Flame Resistant Viscose Filter Apparatus and Method

Abstract

A filter assembly includes a filter pad comprising flame resistant viscose. The filter assembly also includes a bonding emulsion. The bonding emulsion may comprise casein resin. The bonding emulsion may additionally comprise acrylic resin. The filter assembly also includes a structural support. In particular embodiments, at least a portion of the fibers are treated with a solution that is fire resistant or fire retardant.

What is claimed is: 
     
         1 . A filter assembly comprising:
 a filter pad comprising flame resistant viscose;   a bonding emulsion; and   a structural support.   
     
     
         2 . The filter assembly of  claim 1 , wherein the filter pad comprises flame resistant viscose blended with fibers selected from the group consisting of natural fibers, synthetic fibers, and hybrid fibers. 
     
     
         3 . The filter assembly of  claim 1 , wherein the filter pad comprises flame resistant viscose blended with synthetic fibers. 
     
     
         4 . The filter assembly of  claim 1 , wherein the filter pad comprises flame resistant viscose blended with wool fibers. 
     
     
         5 . The filter assembly of  claim 1 , wherein the bonding emulsion comprises casein resin. 
     
     
         6 . The filter assembly of  claim 1 , wherein the bonding emulsion comprises acrylic resin. 
     
     
         7 . The filter assembly of  claim 1 , wherein the bonding emulsion comprises starch and protein. 
     
     
         8 . The filter assembly of  claim 1 , wherein the bonding emulsion comprises protein. 
     
     
         9 . The filter assembly of  claim 1 , wherein the bonding emulsion comprises polylactic acid. 
     
     
         10 . The filter assembly of  claim 22 , wherein at least a portion of the filter pad is treated with a solution that is fire resistant or fire retardant. 
     
     
         11 . The filter assembly of  claim 1 , wherein the filter assembly has a total dry weight approximately between 50 grams per square meter to 500 grams per square meter. 
     
     
         12 . The filter assembly of  claim 1 , wherein the filter assembly has a dry loft of approximately between 5 mm and 50 mm. 
     
     
         13 . A method of manufacturing a filter assembly, comprising:
 forming a filter pad comprising flame resistant viscose;   applying a bonding emulsion to the filter pad; and   coupling the filter pad to a structural support.   
     
     
         14 . The method of  claim 13 , wherein the filter pad comprises flame resistant viscose blended with fibers selected from the group consisting of natural fibers, synthetic fibers, and hybrid fibers. 
     
     
         15 . The method of  claim 13 , wherein the filter pad comprises flame resistant viscose blended with wool fibers. 
     
     
         16 . The method of  claim 13 , wherein the filter pad comprises flame resistant viscose blended with synthetic fibers. 
     
     
         17 . The method of  claim 13 , wherein the bonding emulsion comprises casein resin. 
     
     
         18 . The method of  claim 13 , wherein the bonding emulsion comprises acrylic resin. 
     
     
         19 . The method of  claim 13 , wherein the bonding emulsion comprises starch and protein. 
     
     
         20 . The method of  claim 13 , wherein the bonding emulsion comprises protein. 
     
     
         21 . The method of  claim 13 , wherein the bonding emulsion comprises polylactic acid. 
     
     
         22 . The method of  claim 13 , further comprising treating at least a portion of the filter pad with a solution that is fire resistant or fire retardant. 
     
     
         23 . The method of  claim 24 , wherein the filter assembly has a total dry weight approximately between 50 grams per square meter to 500 grams per square meter. 
     
     
         24 . The method of  claim 13 , wherein the filter assembly has a dry loft of approximately between 5 mm and 50 mm. 
     
     
         25 . A method of manufacture, comprising:
 carding fibers into a fiber web, wherein the fibers are selected from the group consisting of natural fibers, synthetic fibers, and hybrid fibers;   blending flame resistant viscose with the fiber web;   needle punching the fiber web into a non-woven blanket; and   applying a bonding emulsion to the non-woven blanket.   
     
     
         26 . The method of  claim 25 , further comprising applying a vacuum to the non-woven blanket. 
     
     
         27 . The method of  claim 25 , further comprising passing the non-woven blanket through an oven at over 280 degrees Fahrenheit. 
     
     
         28 . The method of  claim 25 , further comprising coupling a structural support to the non-woven blanket.