Convoluted Dual Density Filter Material

Abstract

A dual layer filter material for separating fluid or particulates from flowing air streams that is comprised of connected layers of nonwoven batting with one layer having a convoluted surface.

Claims

1. A dual layer filter material for separation of fluid or particulates from air streams comprised of: a first stage that is a non-woven batting comprised of regular polyester fibers and low-melt polyester fibers; a second stage that is a non-woven batting comprised of regular polyester fibers and low-melt polyester fibers; wherein a surface of the first stage and a surface of the second stage are connected to each other.

2. The filter material of claim 1, wherein the first stage has a convoluted surface comprised Of a multiplicity of peaks and valleys.

3. The filter material of claim 1, wherein the connection between the first stage and second stage is accomplished by a glue adhesive.

4. The filter material of claim 1, wherein the polyester fibers of the first stage that are not low-melt polyester fibers are at least 25 denier.

5. The filter material of claim 1, wherein the polyester fibers of the second stage that are not low-melt polyester fibers are no greater than 15 denier.

6. The filter material of claim 2, wherein the first stage also has a generally flat surface opposite its convoluted surface.

7. The filter material of claim 6, wherein the height of the peaks of the convoluted surface above the generally flat surface exceeds the height of the valleys of the convoluted surface above the generally flat surface.

8. The filter material of claim 7, wherein the height of the peaks of the convoluted surface above the generally flat surface is at least two times greater than the height of the valleys of the convoluted surface above the generally flat surface.

9. The filter material of claim 1, wherein both the first stage and second stage are porous.

10. The filter material of claim 1, wherein both the first stage and second stage are impregnated with resin and that resin has been cured.

11. The filter material of claim 10, wherein the resin is a pure acrylic resin.

12. A dual layer filter material for separation of fluid or particulates from air streams that is comprised of: a porous first layer that has a top surface and a bottom surface and that is comprised of polyester fibers, low-melt polyester fibers, and resin; a porous second layer that has a top surface and a bottom surface and that is comprised of polyester fibers, low-melt polyester fibers, and resin; wherein the bottom surface of the first layer is adhered to the top surface of the second layer, and the resin in both layers is cured.

13. The filter material of claim 12, wherein the top surface of the first layer features a multiplicity of peaks and valleys.

14. The filter material of claim 13, wherein the distance between the tops of the peaks and the bottom surface of the first layer is greater than distance between the tops of the valleys and the bottom surface of the first layer.

15. The filter material of claim 14, wherein the distance between the tops of the peaks and the bottom surface of the first layer is at least double the distance between the tops of the valleys and the bottom surface of the first layer.

16. The filter material of claim 12, wherein a majority of the polyester fibers of the first layer are 25 denier or greater.

17. The filter material of claim 12, wherein the polyester fibers of the second layer are no greater than 15 denier.

18. The filter material of claim 12, wherein the resin is pure acrylic resin.

19. The filter material of claim 12, wherein the first layer and second layer are adhered together by a glue adhesive.

20. A dual layer filter material for separation of fluid or particulates from air streams that is comprised of: a first stage that is a porous non-woven batting comprised of polyester fibers, low-melt polyester fibers, and acrylic resin, wherein a majority of the polyester fibers are 25 denier or greater and the resin has been cured; a second stage that is a porous non-woven batting comprised of polyester fibers, low-melt polyester fibers, and acrylic resin, wherein the polyester fibers are no greater than 15 denier and the resin has been cured; wherein the first stage has a planar bottom surface and a convoluted top surface comprised of a multiplicity of peaks and valleys; wherein the second stage has a planar top surface and a planar bottom surface; an adhesive layer connecting the planar bottom surface of the first stage and the planar top surface of the second stage.

Description

DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a perspective view of the dual layer filter material 10. FIG. 1 illustrates that the dual layer filter material 10 is comprised of a first stage 30 and a second stage 40 that are joined by an adhesive layer 20. As can be appreciated from FIG. 1, the first stage 30 has a convoluted top surface that has the appearance of a repeated wave-like pattern comprised of a multiplicity of “peaks” and “valleys.”

[0019] FIG. 2 is a close-up detail view of the dual layer filter material 10 that is a close-up view of the section of the dual later filter material 10 in the circle 2 that appears in FIG. 1. As can be seen in more detail in FIG. 2, the first stage 30 has a convoluted top surface comprised of a multiplicity of peaks 32 and valleys 31 that are arranged in a wave-like pattern.

[0020] FIG. 3 is a side view of only the first stage 30. As can be seen in reference to FIG. 3, the convoluted top surface of the first stage 30 is comprised of a multiplicity of peaks 32 and valleys 31. The peaks 32 and valleys 31 rise above the first stage bottom surface 36, which is the bottom surface of the first stage 30, to a respective peak height (H) and a respective valley height (h), wherein the peak height H is greater than the valley height h. In most embodiments, the peak height H will be at least double the valley height h, and as shown in FIG. 3, in a preferred embodiment the peak height is three or more times the valley height h, as measured from the first stage bottom surface 36.

[0021] FIG. 4 is a side view demonstrating one part of a manufacturing process that may be used during the manufacturing of the first stage 30. As illustrated, the initial first stage material after curing 50 may be run through rollers (R) and cut by a cutter (C) into two separate sheets of first stage 30 material, each having a convoluted top surface as a result of the action of the cutter C. The cutter C may also be heated to the extent necessary to melt the low melt polyester fibers that are contained within the first stage material after curing 50 and that are ultimately located at the level of the peaks 32 and valleys 31 of the convoluted top surface after cutting.

[0022] FIG. 5 is a side view of the initial first stage material after curing 50 as it might appear immediately after a cutter C device or other similar tool has cut it into two separate sheets of the first stage 30 material along a wave-like cutting line 37, but immediately before the two sheets are pulled apart during the manufacturing process. Again, what is illustrated is a preferred embodiment in which the peak height H exceeds the valley height h for both of the sheets of first stage 30 material that will ultimately be pulled apart during manufacturing and then each will have its bottom surface (that is generally flat in most embodiments) adhered to a surface of second stage material 40.

[0023] As discussed above, when the first stage bottom surface 36 is physically attached with, or adhered to, a surface of the second stage 40, this may be done by using low melt point film between the layers and adding heat, or by sewing or stitching the two stages together, or possibly by needle punching the two layers for mechanical connection, but as also explained, in a preferred embodiment, the two stages are adhered to each other by using glue adhesive. It should be appreciated that regardless of the manner in which the first stage and second stage are physically connected to each other to form the dual layer filter material, there is at least some continuity of porosity between the two stages/layers at the location where they interface and are adhered together. Clearly this is the case in instances of mechanical connection such as with needling or sewing, but this would also be true for adhering the two stages/layers together, such as with use of low melt point film and application of heat or with gluing of the two stages because even though the fibers of each stage at the location of their interface and adhesion would be adhered to each other, there would also be overlap or partial overlap between the pores that exist between the fibers of each stage at the location of interface/adhesion between the stages/layers. Thus, there is at least some continuity of porosity between the stages/layers, and of course if there were not, there would be no air flow through the filter material, which is not the case.

[0024] The terms “fluid” and “liquid” are used synonymously in this specification and have the same meaning and are treated as interchangeable terms. Likewise, the terms “air stream” and “stream of air” and “flowing air” are used synonymously in this specification and have the same meaning and are treated as interchangeable terms. Furthermore, it is understood that the term “air” as used in this specification has its plain and ordinary meaning. Air is a mixture of primarily Nitrogen and Oxygen, with much smaller amounts of other gases, such as Carbon Dioxide, Neon, and Hydrogen, etc.

[0025] The embodiments and other features, aspects, and advantages of the present invention may be best understood and appreciated with reference to the drawings, descriptions, and claims. Where used in the various figures of the drawings, the same numerals designate the same or similar parts. Furthermore, When the terms “top”, “bottom”, “front”, “back”, “first”, “second”, “third”, “end”, “ends”, “side”, “sides”, “edge”, “edges” and similar terms are used herein, it should be understood that, unless otherwise specifically stated or otherwise made specifically clear by context, these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings, and such terms are utilized in order to facilitate describing the invention and in order to facilitate a better understanding of the invention.

[0026] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description of the invention that is provided in this specification. It is, therefore, contemplated that the appended claims will cover such modifications and variations that fall within the scope of the invention.