# US 7,407,701 B2 · Lofted composite with enhanced air permeability

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- Number: US 7,407,701 B2
- Document ID: US7407701B2
- Status: Granted
- Kind: B2
- Application number: 11/189,686
- Filed: 2005-07-26
- Published: 2006-02-02
- Granted: 2008-08-05
- Earliest claimed: 2004-07-30
- Assignees: KX Technologies LLC
- Inventors: Richard D Kendrick
- Web page: https://patentgrep.com/patent/US7407701B2

## CPC

- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/022: {Non-woven fabric}
- B32B 29/02: next to a fibrous or filamentary layer
- D04H 1/407: containing absorbing substances, e.g. activated carbon
- D04H 1/413: containing granules other than absorbent substances
- D06N 3/0056: {characterised by the compounding ingredients of the macro-molecular coating (D06N3/005 takes precedence)}
- D06N 3/0088: {by directly applying the resin (D06N3/0045 takes precedence)}
- B01D 39/02: Loose filtering material, e.g. loose fibres
- B01D 2239/0407: comprising particulate additives, e.g. adsorbents
- B32B 2250/03: 3 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/0276: Polyester fibres
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2264/0207: Particles made of materials belonging to B32B25/00
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/726: Permeability to liquids, absorption
- Y10T 428/249924: Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T 428/249939: Two or more layers
- Y10T 442/673: Including particulate material other than fiber
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite of the present invention comprises a substrate having deposited on a surface thereof a dry mixture of active particles, lofting fibers, and binder particles. The composite has increased air permeability and lower air resistance than prior art composites that do not incorporate lofting fibers.

## Claims

### Claim 1

A composite comprising:
a discrete substrate having a first surface;
a dry mixture on the first surface of said substrate, said dry mixture comprising active particles, binder particles, and lofting fibers having a denier of greater than 20,
wherein said binder particles coalesce the active particles and the lofting fibers to each other and to said substrate.

### Claim 2 (depends on 1)

A composite of claim 1 wherein said substrate comprises a nonwoven layer having an air permeability of greater than about 600 scfm.

### Claim 3 (depends on 1)

A composite of claim 1 wherein said substrate comprises a wet laid nonwoven layer further including a latex binder.

### Claim 4 (depends on 1)

A composite of claim 1 wherein the active particles comprise an adsorbent, an absorbent, or combinations thereof.

### Claim 5 (depends on 1)

A composite of claim 1 wherein the active particles comprise activated carbon having an average particle size of about 20×50 mesh.

### Claim 6 (depends on 1)

A composite of claim 1 wherein the lofting fibers have a denier greater than about 30.

### Claim 7 (depends on 1)

A composite of claim 1 wherein the lofting fibers have a denier greater than about 45.

### Claim 8 (depends on 1)

A composite of claim 1 wherein the lofting fibers are present in an amount of about 3 to about 12% by weight based on a total weight of the dry mixture.

### Claim 9 (depends on 1)

A composite of claim 1 wherein the lofting fibers comprise polymers, metal, glass, ion-exchange resins, engineered resins, or combinations thereof.

### Claim 10 (depends on 1)

A composite of claim 1 wherein the lofting fibers comprise polyester having a denier of about 45.

### Claim 11 (depends on 1)

A fluid filtration system comprising the composite of claim 1.

### Claim 12

A composite comprising:
a discrete substrate having a first surface;
a dry mixture deposited on the first surface of said substrate, said dry mixture comprising active particles, binder particles, and lofting fibers having a denier of greater than 20,
wherein said composite is heated to a softening temperature of the binder particles, but below a melting temperature of the active particles and the lofting fibers, such that the softened binder particles coalesce the active particles and the lofting fibers to each other and to said substrate; and
said composite having an air permeability of greater than about 200 scfm.

### Claim 13 (depends on 12)

A composite of claim 12 wherein the active particles comprise an adsorbent, an absorbent, or combinations thereof.

### Claim 14 (depends on 12)

A composite of claim 12 wherein the lofting fibers are present in an amount of about 3 to about 12% by weight based on a total weight of the dry mixture.

### Claim 15 (depends on 12)

A composite of claim 12 wherein the lofting fibers comprise polymers, metal, glass, ion-exchange resins, engineered resins, or combinations thereof.

### Claim 16 (depends on 12)

A composite of claim 12 wherein the lofting fibers comprise polyester having a denier of about 45.

### Claim 17 (depends on 12)

A composite of claim 12 wherein said substrate comprises a wet laid nonwoven layer further including a latex binder.

### Claim 18 (depends on 12)

A composite of claim 12 wherein the active particles comprise activated carbon having an average particle size of about 20×50 mesh.

### Claim 19 (depends on 12)

A composite of claim 12 wherein the active particles have microbiological interception capabilities.

### Claim 20 (depends on 12)

A fluid filtration system comprising the composite of claim 12.