Meltblown composites and uses thereof

Details Meltblown composites and uses thereof Meltblown composites and uses thereof

1998-10-20

2001-03-06

Morris, Terrel (Department: 1771)

Fabric (woven, knitted, or nonwoven textile or cloth, etc.)

Nonwoven fabric

Including strand or fiber material which is of specific...

C442S344000, C442S400000, C428S212000, C428S218000

Reexamination Certificate

active

06197709

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to novel melt blown (MB) composites in which staple fibers such as polypropylene, polyethylene, polyesters, nylons, cotton, wool, glass fibers and/or particulate materials including activated carbon, superabsorbent powders and fibers, and shredded textile materials are thoroughly intermingled with MB fibers in the MB composite web in a controllable manner such that a desired density gradient across the composite web is achieved. The invention also relates to such composites which are preferably cold electrostatically charged, to the process of so charging, to a method of using the composite, and a process for making the composite.
BACKGROUND OF THE INVENTION
Melt blown (MB) nonwovens are used for air filters because their ultra fine fibers provide large surface area. However, their high packing density results in high air resistance and only surface filtration is available for most particle sizes. This largely restricts their application to one-time use disposable respirators, surgical face masks and operating room fabrics.
The invention contributes to solving the shortcomings of the prior art.
SUMMARY OF THE INVENTION
This invention provides high-porous MB composites with controllable density across the thickness of the filter by embedding staple fibers into the melt blowing fiber stream. These composites have bulk and low pressure drop—hence their particle holding capacity and service life are increased without reducing the filtration efficiency. Furthermore, the filtration efficiency may be enhanced even more appreciably by electrostatically charging the composites.


REFERENCES:
patent: 5350620 (1994-09-01), Sundet et al.
patent: 5609947 (1997-03-01), Kamei et al.
patent: 5620785 (1997-04-01), Watt et al.
patent: 5679042 (1997-10-01), Varona
patent: 5804512 (1998-09-01), Lickfield et al.

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