Biax-fiberfilm Corporation

Hollingsworth & Vose Company

Mohammad A Hassan

Douglas B Brown

Jeffrey D Stark

David T Healey

Maxim Silin

Bruce Smith

Sudheer Jinka

Greg Wagner Farell

Articles and methods relating to filter media are generally provided. In some embodiments, a filter media has an irregular surface structure. For instance, the filter media may comprise a plurality of peaks that are irregular in one or more ways. A ratio of a peak height standard deviation to an average peak height may be greater than or equal to 0.05, and/or a ratio of a peak spacing standard deviation to an average peak spacing may be greater than or equal to 0.08. In some embodiments, a filter media comprises a non-woven fiber web having a layer thickness of greater than 0.3 mm and/or a stiffness of less than or equal to 100 mg.

Filter media with irregular structure and/or reversibly stretchable layers

A spun-blown non-woven web is disclosed which is formed from a plurality of fibers formed from a single polymer having an average fiber diameter ranging from between about 0.5 microns to about 50 microns; a basis weight of at least about 0.5 gsm; a tensile strength, measured in a machine direction, ranging from between about 20 g to about 4,200 g; a ratio of tensile strength, measured in the machine direction, to basis weight of at least about 20:1; and a ratio of percent elongation, measured in the machine direction, to fiber diameter of at least about 15.

Spun-blown non-woven web

A high loft, nonwoven web is disclosed having a three dimensional structure with fibers oriented in the x, y and z directions. The web has a fiber size distribution of from 0 &#x3bc;m to about 15 &#x3bc;m with at least about 25% of the fibers being above 4 &#x3bc;m. The web has a thickness of less than about 250 millimeters and a basis weight ranging from about 20 g/m2 to about 3,000 g/m2. The web also has a vertical cross-section, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in the machine direction. The web further has a recovery value ranging from about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.

High loft, nonwoven web exhibiting excellent recovery

A process for forming a high loft, nonwoven web is disclosed. The process includes introducing a single molten polymer to a die having a plurality of nozzles. Emitting the molten polymer through the nozzles to form a plurality of filaments. Using air streams to facilitate movement and drawing of the filaments. Directing the filaments, which are transformed into fibers, towards a pair of heated moving surfaces. The pair of heated moving surfaces forming a convergent passage having an entry and an exit. Depositing the fibers into the entry of the convergent passage and routing the fibers between the pair of heated moving surfaces in a machine direction to form a high loft, non-woven web. The web having a fiber size distribution of from 0 &#x3bc;m to about 15 &#x3bc;m with at least about 25% of the fibers being above 4 &#x3bc;m.

Process for forming a high loft, nonwoven web exhibiting excellent recovery

A hybrid non-woven web is disclosed which is a matrix of a stream of fibers of a first material joined to streams of first and second spun-blown fibers. Each of the first and second spun-blown fibers are formed from a thermoplastic composition that contains at least one polymer having a melt flow rate of from between about 5 grams/10 minutes to about 6,000 grams/10 minutes at 230&#xb0; C. Each of the first and second spun-blown fibers also have an average diameter of between about 1 microns to 10 microns and a standard deviation of from between about 0.9 microns to about 5 microns. In addition, the hybrid non-woven web has a tensile strength of at least about 5 gf/gsm/cm width, measured in a machine direction. An apparatus and a method of forming the hybrid non-woven web are also disclosed.

Growing community of inventors

Johnson City, TN, United States of America

Mohammad A Hassan