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US20010037540A1 - Filtration device and process for its manufacture - Google Patents

Filtration device and process for its manufacture Download PDF

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Publication number
US20010037540A1
US20010037540A1 US09/202,147 US20214798A US2001037540A1 US 20010037540 A1 US20010037540 A1 US 20010037540A1 US 20214798 A US20214798 A US 20214798A US 2001037540 A1 US2001037540 A1 US 2001037540A1
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US
United States
Prior art keywords
fibres
web
process according
group
filtration device
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
US09/202,147
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US6440192B2 (en
Inventor
Valeo Paris
Claude Legrand
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
VALEO
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
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Assigned to VALEO reassignment VALEO ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GUERIN, RICHARD, LEGRAND, CLAUDE
Publication of US20010037540A1 publication Critical patent/US20010037540A1/en
Assigned to VALCO reassignment VALCO CORRECTIVE ASSIGNMENT TO CORRECT THE ADDRESS OF THE ASSIGNEE. FILED ON 12/09/1998, RECORDED ON REEL 010064 FRAME 0838 ASSIGNOR HEREBY CONFIRMS THE ASSIGNMENT OF THE ENNTIRE INTEREST. Assignors: GUERIN, RICHARD, LEGRAND, CLAUDE
Application granted granted Critical
Publication of US6440192B2 publication Critical patent/US6440192B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H3/00—Other air-treating devices
    • B60H3/06—Filtering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003—Glass or glassy material
    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2027—Metallic material
    • B01D39/2041—Metallic material the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/10—Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F8/00—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying
    • F24F8/10—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering
    • F24F8/108—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering using dry filter elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F8/00—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying
    • F24F8/10—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S55/00—Gas separation
    • Y10S55/05—Methods of making filter

Definitions

  • the present invention concerns a process for manufacturing a filtration device more particularly intended for filtering gases such as air for ventilating and/or heating and/or air conditioning rooms or motor vehicles.
  • the invention also concerns a filtration device manufactured by the above process.
  • Prior art filtration devices are made by spinning a thermoplastics polymer through nozzles to produce an intermingling of the filaments issuing from the nozzles forming, after cooling, a lap that can constitute a particle filter.
  • the filters obtained in this way have a high specific gravity and a high unit cost.
  • the process for manufacturing a filtration device of the aforementioned type in accordance with the invention is characterised in that it comprises an operation of carding fibres having a length in the range 38 mm to 120 mm and a diameter greater than 10 ⁇ m to form an isotropic web and in that said web is subjected to a mechanical consolidation operation by means of hydraulic binding consisting in passing very fine water jets at a high pressure through the web disposed on a rotating drum followed by a drying operation.
  • the carding operation is carried out using a wool type card
  • said card incorporates “Dispelmel” type randomising units
  • the pressure of the water jets used for the hydraulic binding is in the range 40 bars to 200 bars;
  • the parameters of the card are chosen to obtain a web having a mass per unit surface area in the range approximately 20 g/m 2 to approximately 150 g/m 2 .
  • the filtration device of the above type is characterised in that it comprises an isotropic web.
  • said web is in a single layer
  • the length of said fibres is at least equal to 38 mm;
  • the length of said fibres is at most equal to 120 mm;
  • the average diameter of said fibres is at least equal to 10 ⁇ m
  • said fibres are fibres of the same kind or a mixture of different fibres.
  • said fibres are selected from the group of thermoplastics fibres such as fibres of polypropylene, polyethylene, polyester, polycarbonate, polyamide, the group of acrylic fibres, pre-oxidised acrylic fibres, the group of aramide fibres, the group of phenolic fibres, the group of fluorocarbon fibres, the group of mineral fibres such as glass fibres and the group of metal fibres.
  • thermoplastics fibres such as fibres of polypropylene, polyethylene, polyester, polycarbonate, polyamide, the group of acrylic fibres, pre-oxidised acrylic fibres, the group of aramide fibres, the group of phenolic fibres, the group of fluorocarbon fibres, the group of mineral fibres such as glass fibres and the group of metal fibres.
  • the invention provides a filtration device that is efficient and of lower unit cost and of lower specific gravity than the prior art filtration devices.
  • 1.7 Tex (14 ⁇ m diameter) polypropylene fibres are cut to a length of 40 mm and then introduced into a mixer.
  • the fibre mixture obtained is then carded by means of a two-doffer wool type card equipped with a “Dispelmel” type randomising unit to obtain an isotropic web.
  • the web leaving the card is introduced into a condenser to form a single layer lap.
  • the parameters of the card and/or of the condenser are selected to produce a web or a lap having a mass per unit surface area in the range approximately 20 g/m 2 to approximately 150 g/m 2 .
  • the web or lap is deposited onto a belt and then consolidated by a hydraulic binding operation.
  • the hydraulic binding operation consists in passing very fine water jets at a high pressure (in the range 40 bars to 200 bars) through the web or lap disposed on a rotating drum.
  • the web or lap is mounted on a support to form the filtration device.
  • the particles corresponded to a “fine SAE powder” defined in US Standard SAE J 726/ISO 5011.
  • the particle concentration was 100 mg/m 3 .

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Filtering Materials (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Disclosed is a process for manufacturing a filtration device. The process includes a fiber carding procedure which forms a web. The filtration device in accordance with the invention takes the form of a web consisting of a single layer lap.

Description

  • The present invention concerns a process for manufacturing a filtration device more particularly intended for filtering gases such as air for ventilating and/or heating and/or air conditioning rooms or motor vehicles. [0001]
  • The invention also concerns a filtration device manufactured by the above process. [0002]
  • Prior art filtration devices are made by spinning a thermoplastics polymer through nozzles to produce an intermingling of the filaments issuing from the nozzles forming, after cooling, a lap that can constitute a particle filter. [0003]
  • The prior art processes have the drawback of necessitating the superposition and binding together of a plurality of layers in order to obtain filters that are sufficiently efficient. [0004]
  • The filters obtained in this way have a high specific gravity and a high unit cost. [0005]
  • An aim of the invention is to manufacture a filtration device that is efficient and less dense and more economic than the prior art devices. [0006]
  • The process for manufacturing a filtration device of the aforementioned type in accordance with the invention is characterised in that it comprises an operation of carding fibres having a length in the range 38 mm to 120 mm and a diameter greater than 10 μm to form an isotropic web and in that said web is subjected to a mechanical consolidation operation by means of hydraulic binding consisting in passing very fine water jets at a high pressure through the web disposed on a rotating drum followed by a drying operation. [0007]
  • In accordance with other features of the process in accordance with the invention, separately or in all technically possible combinations: [0008]
  • the carding operation is carried out using a wool type card; [0009]
  • said card incorporates “Dispelmel” type randomising units; [0010]
  • the pressure of the water jets used for the hydraulic binding is in the range 40 bars to 200 bars; [0011]
  • the parameters of the card are chosen to obtain a web having a mass per unit surface area in the range approximately 20 g/m[0012] 2 to approximately 150 g/m2.
  • In accordance with the invention the filtration device of the above type is characterised in that it comprises an isotropic web. [0013]
  • In accordance with other features of the filtration device in accordance with the invention, separately or in all technically possible combinations: [0014]
  • said web is in a single layer; [0015]
  • the length of said fibres is at least equal to 38 mm; [0016]
  • the length of said fibres is at most equal to 120 mm; [0017]
  • the average diameter of said fibres is at least equal to 10 μm; [0018]
  • said fibres are fibres of the same kind or a mixture of different fibres. [0019]
  • said fibres are selected from the group of thermoplastics fibres such as fibres of polypropylene, polyethylene, polyester, polycarbonate, polyamide, the group of acrylic fibres, pre-oxidised acrylic fibres, the group of aramide fibres, the group of phenolic fibres, the group of fluorocarbon fibres, the group of mineral fibres such as glass fibres and the group of metal fibres. [0020]
  • It has been found that the invention provides a filtration device that is efficient and of lower unit cost and of lower specific gravity than the prior art filtration devices. [0021]
  • Another important advantage compared to the prior art is that the head loss when a gas passes through the filtration device is much lower.[0022]
  • Other aspects and advantages of the invention will become apparent in the following description of one embodiment of a filtration device designed to be installed in equipment for heating/air conditioning a motor vehicle. [0023]
  • 1.7 Tex (14 μm diameter) polypropylene fibres are cut to a length of 40 mm and then introduced into a mixer. [0024]
  • The fibre mixture obtained is then carded by means of a two-doffer wool type card equipped with a “Dispelmel” type randomising unit to obtain an isotropic web. [0025]
  • In one variant of the process the web leaving the card is introduced into a condenser to form a single layer lap. [0026]
  • The parameters of the card and/or of the condenser are selected to produce a web or a lap having a mass per unit surface area in the range approximately 20 g/m[0027] 2 to approximately 150 g/m2.
  • The web or lap is deposited onto a belt and then consolidated by a hydraulic binding operation. [0028]
  • The hydraulic binding operation consists in passing very fine water jets at a high pressure (in the range 40 bars to 200 bars) through the web or lap disposed on a rotating drum. [0029]
  • When they bounce off the drum the water jets cause knotting of the fibres imparting a high mechanical strength to the web or lap without significantly increasing its specific gravity. [0030]
  • After drying, the web or lap is mounted on a support to form the filtration device. [0031]
  • Using a 0.84 mm thick web or lap the process has produced a filter having a mass per unit surface area of 66 g/m[0032] 2 and a specific gravity of 0.07.
  • To test the efficiency of a filter obtained in the above manner, it was disposed across a 100 cm[0033] 2 20 cm/s flow of air laden with particles.
  • The particles corresponded to a “fine SAE powder” defined in US Standard SAE J 726/ISO 5011. [0034]
  • The particle concentration was 100 mg/m[0035] 3.
  • The head loss across the filter under the above conditions was only 14 Pa and the efficiency was 80%. [0036]
  • Compared to filtration devices currently on the market, an efficiency comparable to the best of them was obtained with a product having a much lower specific gravity (0.07 compared to 0.12 to 0.30) generating a much lower head loss. [0037]
  • Endurance tests have shown that the efficiency of the filtration device in accordance with the invention is more stable with time. [0038]
  • What is more, the process described hereinabove is carried out continuously and produces the filtration device in a single operation. [0039]

Claims (12)

1. A process for manufacturing a filtration device more particularly intended for filtering gases such as air for ventilating and/or heating and/or conditioning rooms or automobile vehicles, characterised in that it comprises an operation of carding fibres having a length in the range 38 mm to 120 mm and a diameter greater than 10 μm to form an isotropic web and in that said web is subjected to a mechanical consolidation operation by means of hydraulic binding consisting in passing very fine water jets at a high pressure through the web disposed on a rotating drum followed by a drying operation.
2. A process according to
claim 1
 characterised in that the carding operation is carried out using a wool type card.
3. A process according to
claim 2
 characterised in that said card incorporates “Dispelmel” type randomising units.
4. A process according to any one of
claims 1
 to
3
 characterised in that the pressure of the water jets is in the range 40 bars to 200 bars.
5. A process according to any one of
claims 1
 to
4
 characterised in that the parameters of the card are chosen to obtain a web having a mass per unit surface area in the range approximately 20 g/m2 to approximately 150 g/m2.
6. A process according to any one of the preceding claims characterised in that the web is in a single layer.
7. A process according to any one of the preceding claims characterised in that said fibres are fibres of the same kind or a mixture of different fibres.
8. A process according to
claim 7
 characterised in that said fibres are selected from the group of thermoplastics fibres such as fibres of polypropylene, polyethylene, polyester, polycarbonate, polyamide, the group of acrylic fibres, pre-oxidised acrylic fibres, the group of aramide fibres, the group of phenolic fibres, the group of fluorocarbon fibres, the group of mineral fibres such as glass fibres and the group of metal fibres.
9. A filtration device for filtering gases such as air for ventilating and/or heating and/or air conditioning rooms or motor vehicles manufactured in particular by the process according to any one of the preceding claims characterised in that it consists of an isotropic web.
10. A filtration device according to
claim 9
 characterised in that the web is in a single layer.
11. A filtration device according to
claim 9
 or
claim 10
 characterised in that the isotropic web is made up of fibres having a length in the range 38 mm to 120 mm and an average diameter at least equal to 10 μm.
12. A filtration device according to
claim 9
 or
claim 10
 characterised in that the isotropic web is made up of polypropylene fibres having a length in the range 38 mm to 120 mm and an average diameter at least equal to 10 μm.
US09/202,147 1997-04-10 1998-03-27 Filtration device and process for its manufacture Expired - Fee Related US6440192B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
FR9704524A FR2761901B1 (en) 1997-04-10 1997-04-10 METHOD FOR PRODUCING A FILTERING DEVICE AND FILTERING DEVICE IN PARTICULAR FOR AERATION AND / OR AIR CONDITIONING OF PREMISES OR VEHICLES
FR9704524 1997-04-10
FR97/04524 1997-04-10
PCT/FR1998/000633 WO1998045023A1 (en) 1997-04-10 1998-03-27 Filtration device and process for its manufacture

Publications (2)

Publication Number Publication Date
US20010037540A1 true US20010037540A1 (en) 2001-11-08
US6440192B2 US6440192B2 (en) 2002-08-27

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Country Status (6)

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US (1) US6440192B2 (en)
EP (1) EP0925101B1 (en)
JP (1) JP2000512900A (en)
DE (1) DE19880664T1 (en)
FR (1) FR2761901B1 (en)
WO (1) WO1998045023A1 (en)

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US20060277731A1 (en) * 2003-04-08 2006-12-14 Jochen Schreiber Method for stitch-bonding or finishing a material web by means of hidrodynamic needling, and product produced according to this method

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FR2800993B1 (en) * 1999-11-17 2003-08-15 Valeo METHOD FOR PRODUCING A FILTRATION DEVICE AND FILTRATION DEVICE FOR GAS FILTRATION SUCH AS AIR FOR AERATION AND / OR HEATING AND / OR AIR CONDITIONING OF PREMISES OR MOTOR VEHICLES.
FR2806320B1 (en) * 2000-03-15 2003-02-07 Valeo FILTRATION DEVICE FOR FITTING A VENTILATION AND / OR HEATING AND / OR AIR CONDITIONING APPARATUS, PARTICULARLY FOR A MOTOR VEHICLE
FR2806319B1 (en) * 2000-03-15 2002-10-25 Valeo FILTRATION DEVICE FOR FITTING A VENTILATION AND / OR HEATING AND / OR AIR CONDITIONING APPARATUS, PARTICULARLY FOR A MOTOR VEHICLE
FR2806318B1 (en) * 2000-03-15 2002-10-25 Valeo FILTRATION DEVICE FOR FITTING A VENTILATION AND / OR HEATING AND / OR AIR CONDITIONING APPARATUS, IN PARTICULAR FOR A MOTOR VEHICLE
DE10053233A1 (en) * 2000-10-26 2002-05-16 Tesa Ag Use of a roughened textile fabric as pollen protection for windows and doors
US7582270B2 (en) 2002-10-28 2009-09-01 Geo2 Technologies, Inc. Multi-functional substantially fibrous mullite filtration substrates and devices
US7572311B2 (en) 2002-10-28 2009-08-11 Geo2 Technologies, Inc. Highly porous mullite particulate filter substrate
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Publication number Priority date Publication date Assignee Title
US20050233666A1 (en) * 2000-12-13 2005-10-20 N.V. Bekaert S.A. Short metal fibers
US20060277731A1 (en) * 2003-04-08 2006-12-14 Jochen Schreiber Method for stitch-bonding or finishing a material web by means of hidrodynamic needling, and product produced according to this method

Also Published As

Publication number Publication date
JP2000512900A (en) 2000-10-03
DE19880664T1 (en) 1999-05-12
FR2761901A1 (en) 1998-10-16
EP0925101B1 (en) 2004-04-21
EP0925101A1 (en) 1999-06-30
US6440192B2 (en) 2002-08-27
WO1998045023A1 (en) 1998-10-15
FR2761901B1 (en) 1999-05-14

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