Method of manufacturing a composite filter media

Details Method of manufacturing a composite filter media Method of manufacturing a composite filter media

2011-04-12

2011-04-12

Del Sole, Joseph S (Department: 1743)

Plastic and nonmetallic article shaping or treating: processes

Direct application of electrical or wave energy to work

Direct application of fluid pressure

C264S103000, C264S173100

Reexamination Certificate

active

07922959

ABSTRACT:
A method of making a composite filter media includes, in an exemplary embodiment, forming a nonwoven fabric mat that includes a plurality of synthetic fibers by a spunbond process, and calendering the nonwoven fabric mat with embossing calender rolls to form a bond area pattern comprising a plurality of substantially parallel discontinuous lines of bond area to bond the synthetic fibers together to form a nonwoven fabric, the nonwoven fabric having a filtration efficiency of about 35% to less than 50%, measured in accordance with EN 1822 (1998) test procedure. The method also includes applying a nanofiber layer by electro-blown spinning a polymer solution to form a plurality of nanofibers on at least one side of the nonwoven fabric mat to form the composite filter media, the composite filter media having a minimum filtration efficiency of about 70%, measured in accordance with EN 1822 (1998) test procedure.

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