Filter composite embodying glass fiber and synthetic resin fiber

Abstract

A filter composite comprises a first layer of glass fibers having random orientation, and synthetic resinous fibers extending in close association with the glass fibers, the glass fibers having: i) diameters between 1 and 16 microns ii) lengths between about ¼ and 1½ inches the synthetic fibers having denier between 1.6 and 40, and length between ¼ and 2 inches.

I claim:  
     
         1 . In a filter composite the combination comprising 
 a) a first layer of glass fibers having random orientation, and    b) synthetic resinous fibers extending in close association with said glass fibers,    c) said glass fibers having: 
 i) diameters between 1 and 16 microns  
 ii) lengths between about ¼ and 1½ inches  
   d) said synthetic fibers having denier between 1.6 and 40, and length between ¼ and 2 inches.    
     
     
         2 . The combination of  claim 1  wherein said synthetic resinous fibers are distributed in a homogeneous mix with said first layer glass fibers.  
     
     
         3 . The combination of  claim 1  wherein said synthetic resinous fibers together comprise between 10 and 60% by volume of the total composite volume.  
     
     
         4 . The combination of  claim 2  wherein the composite includes an additional layer of non-woven NYLON or RAYON fiber extending adjacent said first layer.  
     
     
         5 . The combination of  claim 4  wherein said non-woven glass fiber layer consists of non-woven NYLON or RAYON laminated onto the layer of glass fibers.  
     
     
         6 . The combination of  claim 5  wherein said synthetic resinous fibers together comprise between 10 and 60% by volume of the total composite volume.  
     
     
         7 . The combination of  claim 1  wherein said synthetic resinous fibers extend in a second layer adjacent said first layer.  
     
     
         8 . The combination of  claim 7  wherein the composite includes an additional layer of non-woven NYLON or RAYON fiber extending adjacent one of said first and second layers.  
     
     
         9 . The combination of  claim 8  wherein said non-woven glass fiber layer consists of NYLON or RAYON.  
     
     
         10 . The combination of  claim 4  including bonding resin adherent to the fibers in said layers, the filter composite being porous.  
     
     
         11 . The combination of  claim 8  including bonding resin adherent to the fibers in said layers, the filter composite being porous.  
     
     
         12 . The combination of  claim 10  wherein the bonding resin saturates said layers.  
     
     
         13 . The combination of  claim 11  wherein the bonding resin saturates said layers.  
     
     
         14 . The combination of  claim 1  wherein said synthetic resinous fibers consist of polyester resin, or other man-made fibers.  
     
     
         15 . The combination of  claim 1  wherein said synthetic resinous fibers have one or more of the following shapes: 
 i) crimped  
 ii) hollow  
 iii) straight shafts  
 iv) solid shafts  
 
     
     
         16 . The combination of  claim 4  wherein said synthetic resinous fibers consist of one of the following: 
 i) polyester resin  
 ii) other man-made fibers  
 
     
     
         17 . The combination of  claim 4  wherein said synthetic resinous fibers have one of the following shapes: 
 i) crimped  
 ii) hollow  
 iii) straight shafts  
 iv) solid shafts  
 
     
     
         18 . The combination of  claim 1  wherein the bulk of said glass fibers have: 
 i) diameters between 1 and 16 microns  
 ii) lengths between ¼ and 1½ inches.  
 
     
     
         19 . The combination of  claim 1  wherein the filter composite has weight between 0.01 and 0.05 lbs, per square foot.  
     
     
         20 . The combination of  claim 8  wherein the filter composite has weight between 0.01 and 0.05 lbs per square foot.  
     
     
         21 . The combination of  claim 1  wherein the filter composite has sufficient thickness to be self supporting during gas flow impingement on said composite, at gas flow velocity between 35 and 2,000 feet per minute.  
     
     
         22 . The combination of  claim 8  wherein the filter composite has sufficient thickness to be self supporting gas flow impingement on said composite at gas flow velocity between 35 and 2,000 feet 3  per minute.  
     
     
         23 . The combination of  claim 1  wherein the composite overall thickness is between 0.010 and 0.100 inches.  
     
     
         24 . The combination of  claim 8  wherein the composite overall thickness is between 0.010 and 0.100 inches.  
     
     
         25 . In a filter composite, the combination comprising 
 a) a first layer of glass fibers having random orientation,    b) an additional layer of non-woven glass fiber extending adjacent said first layer,    c) and including bonding resin adherent to fibers in said layers, the fiber composite being porous,    d) and wherein the bulk of said glass fibers have: 
 i) diameters between 1 and 16 microns  
 ii) lengths between ¼ and 1½ inches.  
   
     
     
         26 . The combination of  claim 25  wherein the additional layer faces the first layer, and consists of NYLON or RAYON.  
     
     
         27 . The combination of  claim 25  wherein the bonding resin consists essentially of thermoplastic resin adapted to be heated during reforming of the filter to selected shape.  
     
     
         28 . The combination of  claim 27  wherein the filter has been reformed to selected shape, said selected shape including pleats.  
     
     
         29 . The combination of  claim 25  wherein the resin is thermosetting.  
     
     
         30 . The method of forming a filter media composite which includes the steps: 
 a) providing a first layer of glass fibers having random orientation,    b) providing an additional layer of synthetic resinous or other man-made fibers extending adjacent said first layer,    c) and providing and adhering bonding resin to fibers in said layers, and then removing sufficient of the bonding resin to establish filter porosity, for allowing gas flow through the filter.    
     
     
         31 . The method of  claim 30  wherein the bonding resin consists essentially of thermoplastic resin, and including reforming the media composite to selected shape and heating the reformed media composite to cause the composite to maintain said selected shape.  
     
     
         32 . The method of  claim 30  wherein the bonding resin is thermosetting.  
     
     
         33 . The method of  claim 30  wherein an additional layer is positioned to face the first layer, and consists of a non-woven fiber backer.