# US 9,435,056 B2 · Fibers made from soluble polymers

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- Number: US 9,435,056 B2
- Document ID: US9435056B2
- Status: Granted
- Kind: B2
- Application number: 14/346,497
- Filed: 2012-09-21
- Published: 2014-08-21
- Granted: 2016-09-06
- Earliest claimed: 2011-09-21
- Assignees: Donaldson Company, Inc.
- Applicants: Donaldson Company, Inc.
- Inventors: Suresh L. Shenoy; Thomas M. Weik
- Web page: https://patentgrep.com/patent/US9435056B2

## CPC

- D01F 8/16: with at least one other macromolecular compound obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds as constituent
- B01D 39/1623: {of synthetic origin}
- C08L 37/00: Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a heterocyclic ring containing oxygen (of cyclic esters of polyfunctional acids C08L31/00; of cyclic anhydrides of unsaturated acids C08L35/00); Compositions of derivatives of such polymers
- C08L 39/08: Homopolymers or copolymers of vinyl-pyridine
- C09D 161/06: of aldehydes with phenols
- C09D 161/26: of aldehydes with heterocyclic compounds
- C09D 161/28: with melamine
- D01D 5/0007: {Electro-spinning (non-woven fabrics produced by electro-spinning D04H1/728)}
- D01F 6/20: from polymers of cyclic compounds with one carbon-to-carbon double bond in the side chain
- D01F 6/42: comprising cyclic compounds containing one carbon-to-carbon double bond in the side chain as major constituent
- D01F 6/56: of polymers of cyclic compounds with one carbon-to-carbon double bond in the side chain
- D01F 6/94: of other polycondensation products
- D01F 8/04: from synthetic polymers
- D04H 1/728: by electro-spinning {(electro-spinning methods and apparatus D01D5/0007)}
- C08L 61/06: of aldehydes with phenols
- C08L 61/26: of aldehydes with heterocyclic compounds
- C08L 61/28: with melamine
- C08L 2201/54: Aqueous solutions or dispersions
- C08L 2203/12: used for fibers
- C08L 2205/04: containing interpenetrating networks
- C08L 2312/00: Crosslinking
- D10B 2321/12: polymers of cyclic compounds with one carbon-to-carbon double bond in the side chain
- D10B 2505/04: Filters
- Y10T 428/2967: Synthetic resin or polymer
- Y10T 428/298: Physical dimension
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- 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)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- 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)
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A fiber can be made having a structure with an axial core and a coating layer. The fiber can have a polymer core and one or two layers surrounding the core. The fine fiber can be made from a polymer material and a resinous aldehyde composition such that the general structure of the fiber has a polymer core surrounded by at least a layer of the resinous aldehyde composition.

## Claims

### Claim 1

A fine fiber comprising a nonreactive polymer and a self-crosslinked resinous aldehyde composition within the fiber wherein the resinous aldehyde composition is present in an amount of greater than 20 parts by weight per 100 parts by weight of the polymer, and further wherein the fine fiber has an average diameter of no greater than 5 microns.

### Claim 2 (depends on 1)

The fine fiber of claim 1 wherein the nonreactive polymer and self-crosslinked resinous aldehyde composition forms a uniform mixture in a semi-interpenetrating network morphology.

### Claim 3 (depends on 1)

The fine fiber of claim 1 comprising three phases, wherein the core phase comprises the polymer, the coating phase comprises the resinous aldehyde composition, and a transition phase comprises a mixture of the polymer and the resinous aldehyde composition.

### Claim 4 (depends on 1)

The fine fiber of claim 1 which is prepared from a resinous aldehyde composition comprising reactive alkoxy groups and a nonreactive polymer.

### Claim 5 (depends on 1)

The fine fiber of claim 1 wherein the resinous aldehyde composition comprises a resinous formaldehyde composition.

### Claim 6 (depends on 5)

The fine fiber of claim 5 wherein the resinous formaldehyde composition comprises a resinous melamine-formaldehyde composition.

### Claim 7 (depends on 1)

The fine fiber of claim 1 wherein the resinous aldehyde composition comprises a melamine-aldehyde composition; and wherein the aldehyde comprises formaldehyde, acetaldehyde, butyraldehyde, isobutyraldehyde, or mixtures thereof.

### Claim 8 (depends on 1)

The fine fiber of claim 1 wherein the resinous aldehyde composition comprises a condensation product of urea and an aldehyde, a condensation product of phenol and an aldehyde, a condensation product of melamine and an aldehyde, or a mixture thereof.

### Claim 9 (depends on 1)

The fine fiber of claim 1 wherein the resinous aldehyde composition comprises a condensation product of benzoguanamine and an aldehyde, a condensation product of glycoluril and an aldehyde, or a mixture thereof.

### Claim 10

A fine fiber comprising a core phase and a coating phase; wherein the core phase comprises nonreactive polymer and the coating phase comprises a self-crosslinked resinous melamine-aldehyde composition; wherein the fine fiber is prepared from a resinous melamine-aldehyde composition in an amount of greater than 20 parts by weight per 100 parts by weight of the nonreactive polymer, and further wherein the fine fiber has an average diameter of no greater than 5 microns.

### Claim 11 (depends on 1)

A filter media comprising a filtration substrate and a layer comprising a plurality of fine fibers of claim 1 disposed on the substrate.

### Claim 12 (depends on 11)

The filter media of claim 11 wherein the fine fiber layer has a thickness of 0.05μ to 30μ.

### Claim 13 (depends on 11)

The filter media of claim 11 wherein the filtration substrate is a non-woven substrate.

### Claim 14 (depends on 11)

The filter media of claim 11 wherein the fine fiber layer is an electrospun layer and the filtration substrate comprises a cellulosic or synthetic nonwoven.

### Claim 15 (depends on 11)

The filter media of claim 11 wherein the filtration substrate comprises a polyester nonwoven, a polyolefin nonwoven, or a blended nonwoven thereof.

### Claim 16 (depends on 11)

The filter media of claim 11 wherein the filtration substrate comprises polypropylene nonwoven.

### Claim 17 (depends on 11)

The filter media of claim 11 wherein the filtration substrate comprises a spunbonded or melt-blown support.

### Claim 18 (depends on 11)

A filter element comprising a filter media of claim 11.