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CN1279997C - 纳米纤维过滤介质 - Google Patents

纳米纤维过滤介质 Download PDF

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Publication number
CN1279997C
CN1279997C CNB038030152A CN03803015A CN1279997C CN 1279997 C CN1279997 C CN 1279997C CN B038030152 A CNB038030152 A CN B038030152A CN 03803015 A CN03803015 A CN 03803015A CN 1279997 C CN1279997 C CN 1279997C
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filter medium
fibre
fiber
less
nanofiber
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CN1625429A (zh
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E·E·科斯洛
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KX Technologies LLC
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Koslow Technologies Corp
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    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/001—Processes for the treatment of water whereby the filtration technique is of importance
    • C02F1/004—Processes for the treatment of water whereby the filtration technique is of importance using large scale industrial sized filters
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/0005—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts
    • A61L2/0011—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts using physical methods
    • A61L2/0017—Filtration
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/0005—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts
    • A61L2/0082—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor for pharmaceuticals, biologicals or living parts using chemical substances
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/02—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using physical phenomena
    • A61L2/022—Filtration
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00—Disinfection, sterilisation or deodorisation of air
    • A61L9/16—Disinfection, sterilisation or deodorisation of air using physical phenomena
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
    • B01D29/13—Supported filter elements
    • B01D29/15—Supported filter elements arranged for inward flow filtration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D29/39—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with hollow discs side by side on, or around, one or more tubes, e.g. of the leaf type
    • B01D29/41—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with hollow discs side by side on, or around, one or more tubes, e.g. of the leaf type mounted transversely on the tube
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D37/02—Precoating the filter medium; Addition of filter aids to the liquid being filtered
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    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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    • B01D39/18—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
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    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003—Glass or glassy material
    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
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    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
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    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
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    • C12H1/00—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages
    • C12H1/02—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material
    • C12H1/04—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material with the aid of ion-exchange material or inert clarification material, e.g. adsorption material
    • C12H1/0408—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material with the aid of ion-exchange material or inert clarification material, e.g. adsorption material with the aid of inorganic added material
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    • C12H1/00—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages
    • C12H1/02—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material
    • C12H1/04—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material with the aid of ion-exchange material or inert clarification material, e.g. adsorption material
    • C12H1/0416—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material with the aid of ion-exchange material or inert clarification material, e.g. adsorption material with the aid of organic added material
    • C12H1/0424—Pasteurisation, sterilisation, preservation, purification, clarification, or ageing of alcoholic beverages combined with removal of precipitate or added materials, e.g. adsorption material with the aid of ion-exchange material or inert clarification material, e.g. adsorption material with the aid of organic added material with the aid of a polymer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
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    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
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Abstract

本发明涉及包括纳米纤维的空气过滤介质，该过滤介质的厚度小于0.25mm、质量因数大于约0.075，和当截留尺寸为约0.18微米的气溶胶颗粒时，效率大于约99.9%，以及在约32L/min的流量下经过尺寸为100cm2的样品时，压降小于约40mm水柱。也可使用纳米纤维涂层通过增加已有过滤介质的FOM来提高已有过滤介质的性能。优选纳米纤维被原纤化。

Description

纳米纤维过滤介质
本申请要求2002年1月31日申请的美国临时申请序列No.60/354062的优先权。
发明概述
本发明涉及过滤介质，其包括：加拿大标准游离度(CanadianStandard Freeness)小于约45的原纤化纤维，该过滤介质具有下述性能指标：厚度小于或等于约0.25mm和质量因数大于约0.075；和当截留尺寸为约0.18微米的气溶胶颗粒时，效率大于约99.9％；以及在约32L/min的流量下经过尺寸为100cm2的样品时，压降小于约40mm水柱；和其中若过滤介质薄于0.25mm，则当调节较薄的过滤介质的效率和压降以补偿达到0.25mm厚的厚度差时，可提供满足或超过该性能指标的过滤介质。
另一方面，本发明涉及过滤介质，其包括：微玻璃纤维和加拿大标准游离度小于约45的原纤化Lyocell纤维的混合物，该过滤介质具有下述性能指标：厚度小于或等于约0.25mm，和质量因数大于约0.075；和当截留尺寸为约0.18微米的气溶胶颗粒时，效率大于约99.9％；以及在约32L/min的流量下经过尺寸为100cm2的样品时，压降小于约40mm水柱；和其中若过滤介质薄于0.25mm，则当调节较薄的过滤介质的效率和压降以补偿达到0.25mm厚的厚度差时，可提供满足或超过该性能指标的过滤介质。
再一方面，本发明涉及过滤介质，其包括；加拿大标准游离度小于约10的原纤化Lyocell纤维，该过滤介质具有下述性能指标：厚度小于或等于约0.25mm和质量因数大于约0.075；和当截留尺寸为约0.18微米的气溶胶颗粒时，效率大于约99.9％以及在约32L/min的流量下经过尺寸为100cm2的样品时，压降小于约40mm水柱；和其中若过滤介质薄于0.25mm，则当调节较薄的过滤介质的效率和压降以补偿达到0.25mm厚的厚度差时，可提供满足或超过该性能指标的过滤介质。
本发明包括引入通常如上所述的过滤介质的过滤体系。
再一方面，本发明涉及制备空气过滤介质的方法，其包括步骤：分散原纤化纤维；和形成厚度小于约0.25mm的原纤化纤维层，以便过滤介质具有下述性能指标：质量因数大于约0.075，和当截留尺寸为约0.18微米的气溶胶颗粒时，效率大于约99.9％；以及在约32L/min的流量下经过尺寸为100cm2的样品时，压降小于约40mm水柱；和其中若过滤介质薄于0.25mm，则当调节较薄的过滤介质的效率和压降以补偿达到0.25mm厚的厚度差时，可提供满足或超过该性能指标的过滤介质。
又一方面，本发明涉及提高已有过滤介质性能的方法，其包括步骤：提供多根纳米纤维；在已有过滤介质上湿铺纳米纤维，其中纳米纤维以约0.5g/m2至约11.0g/m2的比率负载在已有的过滤介质上；和使已有的过滤介质的质量因数增加至少约100％。优选在提供多根原纤化的纳米纤维的步骤中，所述纳米纤维包括微玻璃纤维、Lyocell纳米纤维、丙烯酸纳米纤维或其组合。该方法可进一步包括步骤：提供固体粘结剂，其中将原纤化纳米纤维和固体粘结剂湿铺在已有的过滤介质上，和活化固体粘结剂。
附图的简要说明
认为具有新颖性的本发明特点和本发明的子特性在所附权利要求书中特别给出。附图仅用于说明且没有按比例画出。但本发明本身(在组织和操作方法二者上)可参考对以下优选的实施方案的说明并结合附图而得到最佳理解，其中：
图1是说明当经过过滤介质的空气速度变化时颗粒拦截的图表。
优选实施方案的详细说明
定义
″粘结剂″是指主要用于将其它材料粘结在一起的材料。
″加拿大标准游离度″或″CSF″是指根据纸浆悬浮液可能被排放的速度而测量的纸浆游离度或排放速度值。该方法是熟练造纸领域的人员公知的。
“DOP”是指邻苯二甲酸二辛酯(dioctyl phanthalate)。粒度为0.18微米的单分散DOP液滴用于测试本发明的过滤介质。
“纤维”是指特征在于高长径比例如几百比一的固体。有关纤维的任何讨论包括晶须。
“过滤介质”是指进行流体过滤的材料。
“FOM”或“质量因数”是指[-log(1-FE)]/ΔP
其中FE是在特定的流量下和对于特定的粒度，过滤介质的拦截效率分数。ΔP是在特定的流量下通过过滤介质的压差，也称为压降或压力阻力。在本说明书中，标准气溶胶是在32L/min的流量下经过100cm2的过滤器面积时携带的0.18微米的DOP。应当理解，各向异性介质的FOM值是常数，以便压降与过滤介质厚度成正比例地变化和log(1-FE)也与介质的厚度成正比例地变化，以便对于给定的过滤介质，FOM为常数，与最终过滤介质的厚度无关。
“流体”是指液体、气体或其组合。
″成形″是指将松散的非结构化物质转化成内聚的均匀结构。例如，将松散的纤维转化成纸张。
“HEPA”过滤器或过滤介质是指能除去至少99.97％直径为0.3微米和更大的所有气载粒状物质的高效粒状空气过滤器或过滤介质。
″拦截(intercept)″或″拦截(interception)″是指干预或阻止流过，以实现改变、除去、灭活或影响。
″纳米纤维″是指直径小于约3.0mm的纤维。
″无纺布″是指网或织物或具有相互叠放(但不以针织或织造织物中的高度组织化方式)的各个纤维的结构的其它介质。无纺网一般可通过本领域熟知的方法而制成。这些方法的例子包括但不限于(仅仅是例举的方式)熔体吹塑，纺粘，梳理和气流铺设。
″纸张″或″纸状″是指通常扁平的纤维层或通过湿铺方法形成的材料垫。
″颗粒″是指尺寸范围从胶体至肉眼可见，且对形状没有特别限制但一般具有有限长/宽比的固体。
″片材″是指长度和宽度显著大于其厚度的大致二维的结构。
″晶须″是指具有有限的长径比且介于颗粒和纤维的长径比之间的一种长丝。有关纤维的任何讨论包括晶须。
过滤介质的特征
本发明的高效粒状空气(HEPA)过滤介质包括多根纳米纤维和粘结剂，其成形为厚度小于约0.25mm的层，和当在约20℃和大气压下以及在小于约45mm水柱的压降下，空气以约32L/min的流量流过100cm2的过滤介质的直径圆盘时，对于直径为约0.18微米的气溶胶颗粒所述层的效率大于约99.9％。本发明的过滤介质使得可增加引入到最终的过滤器设计内的过滤介质量，这是因为它薄且可折叠，从而提高过滤性能。已有的过滤体系可用显著更多的本发明过滤介质来更新，这是因为各层比厚度为0.38-0.457mm的常规HEPA材料薄得多，且在中等的压降下具有类似或改进的气溶胶拦截作用。
包括本发明过滤介质的空气过滤器可用于诸如在建筑物、汽车，尤其密闭汽车内的空气循环体系、真空吸尘器、呼吸过滤器之类的场合或要求过滤空气的其它场合。
在已有过滤介质上涂布纳米纤维也可用于提高已有过滤介质的性能和可提供已有过滤器增加大于约100％的质量因数(FOM)。
过滤介质也可带静电以提供增强的过滤性能。过滤介质的进一步处理可提供在呼吸器中可用的微生物拦截的杀菌性能从而用于核、生物和化学(NBC)防御。
生产改进的空气过滤介质有两种基本的方法。第一种是生产具有提高“质量因数”(FOM)的材料，其中质量因数约等于颗粒拦截的对数除以通过过滤介质的压差。尽管在FOM概念上具有变化，但基本等式是：
FOM＝[-log(1-FE)]/ΔP
其中FE是在特定的流量下和对于特定的粒度，过滤介质的拦截效率分数，和ΔP是也在特定的流量下测量的压降。
当过滤介质的深度为各向同性并以层流状态操作时，对于这种过滤介质，FOM基本上是常数，而与不同样品的过滤介质的基重的任何变化无关。当比较各种过滤介质时，这是非常有用的工具。例如，通过在空气过滤介质上施加静电荷，或对于使用在“滑动(slip)”状态下操作的极小纤维的材料，FOM通常大大地得到改进。
然而，当两种过滤介质具有相同的FOM，但一个比另一个厚许多倍时，显然人们将使用薄的过滤介质，这是因为在过滤器产品的设计中，空间几乎总是很受欢迎。当折叠过滤介质时，过滤介质的厚度在实现最大过滤器面积上扮演关键性作用。若多至两倍的滤纸可堆积到过滤器内，则与基本的情况相比，空气流过滤纸的速度减半。另外，空气过滤器的颗粒拦截效率随着空气流过滤纸速度的下降而改进。这对于必须扩散到过滤器表面上的小颗粒来说尤其重要。图1示出了当经过过滤介质的空气速度变化时的颗粒拦截。在已调节厚度之后，最佳的纳米HEPA是本发明的HEPA材料。通过添加更多的过滤介质到过滤器设计(更多的褶皱)中导致空气流动的任何下降(这通过使用薄材料而变得可能)提供显著的优点。额外的褶皱允许过滤体系具有较低的压降和改进的颗粒拦截效率，这是因为当起褶时，它在较低的空气流量下操作所致。过滤介质的厚度因此间接影响过滤效率和摺叠过滤器中的压降这二者，因为它改变褶皱的最佳堆积。
本发明提供具有良好FOM值且极薄的有效平片过滤介质。可生产具有与现代环氧玻璃滤纸相同FOM的过滤介质，但其厚度仅为玻璃介质的几分之一且具有类似的总体刚度和拉伸性能。本发明提供优选方法制备摺叠的空气过滤器。
纳米纤维
本发明的过滤介质由纳米纤维组成，所述纳米纤维可以是有机或无机材料，其中包括但不限于聚合物、工程树脂、陶瓷、纤维素、人造丝、玻璃、金属、活化矾土、碳或活性炭、二氧化硅、沸石或其组合。可以考虑有机和无机纤维和/或晶须的组合且在本发明的范围内，例如可一起使用玻璃、陶瓷或金属纤维和聚合物纤维。
当通过湿铺方法，由纤维素的纳米纤维或聚合物纤维生产过滤介质时，这种纤维的加拿大标准游离度还应当小于或等于45，和可以小于或等于约2。优选地，显著比例的纤维的直径应当小于或等于约1000纳米，更优选小于或等于约400纳米，和可为250纳米，和最优选直径小于或等于约200纳米的纤维。优选切断纤维到约1mm至约8mm的长度，优选约2mm至约6mm，和更优选约3mm至约4mm。最优选原纤化纤维，这是因为它们特别小的尺寸和潜在的低成本。
优选地，根据本发明加工的原纤化合成纤维素或丙烯酸纤维可产生本发明的超细过滤介质。可通过在有机溶剂如氧化胺中直接溶解和纺丝木浆来制备这种原纤化纤维素纤维，且被称为Lyocell纤维。Lyocell纤维的优点是能以一致、均匀的方式生产，从而产生可重复的结果，这对于例如天然纤维素纤维来说情况可能并不如此。此外，Lyocell的原纤常常卷曲。卷曲提供大量的纤维缠绕，从而导致具有高干强度和显著残留的湿强度的最终过滤介质。此外，可使用中等投资成本的设备大量地生产原纤化Lyocell纤维。要理解，除了纤维素以外的纤维可被原纤化以生产极细的原纤，如人工纤维，尤其丙烯酸或尼龙纤维或其它纤维素材料。原纤化纤维的用量为所述过滤介质重量的约5-40％。
可在本发明中使用原纤化和非原纤化纤维的组合。例如，微玻璃纤维可与原纤化聚合物纤维混合，以降低全部纤维混合物的成本和辅助分散，同时维持所得的性能。优选地，微玻璃纤维的直径为约0.25微米至约1微米，和优选约0.5微米至约0.75微米，和更优选约0.65微米。微玻璃纤维的量可以为过滤介质重量的最多约90％。
最优选的实施方案包括平均直径小于约200纳米和约3至约5mm的短切纤维长度的原纤化的Lyocell纳米纤维。原纤化Lyocell纤维可与一部分便宜的微玻璃纤维混合，以降低成本，但在可接受的压降下仍维持所需的效率。
增强过滤介质的机械强度
可通过在不明显妨碍空气流动经过过滤介质的支撑层上形成过滤介质来提高过滤介质的机械强度。支撑层可以是任何透气的基质，条件是支撑层的孔径不要大到在真空压力下纳米纤维被牵引通过透气基质。支撑层可以是由织物、无纺布、纺粘、熔体吹塑、纤维素和其它纤维材料制备的材料。这种基质的实例是纺粘聚酯，如购自OldHickory，Tennessee的BBA Nonwovens Reemay，Inc的REEMAYTM 2004或REEMAYTM 2275。支撑层也可被处理或由抗霉、霉菌、真菌或细菌的材料制备。
赋予过滤介质机械强度的另一方式是混合一部分粘结剂与纳米纤维。本领域公知，添加环氧、丙烯酸或其它树脂到造纸工艺中可提供增强的湿强度，但这些水分散的树脂常常在最终产品内引起较低的渗透率，特别地当纤维尺寸下降时。尽管这些树脂和树脂体系可在本发明中使用，但优选使用本领域已知的粉末、颗粒或者纤维形式的热塑性或热固性材料。选择粘结剂，以便粘结剂材料的熔点充分低于纳米纤维的熔点，以便可加热过滤介质来活化粘结剂，同时过滤介质不会熔化并进而丧失孔隙率。粘结剂优选充分均匀地分布在整个过滤介质上，以便随后当活化时，粘结剂将截留或粘结到基本上所有纳米纤维上。
可用的粘结剂材料包括但不限于聚烯烃，聚卤乙烯，聚乙烯酯，聚乙烯醚，聚乙烯硫酸酯，聚乙烯磷酸酯，聚乙烯胺，聚酰胺，聚酰亚胺，聚噁二唑，聚三唑，聚碳化二亚胺，聚砜，聚碳酸酯，聚醚，聚亚芳基氧，聚酯，聚丙烯酸酯，酚醛树脂，蜜胺-甲醛树脂，甲醛-脲，乙基-醋酸乙烯酯共聚物，其共聚物和嵌段共聚物，和其组合。以上材料和其它有用的聚合物的变体包括基团如羟基，卤素，低级烷基，低级烷氧基，单环状芳基和类似物的取代。其它潜在可用的材料包括聚合物如聚苯乙烯和丙烯腈-苯乙烯共聚物，苯乙烯-丁二烯共聚物和其它非晶或无定形聚合物与结构。
可用于本发明的粘结剂材料的更详细列举包括聚链烯，聚醚，聚乙烯酯，聚乙烯醚，乙基-醋酸乙烯酯共聚物，封端聚缩醛，如聚甲醛，聚(三氯乙醛)，聚(正戊醛)，聚(乙醛)，和聚(丙醛)等；丙烯酸聚合物如聚丙烯酰胺，聚(丙烯酸)，聚(甲基丙烯酸)，聚(丙烯酸乙酯)和聚(甲基丙烯酸甲酯)等；氟碳聚合物，如聚(四氟乙烯)，全氟化乙烯-丙烯共聚物，乙烯-四氟乙烯共聚物，聚(氯三氟乙烯)，乙烯-氯三氟乙烯共聚物，聚(偏二氟乙烯)和聚(氟乙烯)等；聚酰胺，如聚(6-氨基己酸)或聚(ε-己内酰胺)，聚(亚己基己二酰胺)，聚(亚己基癸二酰胺)和聚(11-氨基十一酸)等；聚芳酰胺，如聚(亚氨基-1，3-亚苯基亚氨基异邻苯二甲酰)或聚(间-亚苯基异邻苯二甲酰胺)等；聚对亚苯基二甲基，如聚-对-亚二甲苯基和聚(氯-对-亚二甲苯基)等；聚芳基醚，如聚(氧基-2，6-二甲基-1，4-亚苯基)或聚(对苯醚)等；聚芳基砜，如聚(氧基-1，4-亚苯基磺酰基-1，4-亚苯基氧基-1，4-亚苯基亚异丙基-1，4-亚苯基)和聚(磺酰基-1，4-亚苯基氧基-1，4-亚苯基磺酰基-4，4′-亚联苯基)等；聚碳酸酯，如聚(双酚A)或聚(羰基二氧基-1，4-亚苯基亚异丙基-1，4-亚苯基)等；聚酯，如聚(对苯二甲酸乙二酯)，聚(对苯二甲酸丁二酯)，聚(亚环己基-1，4-二亚甲基对苯二甲酸酯)或聚(甲醛-1，4-环亚己基亚甲基氧基对苯二甲酰)等；聚芳基硫化物，如聚(对苯硫醚)或聚(硫代-1，4-亚苯基)等；聚酰亚胺，如聚(均苯四亚氨基-1，4-亚苯基)等；聚烯烃，如聚乙烯，聚丙烯，聚(1-丁烯)，聚(2-丁烯)，聚(1-戊烯)，聚(2-戊烯)，聚(3-甲基-1-戊烯)，和聚(4-甲基-1-戊烯)等；乙烯基聚合物，如聚(醋酸乙烯酯)，聚(偏二氯乙烯)和聚(氯乙烯)等；二烯聚合物，如1，2-聚-1，3-丁二烯，1，4-聚-1，3-丁二烯，聚异戊二烯，和聚氯丁二烯等；聚苯乙烯；前述的共聚物，如丙烯腈-丁二烯-苯乙烯(ABS)共聚物等及其混合物。
可使用一系列粘结剂纤维，其中包括聚乙烯、聚丙烯、丙烯酸或聚酯-聚丙烯或聚丙烯-聚乙烯双组分纤维或其它。优选的纤维粘结剂材料可包括FYBREL合成纤维和/或SHORT STUFFEST-8，这二者均是聚烯烃基材料。FYBREL是一种聚烯烃基合成纸浆，它是一种高度原纤化的纤维且商购于日本的Mitsui Chemical Company。FYBREL具有优良的热模塑性并给过滤介质提供光滑的表面。SHORT STUFFEST-8商购于MiniFibers，Inc.，Pittsburgh，Pennsylvania，和是一种高度原纤化的高密度聚乙烯。同样优选低密度聚乙烯(LDPE)粘结剂颗粒，如由Tuscola，Illinois的Equistar Chemicals，L.P.制备的MICROTHENEGrade FN 510。聚醋酸乙烯酯(PVA)也可用作粘结剂。优选的PVA是商购于Kuraray Company，Ltd.，Osaka，日本的KURALONTMVPB071。
优选，粘结剂的用量为约1％至约35％重量，更优选约3％至约10％，最优选约5％至约7％。
添加剂
颗粒、纤维、晶须或粉末形式的一种或多种添加剂也可与纳米纤维混合，以有助于拦截其它污染物或除去湿气和/或臭味。有用的添加剂可包括但不限于金属颗粒，活化矾土，活性炭，二氧化硅，聚合物粉末颗粒和纤维，玻璃珠粒或纤维，纤维素纤维，离子交换树脂，工程树脂，陶瓷，沸石，硅藻土，硅酸盐、铝硅酸盐、钛酸盐、骨炭、钙羟基磷灰石、氧化锰、氧化铁、镁氧矿、珍珠岩、滑石、粘土、碘化树脂、活化铝土矿，漂白土，硫酸钙，超吸收聚合物(SAP)，或其组合。也可根据特定应用化学处理添加剂，以赋予抗微生物或杀生物能力。这些添加剂优选以使得在使用过程中所得过滤介质中的空气流动基本上不受阻碍的足够量存在。添加剂的量取决于过滤体系的特定功能。
制备本发明HEPA过滤介质的方法
可根据本领域熟练技术人员已知的方法制备本发明的HEPA过滤介质。干铺工艺包括纺粘、静电纺纱、海岛纺丝(spinningislands-in-sea)工艺、原纤化薄膜、熔体吹塑，和本领域熟练技术人员已知的其它干铺工艺。例举的干铺工艺以短切纤维开始，所述短切纤维可通过梳理成单根纤维而分开，然后通过气动方法铺在一起到所需厚度，形成非粘合的纤维片材。然后对该非粘合纤维进行水力喷射，使纤维原纤化并水力缠绕(hydroentangle)。可在一些塑料膜上进行类似的工艺，当所述塑料膜暴露于高压水射流时，转化成原纤化纤维网。
在优选的湿铺工艺中，将纤维丝束切断成特定的长度，通常在约1mm至约8mm范围内，和尤其在约3mm至约4mm范围内。在具有类似于掺合器特征的设备内，或在较大规模上在常称为“hi-low”、“打浆机”或“匀浆机”的机器内，原纤化短切纤维。使纤维经历反复的应力，同时进一步切断并使纤维长度的下降最小。当纤维经历这些应力时，由于无定形和结晶区域之间的作用力弱导致纤维劈裂，和加拿大标准游离度(CSF)开始下降，其中所述加拿大标准游离度通过本领域公知的方法来测定。可间隔地取出所得纸浆样品，和将CSF可用作原纤化程度的间接量度。尽管CSF值略微敏感于纤维长度，但它更强烈敏感于纤维的原纤化程度。因此，CSF是监控纤维原纤化程度的合适方式，而CSF是从纸浆中除水的容易程度的量度。若表面积非常高，则在给定量的时间下非常少的水从纸浆中排出，和随着纤维更深入地原纤化，CSF值将逐渐变低。给定CSF值的原纤化纤维可直接用于生产纸张或在各种不同的设备(包括脱水压机或传动带)上脱水，产生脱水纸浆。已脱水纸浆可随后用于制备湿铺纸张。一般地，对于本发明的应用来说，使用CSF低于45的纸浆，和优选CSF应当小于或等于约2。纤维可被直接送入到纸浆制备体系中，以生产适合于造纸的配料。过滤介质的最终重量优选约21至约65g/m2，优选约32至约48g/m2，基于过滤介质的总重量。以这一方式原纤化的纤维包括Lyocell和选择不同等级的不完全结晶的丙烯酸、尼龙或其它合成纤维。
可在形成湿铺或干铺纸张之前或之后，根据本领域已知的方法，如纳米纤维的电晕放电处理或化学处理，使过滤介质带静电。也可在纤维的纳米纤维混合物如丙烯酸和尼龙纤维的混合物内，通过摩电效应产生静电荷。静电荷通过电动拦截可提供增强的微粒拦截。
例举的湿铺工艺包括在掺合器内在混合下在水中分散CSF为约2的原纤化Lyocell纤维纸浆，形成具有约1％至约2％稠度的配料。可向该分散液中添加其它纤维和粘结剂或成分。此后，可在湿铺过滤介质的生产中直接使用各成分的完全混合物。
使用纳米纤维涂层改进已有过滤介质的FOM
在本发明另一实施方案中，已表明，在基质如已有过滤介质上局部涂布纳米纤维可提高已有过滤介质的FOM至少约100％。使用湿铺工艺，以约0.5g/m2至约11.0g/m2，和优选约1.08g/m2的速度将纳米纤维负载在已有的过滤介质上。纳米纤维强烈粘附到基质上，也同样可使用纳米纤维通过充当主粘结剂将其它纤维或成分粘附在基质上。固体形式的常规粘结剂材料可用于提高对基质的粘附，但在所有场合中这不是必须的。
优选地，丙烯酸纳米纤维或原纤化Lyocell纤维(单独和与微玻璃纤维的组合)显著改进已有过滤介质的FOM。可在过滤介质的起始生产过程中施加纳米纤维或在所需小量纳米纤维给定的名义成本下生产之后涂布在其上。可使用加拿大标准游离度小于约45、优选小于约10和优选约2和短切纤维长度为约3mm至约8mm的的丙烯酸纳米纤维。根据本领域已知的方法原纤化这种丙烯酸纤维。可以以商品牌号RES-25从Sterling Fibers，Inc.，Pace，Florida、以商品名CASHMILONTM从AsahiKasei Corporation，Tokyo日本和/或从Mitsubishi RayonAmerica，New York以3mm长度的可原纤化短切纤维形式获得优选的丙烯酸短切纤维。
在采用纳米纤维涂层的已有空气过滤介质的例举处理中，如上所述切断纤维丝束到约3至约4mm长度并原纤化。然后在已有的过滤介质或其它支撑基质的片材上湿铺原纤化的纳米纤维，其中包括微玻璃纤维(若使用的话)。
实施例
提供以下实施例说明本发明，而不应理解为限定本发明的范围。
使用获自Air Techniques，International of Owings Mill，Maryland的Model TDA-100，进行气溶胶拦截和气流阻力测量。在该研究中使用单分散的0.18微米的油气溶胶颗粒。流量为32slpm。利用Tinius Olsen Testing Machine Company，Inc.of Horsham，Pennsylvania的机械试验站测量拉伸强度。HEPA过滤介质或如下所示在支撑层上的纳米纤维涂层的厚度不考虑任何支撑基质的厚度。
根据下述通用步骤制备本发明的HEPA过滤介质的手工片材(handsheet)。称取材料并在不锈钢韦林氏掺合器中与2.0L去离子水共混至少3分钟。当使用微玻璃纤维时，在与纳米纤维和粘结剂(若存在的话)混合之前独立地共混它们约3分钟。在纤维混合物倾倒在30.5×30.5cm2不锈钢FORMAXTM造纸框(deckle)内，用在100目的基本筛网上平铺的REEMAYTM 2004无纺布片材作为支撑层。填充所述框至总共有含不同纤维的约12L水。使用具有60个直径为2cm的孔的30.5×30.5cm2不锈钢搅拌器片，从顶部到底部上下翻转纤维混合物约8-10次。通过在框下方施加轻微真空从纤维混合物中除去水，引起纤维在REEMAYTM无纺布上形成。一旦大量水被除去，则采用真空泵进行补充脱水，以除去额外过量的湿气和产生相对光滑、平坦、很薄的纸状片材。将所得片材从筛网中分离并在顶部和底部上与沾吸(blotter)片材组合。轻轻地用2.27kg大理石擀辊辊压组合片材，以除去过量水和使片材的顶部表面平滑。然后将该片材放置在两块新鲜和干燥的沾吸片材之间并在约120℃下放置在FORMAX片材干燥器上约10至约15分钟。将干燥的过滤介质与沾吸片材分离并在FORMAX片材干燥器上直接加热各侧约5分钟，以活化存在的任何粘结剂。
在其中纳米纤维涂布于过滤介质或其它粗糙基质上的实施例中，用选择的过滤介质或基质而不是REEMAYTM无纺布给框做衬底，和如前所述在其上湿铺纳米纤维。
实施例1和2：具有原纤化Lyocell和微玻璃纳米纤维的HEPA过滤介质
这些实施例说明了用加拿大标准游离度为约8的原纤化Lyocell纳米纤维在与微玻璃纤维混合的含水分散液中制备的HEPA过滤介质的性能，其中所述微玻璃纤维的纤维直径为0.65微米，以商品牌号FIBREGLASSTM#106获自Johns Manville Company of Denver，Colorado。表I和II示出了过滤介质的组成与特征。
表I
  实施例号   Lyocell(wt％)   片材重量(g)   厚度(mm)   效率(％)   ΔP(mmH2O)        拉伸强度(@50in/min)
  力(kg/ft)   伸长(mm)
  1   30   2.8   0.2159   99.963   29.8   1.110   2.340
  2   25   4.5   0.2921   100   48.9   1.150   1.930
实施例3-7：具有原纤化Lyocell和微玻璃纳米纤维的HEPA过滤介质
采用加拿大标准游离度为约2的原纤化Lyocell纳米纤维在与FIBREGLASSTM#106微玻璃纤维混合的含水分散液中制备实施例3-7。在这些和以下的实施例中，将商购于Kuraray Company，Ltd.，Osaka，日本的KURALONTM聚醋酸乙烯酯(PVA)用作粘结剂。实施例3进一步包括MICROTHENEGrade FN510作为粘结剂。MICROTHENE含有0.5wt％无定形的沉淀二氧化硅。表II示出了组成。表III示出了过滤介质的特征。
表II
  实施例号  Lyocell(wt％)   玻璃(wt％)  PVA(wt％)   FN510(wt％)
  3   5   85   7.5   7.5
  4   2.5   90   7.5   -
  5   2.5   92.5   5   -
  6   2   95   3   -
  7   2   95   3   -
表III
  实施例号  Lyocell(wt％)   片材重量(g/ft2)   厚度(mm)   效率(％)   ΔP(mmH2O)           拉伸强度(@50in/min)
  力(kg/ft)       伸长(mm)
  3   5   4.0   0.2413   99.969   36.7   1.170   1.025
  4   2.5   4.5   0.2540   99.966   35.57   2.938   1.943
  5   2.5   4.5   0.2794   99.975   32.20   1.938   1.469
  6   2   4.5   0.2794   99.979   30.40   1.608   1.227
  7   2   4.5   0.2540   99.9945   33.57   1.073   0.973
实施例1-7的HEPA过滤介质在厚度显著小于常规HEPA材料下，在截留0.18微米气溶胶颗粒中显示出优良的效率。
实施例8-20：具有CSF为2的原纤化Lyocell和微玻璃纳米纤维的HEPA过滤介质
这些实施例进一步示出了在没有粘结剂和具有下表所示的不同用量粘结剂的情况下，用原纤化Lyocell纳米纤维和FIBREGLASS#106微玻璃纤维制备的本发明的HEPA过滤介质的性能。所使用的粘结剂是PVA和含有0.5wt％无定形的沉淀二氧化硅的MICROTHENEGrade FN-510，基于MICROTHENE和二氧化硅的总重量。
表IV
  实施例号  Lyocell(wt％)   玻璃(wt％)  PVA(wt％)   FN510(wt％)
  8   2.5   90   7.5   -
  9   2.5   92.5   5   -
  10   2.5   90   7.5   -
  11   10   65   -   25
  12   10   75   -   15
  13   10   80   -   10
  14   7.5   85   -   7.5
  15   5   80   7.5   7.5
  16   2.5   90   7.5   -
  17   2.5   92.5   5   -
  18   2.5   95   2.5   -
  19   2   95   3   -
  20   30   70   -   -
表V
  实施例号   片材重量(g/ft2)   厚度(mm)   效率(％)   ΔP(mmH2O)         拉伸强度(@50in/min)
  力(kg/ft)       伸长(mm)
  8   4.5   0.2413   99.9988   34.30   0.143   1.210
  9   4.5   0.2413   99.9983   35.00   0.562   1.625
  10   4.23   0.2413   99.9906   37.00   0.3195   0.835
  11   5.0   0.2667   99.9945   37.30   0.4770   1.150
  12   5.0   0.3302   99.9994   37.60   0.298   1.278
  13   5.0   0.3175   99.9996   37.00   0.398   1.645
  14   5.0   0.3302   99.9998   38.40   0.2795   1.442
  15   4.0   0.2159   99.9810   27.30   0.208   1.310
  16   4.0   0.2540   99.9880   29.40   0.251   0.978
  17   4.0   0.2413   99.9929   32.80   0.211   0.733
  18   4.0   0.2540   99.9870   32.00   0.252   0.735
  19   4.0   0.2540   99.9850   33.80   0.446   0.883
  20   3.0   0.1397   99.938   27.50   0.727   1.795
所有实施例表明在截留0.18微米气溶胶颗粒中的优良效率，因此将超过常规的HEPA材料的性能。
实施例21-35：具有CSF为2的原纤化Lyocell和微玻璃纳米纤维以及不同量PVA粘结剂的HEPA过滤介质
这些实施例说明了当用不同量PVA粘结剂制备的HEPA过滤介质的不同性能。表VI示出了过滤介质的组成和表VII示出了性能结果。
表VI
  实施例号  Lyocell(wt％)   玻璃(wt％)  PVA(wt％)
  21   2.5   90   7.5
  22   2.5   90   7.5
  23   2.5   92.5   5
  24   2.5   92.5   5
  25   2.5   95   2.5
  26   2.5   95   2.5
  27   2   95   3
  28   2   95   3
  29   2.5   90   7.5
  30   2.5   92.5   5
  31   2.5   95   2.5
  32   2   95   3
  33   29   70   1
  34   29   70   1
  35   28.5   70   1.5
表VII
  实施例号   片材重量(g/ft2)   厚度(mm)   效率(％)   ΔP(mmH2O)           拉伸强度(@50in/min)
  力(kg/ft)       伸长(mm)
  21   4.0   0.3302   99.9270   31.40   0.896   0.868
  22   4.0   0.2159   99.9958   29.60   0.176   0.980
  23   4.0   0.3429   99.970   32.85   1.043   1.208
  24   4.0   0.2159   99.9976   32.00   0.234   1.195
  25   4.0   0.2540   99.9900   32.20   0.407   0.628
  26   4.0   0.3175   99.9860   32.50   0.876   1.173
  27   4.0   0.3048   99.9903   34.90   0.322   0.705
  28   4.0   0.2159   99.9961   34.85   0.547   1.730
  29   4.5   0.3683   99.9710   36.45   1.561   1.300
  30   4.5   0.3810   99.9870   33.25   1.402   1.453
  31   4.5   0.3429   99.9956   36.10   0.441   0.778
  32   4.5   0.4064   99.9956   37.60   1.011   1.055
  33   3.0   0.1778   99.9805   35.63   0.8705   1.158
  34   3.0   0.1651   99.9880   35.23   0.629   1.083
  35   3.0   0.1829   99.9880   35.23   0.793   1.203
表VII中的实施例表明在中等压降下对0.18微米的气溶胶颗粒优良的拦截效率。
实施例36-38：具有CSF为2的原纤化Lyocell和微玻璃纳米纤维以及不同量PVA粘结剂的摺叠(pleated)和非褶叠(unpleated)HEPA过滤介质的比较
这些实施例说明了当褶摺叠(在表IX中用字母P表示)时本发明的HEPA过滤介质保持其初始的非摺叠的性能。在制备过滤介质中使用加拿大标准游离度为2的Lyocell纳米纤维。PVA为使用的粘结剂。
表VIII
  实施例号   Lyocell(wt％)   玻璃(wt％)  PVA(wt％)
  36   29.5   70   0.5
  37   30   70   -
  38   25   70   5
表IX
  实施例号   片材重量(g/ft2)   厚度(mm)   效率(％)   ΔP(mmH2O)           拉伸强度(@50in/min)
  力(kg/ft)       伸长(mm)
  36   3.0   0.1651   99.985   34.95   0.741   1.053
  36P   99.985   34.90
  37   3.0   0.1651   99.990   36.05   0.756   1.168
  37P   99.988   35.3
  38   3.0   0.1651   99.988   33.20   0.704   1.965
  38P   99.988   33.40
实施例39-66：具有CSF为2的原纤化Lyocell和微玻璃纳米纤维以及不同量EST-8粘结剂的HEPA过滤介质
这些实施例说明了当不同量EST-8聚乙烯纤维用作粘结剂时HEPA过滤介质的不同性能。
表X
  实施例号  Lyocell(wt％)   EST-8(wt％)   玻璃(wt％)   实施例号  Lyocell(wt％)   EST-8(wt％)   玻璃(wt％)
  39   10   15   75   53   10   15   75
  40   10   10   80   54   10   10   80
  41   15   15   70   55   15   15   70
  42   5   25   70   56   5   25   70
  43   10   20   70   57   10   20   70
  44   10   25   65   58   10   25   65
  45   15   25   60   59   15   25   60
  46   25   15   60   60   25   15   60
  47   20   20   60   61   20   20   60
  48   20   20   60   62   20   20   60
  49   20   20   60   63   20   20   60
  50   10   30   60   64   10   30   60
  51   30   10   60   65   30   10   60
  52   30   10   60   66   30   10   60
表XI
  实施例号   片材重量(g/ft2)   厚度(mm)   效率(％)   ΔP(mmH2O)           拉伸强度(@50in/min)
  力(kg/ft)       伸长(mm)
  39   4.0   0.2667   99.9934   38.40   0.713   1.905
  40   4.0   0.2540   99.9972   38.15   0.587   1.430
  41   3.5   0.2286   99.9710   32.80   1.010   1.993
  42   3.5   0.2032   99.9640   31.20   0.461   1.265
  43   3.5   0.1905   99.9710   33.05   0.674   1.803
  44   3.5   0.2032   99.9380   32.55   0.926   2.268
  45   4.0   0.2032   99.9600   36.60   1.073   2.000
  46   3.0   0.1778   99.890   32.60   1.041   1.745
  47   3.5   0.2159   99.9630   38.25   1.136   1.740
  48   3.0   0.1778   99.880   32.30   1.363   2.070
  49   3.25   0.1829   99.890   32.90   1.427   2.216
  50   3.5   0.2032   99.880   30.50   0.642   1.598
  51   3.25   0.1829   99.964   39.05   1.394   2.055
  52   3.0   0.1829   99.944   36.65   1.319   2.090
  53   4.0   0.2667   99.9934   38.4   0.713   1.905
  54   4.0   0.2540   99.9972   38.15   0.587   1.430
  55   3.5   0.2286   99.971   32.80   1.010   1.993
  56   3.5   0.2032   99.964   31.2   0.461   1.265
  57   3.5   0.1905   99.971   33.05   0.674   1.803
  58   3.5   0.2032   99.938   32.55   0.926   2.268
  59   4.0   0.2032   99.960   36.60   1.073   2.000
  60   3.0   0.1778   99.890   32.60   1.041   1.745
  61   3.5   0.2159   99.963   38.25   1.136   1.740
  62   3.0   0.1778   99.880   32.3   1.363   2.070
  63   3.25   0.1829   99.890   32.90   1.427   2.216
  64   3.5   0.2032   99.880   30.5   0.642   1.598
  65   3.25   0.1829   99.964   39.05   1.394   2.055
  66   3.0   0.1829   99.944   36.65   1.319   2.090
实施例67-71：具有CSF为2的原纤化Lyocell和微玻璃纳米纤维以及不同量EST-8粘结剂的摺叠和非摺叠HEPA过滤介质的比较
下述实施例比较用30wt％Lyocell纳米纤维、60wt％玻璃微纤维(FIBREGLASS#106)和10wt％EST-8作为粘结剂制备的摺叠和非摺叠HEPA过滤介质的性能。
表XII
  实施例号   片材重量(g/ft2)   厚度(mm)   效率(％)   ΔP(mmH2O)           拉伸强度(@50in/min)
  力(kg/ft)       伸长(mm)
  67   3.25   0.1905   99.960   39.45   1.254   1.655
  67P   99.963   39.00
  68   3.0   0.1651   99.959   38.45   1.348   2.375
  68P   99.959   38.70
  69   3.25   0.1905   99.960   39.5   1.254   1.655
  69P   99.963   39.00
  70   3.25   0.1905   99.967   39.65   1.282   1.521
  70P   99.971   41.00
  71   3.0   0.1651   99.959   38.45   1.348   2.375
  71P   99.959   38.65
同样，摺叠过滤器显示出与非摺叠过滤器基本上相同的性能特征。所有均具有对亚微米颗粒的优良拦截能力，因为本文所述试验的效率是采用0.18微米的气溶胶颗粒进行的。对于打褶来说拉伸强度也是最佳的。在拦截效率中获得的优点弥补了略微较高的阻力。
实施例72-75：具有纳米纤维涂层的已有过滤介质的FOM的改进
下述实施例说明了FOM的增加，并进而说明负载0.15g/ft2(干重)纳米纤维的已有过滤介质的过滤性能的增加。采用0.18微米的气溶胶颗粒，以32slpm的流量在100cm2的定位模具(jig)上进行所有测量。用FM表示初始的过滤介质并用它的气溶胶渗透分数、气流阻力和FOM来定义。FM1和FM2是无纺布。在实施例72中，使用以上所述的湿铺工艺，用25％加拿大标准游离度为约2的丙烯酸纳米纤维和75％FIBREGLASS#106微玻璃纤维涂布初始过滤介质FM1。实施例72中的丙烯酸纤维获自于Mitsuibishi Rayon America。在实施例73中，用25％加拿大标准游离度为约2的Lyocell纤维和75％FIBREGLASS #106微玻璃纤维涂布初始过滤介质。在实施例74中，用25％加拿大标准游离度为约2的原纤化Lyocell纳米纤维涂布初始过滤介质FM1。在实施例75中，用同样获自于Mitsuibishi Rayon America的100％丙烯酸纳米纤维涂布初始过滤介质FM2。根据表XIII可看出，向已有过滤介质中添加小量纳米纤维显著提高FOM，进而提高过滤介质的性能。
表XIII
  实施例号   渗透分数   ΔP(mmH2O)   FOM   FOM的改进
  FM1   0.953   0.5   0.0397
  72   0.592   2.7   0.0843   112％
  73   0.636   1.95   0.1008   154％
  74   0.472   2.25   0.1449   265％
  FM2   0.950   0.1   0.2328
  75   0.736   0.2   0.6656   186％
实施例76-79：具有纳米纤维涂层的发动机滤纸的FOM的改进
下述实施例说明了FOM的增加，并进而说明负载1.6g/m2(干重)纳米纤维的已有过滤介质的过滤性能的增加。初始过滤介质(表示为FM3)是在标准的汽车发动机的空气吸入过滤器中使用的标准树脂粘合的纤维素过滤介质。采用0.18微米的气溶胶颗粒以32slpm的流量在100cm2的定位模具内试验渗透性。实施例76用加拿大标准游离度为约2的原纤化Lyocell纳米纤维涂布。实施例77和78用约25％原纤化Lyocell纳米纤维和约75％FIBREGLASS#106微玻璃纤维涂布。实施例79用约25％加拿大标准游离度为约2的丙烯酸纳米纤维和约75％FIBREGLASS #106微玻璃纤维涂布。实施例79使用获自于Mitusibishi Rayon America的丙烯酸纳米纤维并原纤化成3mm的长度。如表XIV所示，在添加涂布于其上的小量纳米纤维的情况下获得FOM的显著改进。对于低成本的过滤器，这一小量的纳米纤维是改进过滤器性能的经济方式。
表XIV
  实施例号   渗透分数   ΔP(mmH2O)   FOM   FOM的改进
  FM3   0.906   4.1   0.0105
  76   0.525   11.9   0.0235   124％
  77   0.420   8.25   0.0457   335％
  78   0.742   7.85   0.0476   353％
  79   0.405   8.2   0.0478   355％
尽管已结合特定优选的实施方案具体描述了本发明，但显然根据上文描述，许多替换、修改和变化对本领域熟练技术人员来说是显而易见的。因此认为，所附权利要求书包括落入本发明真实范围和主旨内的任何这些替换、修改和变化。

Claims (15)

1.一种过滤介质，它包括加拿大标准游离度小于45的原纤化纤维，所述过滤介质具有下述性能指标：
厚度小于或等于0.25mm，和质量因数大于0.075，和
当截留尺寸为0.18微米的气溶胶颗粒时，效率大于99.9％，以及在32L/min的流量下经过尺寸为100cm2的样品时，压降小于40mm水柱；和
其中若所述过滤介质薄于0.25mm，则调节所述较薄的过滤介质的效率和压降以补偿达到0.25mm厚的厚度差，以提供满足或超过所述性能指标的过滤介质。
2.权利要求1的过滤介质，它还包括微玻璃纤维。
3.权利要求1的过滤介质，其中所述原纤化纤维带静电或产生静电荷。
4.权利要求1的过滤介质，它还包括选自下述的添加剂：活性炭、活化矾土、沸石、硅藻土、硅酸盐、铝硅酸盐、钛酸盐、骨炭、钙羟基磷灰石、氧化锰、氧化铁、镁氧矿、珍珠岩、滑石、聚合物颗粒、粘土、碘化树脂、离子交换树脂、陶瓷或其组合。
5.权利要求4的过滤介质，其中化学处理所述添加剂以给所述过滤介质赋予抗微生物或杀生物能力。
6.权利要求1的过滤介质，它还包括与原纤化纤维混合的微玻璃纤维，和其中所述原纤化纤维包括Lyocell、丙烯酸纤维、尼龙或其组合。
7.权利要求6的过滤介质，其中所述微玻璃纤维的纤维直径小于1微米。
8.权利要求6的过滤介质，其中所述原纤化纤维具有250纳米的纤维直径以及1mm至8mm的短切纤维长度。
9.权利要求6的过滤介质，其中所述原纤化纤维的用量是所述过滤介质重量的5％至40％。
10.权利要求1-9任一项的过滤介质，其中所述原纤化纤维的加拿大标准游离度小于10。
11.权利要求1-4，6-9中任一项的过滤介质，进一步包括支撑层，所述支撑层包含选自以下的材料：织物、无纺布、纺粘纤维、熔体吹塑纤维和纤维素。
12.权利要求1-4，6-9中任一项的过滤介质，其中湿铺所述原纤化纤维，以形成所述过滤介质。
13.权利要求1-4中任一项的过滤介质，其中所述原纤化纤维包括Lyocell、丙烯酸纤维、尼龙或其组合。
14.一种空气过滤器，包括权利要求1-4，6-10中任一项的过滤介质。
15.一种制备权利要求1的过滤介质的方法，其包括步骤：
分散原纤化纤维；和
形成厚度小于或等于0.25mm的原纤化纤维层。
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CN107921343A (zh) * 2015-07-16 2018-04-17 Fp创新研究所 包含纤维素长丝的过滤介质
US11707555B2 (en) 2020-07-01 2023-07-25 Duke University Nanofiber reinforcement of attached hydrogels
US11701452B2 (en) 2021-10-12 2023-07-18 Duke University Synthetic hydrogel composite
US12064533B2 (en) 2022-05-04 2024-08-20 Duke University Synthetic hydrogel composite

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CA2474854A1 (en) 2003-08-07
EP1483034A1 (en) 2004-12-08
JP2008229619A (ja) 2008-10-02
JP5307772B2 (ja) 2013-10-02
US6872311B2 (en) 2005-03-29
AU2003210565B2 (en) 2008-03-13
WO2003064006A1 (en) 2003-08-07
HK1074018A1 (en) 2005-10-28
US20030177909A1 (en) 2003-09-25
CA2474854C (en) 2010-04-27
DE60333550D1 (de) 2010-09-09
CN1625429A (zh) 2005-06-08
ATE475468T1 (de) 2010-08-15
EP1483034A4 (en) 2006-01-25
IL163159A (en) 2008-03-20
EP1483034B1 (en) 2010-07-28
JP2010284649A (ja) 2010-12-24
JP2005527344A (ja) 2005-09-15

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