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US 2016/0256806 A1Published application
Composite filter media including a nanofiber layer formed directly onto a conductive layer
AssigneeLydall, Inc.
InventorsRobert G. Sanders, Stephen Edward Gross, Timothy Scott Lintz
Life of this patent
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Abstract
A composite filter media of a nanofiber layer that includes nanofibers formed from non-polar, non-conductive thermoplastic polymers using a solution spinning process to form the nanofibers directly onto a conductive layer is presented, along with the associated methodology for making such media. The conductive layer includes at least about greater than about 5 wt. % conductive fibers, Z-directional conductivity and a uniform surface conductivity of at least about 10−7 microsiemens.
Claims20
A composite filter media, comprising:
- a porous, wetlaid, conductive layer comprising greater than at least about 5 wt. % conductive fibers mixed into a matrix to form the conductive layer, the conductive layer having Z-directional conductivity, a uniform surface conductivity of at least about 10−7 microsiemens, a basis weight of about 10-200 gsm, and a Frazier of about 200-1000 cubic feet per minute (cfm);
- a nanofiber layer comprising solution spun nanofibers formed from non-polar, non-conductive thermoplastic polymers, the nanofiber layer having a basis weight of about 0.5-2.0 gsm and an average fiber diameter of about 300-800 nm, wherein the nanofiber layer is formed directly onto the conductive layer;
- one or more optional prefilter layer(s) having a basis weight of about 5-60 gsm;
- and
- an optional adhesive layer between the nanofiber layer and the prefilter layer.
2 more elements
A method of making a composite filter media comprising:
- providing a porous, wetlaid, conductive layer, the conductive layer comprising greater than at least about 5 wt. % conductive fibers mixed into a matrix to form the conductive layer, the conductive layer having Z-directional conductivity, a uniform surface conductivity of at least about 10−7 microsiemens, a basis weight of about 10-200 gsm, and a Frazier of about 200-1000 cubic feet per minute (cfm);
- and
- solution spinning nanofibers directly onto the conductive layer, thereby forming a nanofiber layer, wherein the nanofibers are formed from non-polar, non-conductive thermoplastic polymers, and wherein the nanofiber layer has a basis weight of about 0.5-2.0 gsm and an average fiber diameter of about 300-800 nm.
Dependencies are inferred from the claim text.