at each sample point, measure turbidity.Comprised and contrasted 1 and contrast 2 data, contrasting 1 is the activated carbon composite piece with the formula of 55% activated carbon media and 45% polymeric binder, and contrasting 2 is the carbon filters that form from granular active carbon (GAC).

table 3

Sample	First liter (NTU)	1 gallon (NTU)	5 gallons (NTU)	10 gallons (NTU)
					Contrast 1	4.68	--	--	--
Contrast 2	124.5	--	--	--
					1	25.7	1.47	0.2	0.12
2	12.2	1.64	0.18	0.12
					3	32.8	3.15	0.3	0.15
4	1.28	0.13	0.11	0.18
					5	16.9	2.8	0.68	0.16

6	25.1	2.66	1	0.3
					7	5.92	1.22	0.33	0.23
8	8.21	2.66	0.69	0.42
					9	21.6	1.24	0.43	0.67
10	19.5	5.62	1.67	0.59
					11	19.5	3.79	0.55	0.17
12	10.9	0.34	0.31	0.35
					13	47.1	5.96	1.07	0.44
14	83.4	21.5	5.92	1.8
					15	136	15.6	2.13	0.98
16	250	17.5	3.24	1.23
					17	56.3	10.1	2.12	0.36
18	34.1	1.46	0.56	0.23
					30	43.3	0.71	0.41	0.19
32	47.7	1.04	0.34	0.47
					33	59	4.44	0.37	0.21
34	22.4	3.32	0.57	0.18
					35	20.6	0.51	0.15	0.3
36	25.4	0.47	0.31	0.61
					37	45.2	6.71	1.72	0.13

Referring to table 3, load the net charcoal particulate that comes off in the flow process of initial 0-5 gallon.The net trapping situation of larger carbon granule is better than less particle.Between 1 gallon to 5 gallons, particulate looks minimizing.The amount of coming off is less than the GAC axial flow filter (except sample 15 and 16) of standard; Even if the particle for 80 * 325 order sizes is also like this.

Calendering does not increase initial flush turbidity.In addition, calendering looks and has reduced initial turbidity, particularly for 80 * 325 charcoals.

For clean pressure drop, filter is connected to urban water supply, the Pressure gauge through calibrating is immediately before system.Filter in the exit of system to atmosphere opening.Municipal water is carried by measuring the rotometer of flow velocity with the required speed of 0.25,0.50,0.75,1.0,2.0,3.0 and 4.0 gallon per minute, and described speed corresponds respectively to 0.9,1.9,2.8,3.8,7.6,11.4,15.1 liter/min.Under different in flow rate, assessment has and does not have the pressure drop of the system of medium.The system banner that there is no medium is contrast 3.

table 4

Sample number into spectrum	0.25 gpm psi	0.50 gpm psi	0.75 gpm Psi	1.0 gpm psi	2.0 gpm psi	3.0 gpm psi	4.0 gpm psi
								Contrast 3	0	0	2	3	14	31	56
1	0	0.5	1	3	15	30	53
								2	0	1	1	2	14	31	56
3	1	1	2	4	18	33	58
								4	1	1	--	4	18	30	58
5	0	0	2	3	13	30	56
								6	0	0	1	3	15	32	57
7	0	1	2	4	15	32	56
								8	0	1	2	3	14	32	54
9	0	1	2	3	16	31	56
								10	0	1	2	4	16	32	57
11	0	1	2	3	16	31	56
								12	0	0	2	3	15	32	58
13	0	0	--	3	15	25	57
								14	0	0	1	2	14	31	55
15	0	1	2	4	15	31	58
								16	0	0	1	4	14	32	57
17	0	0	2	4	16	32	56
								18	0	1	2	4	15	31	56
30	0	0	2	3	14	32	57
								32	0	1	2.5	4	16	34	61
33	0	0.5	2	4	17	33	60
								34	0	1	3	5	17	35	60
35	1	1	3	4.5	16	31	58
								36	0	1	3	5	16	33	58
37	0	1	3	5	17	37	62

With reference to table 4, in all cases, system adds that the observation pressure drop that loads web filter is in the 6psi (41.4kPa) of system pressure drop of system and storage tank (having/do not install filter).Web filter does not have considerable contribution to overall presure drop.In this process of the test, do not observe the impaired sign of filter.

The filter staying from pressure drop test, shift out and do not roll sample 17 net media.The size of the particle staying after high-potting with scanning electron microscopy measurement.This filter demonstration has retained 60-65 micron size and larger particle.Net is rolled, uses thinner fibre diameter or other technology that can reduce clearance space or can form adhesion or bond between particle and fiber, should be able to increase the reservation to more tiny particle.

For NSF/ANSI 42 chlorine, reduce test, with containing the water of specifying pH, turbidity, total organic charcoal and the water hardness, (challenge) concentration is attacked in inflow with 2.0mg/L free available chlorine (FAC), under the flow velocity of 0.8 gallon per minute (3.024L/ minute), filter is attacked.For reaching chlorine, reduce requirement, filter must meet maximum 1.0mg/L free available chlorine in minimum 50% minimizing or effluent.The contrast piece that is called " contrasting 4 " is the charcoal piece that is of a size of the polyethylene binder of 6.395 inches of (16.2cm) length of length, external diameter 1.5 inches of (3.8cm), internal diameter 0.375 inch (0.95cm) and 80 * 325 PICA NC506 charcoals that contain 60 % by weight and 40%, as US 7, described in 112,272 (people such as Hughes).End cap is directly bonded to the open end of this charcoal piece.Reduce percentage reports in table 5.

table 5

Sample number into spectrum	After 1 gallon, % reduces	1000 gallons of % reduce	2000 gallons of % reduce	3000 gallons of % reduce	4000 gallons of % reduce	5000 gallons of % reduce
							Contrast 4	99.3	96.3	86.2	73.5	70.1	63.9
20	99.0	95.4	94.1	91.0	87.7	86.1
							22	99.0	97.5	96.5	95.0	93.9	94.4
24	99.3	99.1	99.0	97.6	97.2	96.8
							25	41.0	38.8	31.0	27.1	32.9	28.2
38	99.0	95.5	92.4	88.1	85.6	84.1
							39	99.3	94.9	91.3	87.8	88.3	78.2
40	99.3	99.1	96.9	95.1	94.9	93.0
							41	55.1	38.9	33.5	28.7	34.7	29.6
44	99.4	98.9	99.0	93.9	94.8	86.5
							45	99.4	97.8	96.5	92.5	91.9	86.1

With reference to table 5, because filter sample is the medium preparation with fixed mass, in chlorine minimizing test, roll sample and obtain similar result without rolling between sample.

For NSF/ANSI 42 particles, reduce test, use the online corpuscular counter of III class test use, with approximately 1,000, concentration is attacked in the inflow of 000 particle, under the initial flow rate of approximately 2.5 gallon per minute (9.5L/ minute), filter is attacked.According to NSF/ANSI 42 standards, system is when testing to accept specifically to grade according to this standard, and the quantity that should reduce the particle in test particle magnitude range reaches at least 85%.The grading of system should be with in the same size by the measured smallest particles of effectively being removed of this test.If claim larger minimizing percentage, should be confirmed by test.Also to contrasting 4, test.

table 6

Sample

The grading of class grading/micron

The first circulation is flowed out

The 4th circulation is flowed out

25% reduces outflow

50% reduces outflow

75% reduces outflow

Average % reduces

Contrast 4

III 5-15

＞85

--

96.2

＞99.8

＞99.9

96.2

39

III 5-15

＞97.3

78.6

79.7

25.0

＞97.1

61.1

40

III 5-15

99.7

＞99.5

＞98.9

＞99.3

＞99.8

99.8

With reference to table 6, calendering sample 39 is compared with contrast charcoal piece with 40 and is demonstrated improved particle and remove situation.

For a gram life test, the fixed concentration that filter is exposed to AC crude test dust is the aqueous solution of 1 gram of test dust/gallon.Terminal reaches 20psi (6.9kPa) by the change in pressure drop on whole medium and determines.Report reaches the gallonage that definite terminal will see through filter.Gram life-span is higher, shows with the service life of this test dust measurement longer.Also to contrasting 4, test.

table 7

Sample	In gram life-span of gallon (liter) number
		Contrast 4	25(95)
Contrast 4 (repetitions)	180(681)
		20	＞1000(＞3785)
38	150(568)
		39	55(208)
24	500(1893)
		40	130(492)

With reference to table 7, without the

sample

20 and 24 of calendering, demonstrate the highest gram lifetime results, for contrast 2.5 times of piece above until 40 times more than.

For Gurley value, test, as US 5,328, described in 758 (Markell), use the 50cc air of GurleyModel 4110 densimeter measurements under 124mm water pressure required time of net sample through area about 645 square millimeters (1 square inches) under room temperature (about 23 ℃).The sample providing in table 4 has represented a series of pressure drops shown in table 2.

table 8

Sample	Gurley value second
		44	＜0.2
45	0.30
		42	0.40
27	＜0.2
		26	＜0.2

With reference to table 8, for each filter that uses calendering net and net without calendering, Gurley value was less than for 1 second.

example 5

To be assembled into as follows filter according to the net of the sample 20 of example 1 (loading the net of coconut palm base charcoal) and 26 (loading the net of cationic ion-exchange resin).Bonding by the 100mm diameter disc that loads net medium is carried out with adhesive method along the internal edge of plastic hoop with the external diameter 100mm of 94mm internal diameter opening, prepare these test specimens.By the thin bead of hotmelt be added to load net medium 100mm diameter disc around.Another 100mm disc is directly layered in to the top (use binding agent) of front one deck.Repeat this lamination process and reach seven layers of charcoals loading net, the ion-exchange of following stacked target loads net, and then stacked 3 layers of charcoal load net.Another plastic hoop is bonded to the top that medium stacks with bonding mode.Use the laminate filter that loads net to assemble by table 9.

table 9

Sample	Charcoal stratum reticulare number	Charcoal net grams	Ion-exchange stratum reticulare number	Ion-exchange net grams	Total media grams
						46	10	56.55	2	12.16	68.71
47	10	56.01	3	20.49	76.50
						48	10	55.13	4	27.35	82.48

example 6

test

The filter of example 5 is carried out to the assessment that TTHM reduces and gravity current is crossed speed.

For NSF/ANSI 53 TTHM, reduce test, as follows the TTHMs of filter or TTHM minimizing are evaluated: first, by the suitable NSF/ANSI universal test water of 5 gallons (18.9 liters) is poured into through filter, filter is nursed one's health.With chloroform, flow into attack water 450+/-90ppb tests filter under gravity flox condition.Below the data of report are to adopt the condition of seeing through (gravity flows) of pouring into as described in ANSI 53 standards to collect.

table 10

With reference to table 10, the maximum of the 80ppb chloroform based on allowed flows out concentration, and

sample

46 and 47 meets respectively NSF 53 TTHM standards for 60 gallons (227 liters) and 70 gallons (265 liters).The result that these TTHM remove shows, to process gallonage/gram charcoal, gravity filtration has improvement.The Brita OB01/OB03 Classic type water pot of contrast requires the active medium of about 150 grams just can reach 80 gallons of the minimums (303 liters) of test.This is to compare with the sample 46 that contains 68-77 gram of active medium and 47.In addition,

sample

46 and 47 velocity ratio Brita product are fast about 4 times.

For gravity current, cross speed, measured per gallon solution through the required Delta Time of example 5 filters.

table 11

	Gallon 1 (min)	Gallon 2 (min)	Gallon 3 (min)	Gallon 4 (min)	Gallon 5 (min)	Gallon 10 (min)	Gallon 20 (min)	Gallon 30 (min)	Gallon 40 (min)	On average fill with the time (min)
											46	7.08	6.00	6.55	6.17	6.15	6.30	6.08	6.23	6.28	6.32
48	8.70	7.42	7.27	7.40	7.35	8.25	8.85	11.08	9.40	8.41

For comparing object, Brita OB01/OB03 Classic it was reported that common needs come by 0.5 gallon (1.9 liters) for 15 minutes.PUR Ultimate water pot filter it was reported that need within approximately 15 minutes, could filter enough water is full of 8-10 cup OK a karaoke club Kraft bottle (carafe).

example 7

Some samples of example 1 and 2 are assembled into filter as follows.By U.S. Patent No. 7,112, the method described in 272 (people such as Hughes), preparation size is 8 " L * 1.125 " external diameter * 0.7 " charcoal piece of internal diameter.This charcoal piece consist of 20%Aquaguard 80 * 325 active carbons and 80% polyethylene binder.PARTICLE is loaded to net materials coiling charcoal piece, until the external diameter of the structure of gained is about 3 inches (7.6cm).These 8 inches of (20cm) parts are cut into the final lengths of 5 inches (13cm), for test objective.End cap is bonded to the two ends of this composite construction with adhesive method.

The contrast product that is called " contrasting 5 " contains 70% active medium and 30% polymeric binder.End cap is directly bonded to the two ends of this charcoal piece.

example 8

test

According to NSF/ANSI 42 chloramines, reduce test, the filter forming is carried out to the assessment of chloramines minimizing according to example 7.According to the maximum of this standard, flowing out concentration is 0.5ppm.Also to contrasting 5, test.

table 12

With reference to table 12, through the sample 42 of calendering, compare with contrast 5 with 43, can allow the test(ing) liquid that surpasses doubling dose to see through filter, keep below 0.5ppm chloramines simultaneously.

example 9

With meltblown web, form the cylinder filter of direct forming.The metallocene catalysis polypropylene of selling (can derive from ExxonMobil) with trade name Vistamaxx 2125 is extruded through to 10 inches (2.5cm) wide hole drilling die (DOD) with the speed of 6.5lb/hr (2.9kg/hr).For all samples, melt temperature is approximately 265 ℃.Mould is 12 inches (30.5cm) to the distance of collector.Collect and characterize base net sample (not loading particle), so that condition is witnessed.The basic weight of base net is 53gsm.Thickness is 0.014 inch (0.355mm).At room temperature (about 22 ℃), under an atmospheric environmental pressure, air-flow is used the 5.3cm/ uniform surface speed of second, measures 0.55mm H ₂the pressure drop of O.According to Davies, C.N., " The Separation of Airborne Dust andParticles; " Institution of Mechanical Engineers, LondonProceedings 1B, the method proposing in 1952, these conditions are corresponding to the effective fiber diameter (EFD) of 19 microns.

Reached after target effective fibre diameter, particle is added to particle loader hopper, feed roller speed is adjusted into the coconut palm matrix activated carbon 60 * 140 (can trade name PicaNC506 sell) of about 90 % by weight of transmissibility.The air pressure settings that enters particle loader hopper is about 2.5psig, so that particle is uniformly distributed in net.

After having verified condition, by load particle melt and spray or blowing microfibre (BMF) precursor is collected on the rigid pipe that approximate size is 1.45 inches of (3.7cm) external diameters and 13.9 inches of (35.2cm) length.On this pipe, there are a plurality of about 0.15 inch of opening that (0.38cm) is square.This root pipe is arranged on axle, in position by two rubber brakes that slide along axle.This root axle is arranged in the chuck with the speed change hammer drill of the maximum set value operation of 850rpm.Paired spacer (spacer) extends 4 inches (10cm) from collector surface, so that the distance reproduced from mould to footstalk to be provided.Along with sample is collected, footstalk axle can keep lightly against (on arbitrary end of pipe) these spacers.Allow pipe and axle reach omnidistance rotary speed, then enter that particle loading melts and sprays or blowing microfibre (BMF) precursor air stream in.Change acquisition time, to regulate the particle being collected on pipe to load the weight of precursor.Core has the weight of 37g in total length sample.In the weight of collecting each core of fore-and-aft survey, to consider loading to footstalk and particle the variation that precursor air streams contact is relevant.

table 13

example 10

test

According to performance test, the filter that some are formed according to example 9 is assessed, and comprises that initial flush turbidity, pressure drop and chlorine reduce.

For initial flush turbidity, test is undertaken by described in example 4.

table 14

Sample	First liter (NTU)	1 gallon (NTU)	5 gallons (NTU)	10 gallons (NTU)	25 gallons (NTU)	50 gallons (NTU)	100 gallons (NTU)
								49	8	2.9	0.35	0.41	0.12	0.13	0.15
51	45.7	1.1	0.42	0.23	0.33	0.14	0.17
								52	18.7	2.7	0.51	0.11	0.26	0.12	0.15
54	8.7	2.9	0.51	0.32	0.15	0.26	0.19

Sample 49,51,52 and 54 initial flush turbidity are greater than the initial flush turbidity of the contrast 1 shown in table 3, but are less than the initial flush turbidity of the contrast 2 in table 3.Initial flush turbidity is along with the external diameter of cylinder increases and improves.In all situations, turbidity all reduces to the level lower than 0.5NTU.

For clean pressure drop, test is undertaken by described in example 4.There is no the cylinder loading is " contrasting 6 ".

table 15

Sample number into spectrum	0.25 gpm psi	0.50 gpm psi	0.75 gpm psi	1.0 gpm psi	2.0 gpm psi	3.0 gpm psi	4.0 gpm psi
								Contrast 6	＜2	＜2	2	4	16	32	57
49	0.5	1.5	3	5	18	39	64
								51	0.5	1	3	5	18	39	65
52	0	1.5	2.5	5	19	38	64
								54	1	1.5	3	6	18	38	66

The clean pressure drop of these filters is all low, and this filter will be favourable for full family formula filtration application.

For NSF/ANSI 42 chlorine, reduce test, test is undertaken by described in example 4.

table 16

Sample number into spectrum	After 15 gallons, % reduces	～1100 gallons of % reduce	～2300 gallons of % reduce	～3800 gallons of % reduce	～4200 gallons of % reduce	～5000 gallons of % reduce	～8000 gallons of % reduce
								50	91.8	76.1	50.2	32.8	35.2	38.5	26.7
55	98.6	98.4	94.5	90.1	90.0	91.8	80.2
								57	97.1	97.4	97.2	98.0	97.6	96.2	93.6
58	97.6	98.9	97.2	99.0	98.1	95.2	91.7

With reference to table 16, the minimum based on standard desired 50% reduces, and for tested at least 2300 gallons, all samples all can be removed the chlorine of acceptable level.The water gallonage being subject to processing is directly related with the quality of the active medium of this amount.Sample 57 behaves oneself best, even if still reduce the inflow tester that is greater than 90% after 8000 gallons.In view of the low pressure drop of granularity and the structure of charcoal used, this is mysterious.

" embodiment " who mentions in the whole text at this description, " some embodiment ", " one or more embodiment " or " embodiment ", the specific features, structure, material or the feature that mean to describe in conjunction with this embodiment are included at least one embodiment of the present invention.Therefore, this description in the whole text in the word such as " in one or more embodiments ", " in certain embodiments ", " in one embodiment " or " in an embodiment " that occurs of many places, may not refer to same embodiment of the present invention.In addition, specific features, structure, material or characteristic can combine in one or more embodiments in any suitable manner.

Although described the present invention with reference to specific embodiment herein, it will be appreciated that, these embodiment illustrate principle of the present invention and application.Those skilled in the art can understand, can not deviate from the spirit and scope of the present invention, and method and apparatus of the present invention is made to various modifications and variations.Therefore be intended that, the present invention includes modification and variations in the scope that falls into claims and equivalent thereof.

Claims

1. a filter cell, comprising:

Comprise self support type non-woven polymeric webs and a plurality of porous article that is embedded in the adsorber particles in described net, described porous article comprises first surface and second surface;

Liquid impermeability housing around described porous article;

The entrance being communicated with described first surface fluid; With

The outlet being communicated with described second surface fluid,

Wherein, the Gurley time of described net is less than 2 seconds.

2. filter cell according to claim 1, wherein said adsorber particles comprises active carbon, diatomite, ion exchange resin, metal ion exchanged adsorbent, activated alumina, Antimicrobe compound, acid gas adsorbent, arsenic reducing material, iodinated resin or their combination.

3. filter cell according to claim 1, it has the pressure drop that is no more than 150mm water column under environmental condition under the air surface speed of second of 5.3cm/ uniformly.

4. filter cell according to claim 1, the particle mean size of wherein said adsorber particles is no more than 250 μ m.

5. filter cell according to claim 1, its average fill rate is less than 10 minutes/gallon.

6. filter cell according to claim 1, wherein said net volume is around forming described porous article.

7. filter cell according to claim 1, wherein said porous article is to form with a plurality of nets that are adjacent to each other.

8. filter cell according to claim 7, wherein the first net contains the first adsorbent, and the second net contains the second adsorbent.

9. filter cell according to claim 7, wherein the first net comprises the particle of the first particle mean size, the second net comprises the particle of the second particle mean size.

10. filter cell according to claim 1, wherein said net is around core.

11. filter cells according to claim 10, wherein said core comprises charcoal piece.

12. filter cells according to claim 1, wherein base net weight is in the scope of 10 to 1000 grams/m.

13. filter cells according to claim 1, wherein said netting gear has the adsorber particles density within the scope of 0.20 to 0.5g/cc.

14. filter cells according to claim 1, wherein said polymer fiber comprises polypropylene.

15. filter cells according to claim 1, wherein said polymer fiber comprises metallocene catalyzed polyolefin.

16. filter cells according to claim 12, wherein said polyacrylic polymer melt flow index is in 30 to 1500 scope.

17. filter cells according to claim 1, wherein said net is by rolling, heating or exert pressure and compress.

18. filter cells according to claim 1, it has adsorber particles density gradient.

19. 1 kinds of fluid filter systems that comprise fluid source and filter cell, described filter cell comprises:

Liquid impermeability housing around described porous article;

The entrance being communicated with described first surface fluid; With

The outlet being communicated with described second surface fluid,

Wherein, the Gurley time of described net is less than 2 seconds.

20. filter cells according to claim 19, wherein said net volume is around forming described porous article.

21. filter cells according to claim 19, wherein said porous article is to form with a plurality of nets that are adjacent to each other.

22. filter cells according to claim 19, wherein said net is around charcoal piece.

23. 1 kinds of filter cells, comprising:

The block composite of charcoal that comprises active medium and binding agent, for the weight of the block composite of described charcoal, the scope of the content of described active medium is 10 to 90 % by weight, the scope of the content of described binding agent is 10 to 90 % by weight;

Around the net of the block composite of described charcoal, described net comprises self support type non-woven polypropylene fiber and a plurality of adsorber particles being embedded in described net, and for the weight of described net, the scope of the content of described adsorber particles is 50 to 97 % by weight,

Wherein, the Gurley time of described net is less than 2 seconds.

24. 1 kinds of filter cells that comprise a plurality of discs attached to each other, described disc comprises self support type non-woven polypropylene fiber and a plurality of adsorber particles being embedded in described fiber, wherein, the Gurley time of described a plurality of discs is less than 2 seconds.

25. filter cells according to claim 24, wherein more than first disc comprises the first acticarbon particle, more than second disc comprises the second ion exchange resin adsorber particles.

26. 1 kinds of methods of filtering fluid, described method comprises makes filter cell and described fluid contact, described filter cell comprises: have self support type non-woven polymeric webs and a plurality of porous article that is embedded in the adsorber particles in described net, described porous article comprises first surface and second surface; Around the liquid impermeability housing of described porous article, the entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid, wherein, the Gurley time of described net is less than 2 seconds.

27. 1 kinds of methods that form filter cell, described method comprises:

Molten polymer is flowed through a plurality of apertures to form precursor;

Described precursor is refined as to fiber;

The material stream of adsorber particles is guided in the middle of described precursor or fiber;

Described fiber and described adsorber particles are collected to form porous article as nonwoven web;

Described porous article is arranged in liquid impermeability housing; And

By rolling, heating or exert pressure to compress described nonwoven web, to form the compressed web that the Gurley time is less than 2 seconds.

28. methods according to claim 27, also comprise a plurality of nonwoven webs that are adjacent to each other attached to form described porous article.

29. methods according to claim 27, also comprise and will after described nonwoven web coiling, more described nonwoven web be placed in to described housing.

30. methods according to claim 27, also comprise the rheological behavior of controlling described fiber.

31. 1 kinds of filter cells, comprising:

A plurality of coilings form the porous layer of porous article, and wherein said porous layer comprises self support type non-woven polymeric webs and a plurality of adsorber particles being embedded in described net, and described porous article comprises first surface and second surface;

Liquid impermeability housing around described porous article;

The entrance being communicated with described first surface fluid; With

The outlet being communicated with described second surface fluid,

Wherein, the Gurley time of described net is less than 2 seconds.

32. filter cells according to claim 31, wherein said a plurality of porous layer consolidations together.

33. filter cells according to claim 31, wherein said a plurality of porous layers are discrete composite beds.

34. filter cells according to claim 31, wherein said adsorber particles comprises active carbon, diatomite, ion exchange resin, metal ion exchanged adsorbent, activated alumina, Antimicrobe compound, acid gas adsorbent, arsenic reducing material, iodinated resin or their combination.

35. filter cells according to claim 31, wherein said filter cell also comprise by described net around core.

36. filter cells according to claim 31, the adsorber particles density of wherein said net is in 0.20 to 0.5g/cc scope.

37. filter cells according to claim 31, wherein said polymer fiber comprises polypropylene.

38. filter cells according to claim 31, wherein said polymer fiber comprises metallocene catalyzed polyolefin.

39. according to the filter cell described in claim 38, and wherein said polyolefin is polypropylene.

40. according to the filter cell described in claim 37, and wherein said polyacrylic polymer melt flow index is in 30 to 1500 scope.

41. filter cells according to claim 31, wherein more than first layer comprises the polymer fiber with the first effective fiber diameter, and more than second layer comprises the polymer fiber with the second effective fiber diameter.

42. filter cells according to claim 31, wherein said polymer fiber comprises the mixture of effective fiber diameter.

43. filter cells according to claim 31, wherein said adsorber particles is present in more than first layer with the first density, and is present in more than second layer with the second density.

44. filter cells according to claim 31, wherein more than first layer comprises the first adsorbent, and more than second layer comprises the second adsorbent.

45. filter cells according to claim 31, wherein more than first layer comprises the particle with the first particle mean size, and more than second layer comprises the particle with the second particle mean size.

46. filter cells according to claim 31, it has the adsorbent density gradient of axial mode.

47. filter cells according to claim 31, it has the adsorbent density gradient of radial mode.

48. filter cells according to claim 31, also comprise the layer that a plurality of the second nets by self support type non-woven polymer fiber form, and described fiber does not have adsorber particles.

49. 1 kinds of filter cells, comprising:

Reel for more than first and form the porous layer of porous article, wherein said porous layer comprises the first net and a plurality of carbon granule being embedded in described the first net of self support type non-woven polypropylene fiber, and described porous article comprises first surface and second surface;

Liquid impermeability housing around described porous article;

The entrance being communicated with described first surface fluid; With

The outlet being communicated with described second surface fluid,

Wherein, the Gurley time of described the first net is less than 2 seconds.

50. according to the filter cell described in claim 49, and described porous article also comprises more than second porous layer, and wherein said porous layer comprises the second net and a plurality of ion exchange resin being embedded in described the second net of self support type non-woven polypropylene fiber.

51. 1 kinds of methods of filtering fluid, described method comprises makes filter cell and fluid contact, a plurality of porous layers are reeled and are formed porous article, wherein said porous layer comprises self support type non-woven polymeric webs and a plurality of adsorber particles being embedded in described net, and described porous article comprises first surface and second surface; Liquid impermeability housing around described porous article; The entrance being communicated with described first surface fluid; With the outlet being communicated with described second surface fluid, wherein, the Gurley time of described net is less than 2 seconds.

52. 1 kinds of methods that form filter cell, described method comprises:

Molten polymer is flowed through a plurality of apertures to form precursor;

Described precursor is refined as to fiber;

The nonwoven web that is less than 2 seconds using described fiber and described adsorber particles as the Gurley time is collected on mandrel to form porous article; And

Described porous article is arranged in liquid impermeability housing.

53. according to the method described in claim 52, also comprises more than second layers that form more than first layers that comprise the polymer fiber with the first effective fiber diameter and comprise the polymer fiber with the second effective fiber diameter.

54. according to the method described in claim 52, also comprises described adsorber particles is provided to more than first layers and neutralizes with the second density and provide to more than second layers with the first density.

55. according to the method described in claim 52, also comprises more than first layers with the first adsorbent and more than second layers with the second adsorbent are provided.

56. according to the method described in claim 52, also comprises the rheological behavior of controlling described fiber.