Flutable fiber webs with high dust holding capacity
The fiber webs described herein may be incorporated into filter media and filter elements. The fiber webs may exhibit a high dust holding capacity. The fiber webs may also exhibit a low thickness. The fiber webs may be sufficiently flexible and/or deformable so that they may be processed to include a series of waves (also known as flutes) that extend along the cross-machine direction.
1. A fiber web having a machine direction and a cross-machine direction, the fiber web including a series of flutes that extend in the cross-machine direction, the fiber web having a dust holding capacity of greater than about 3 mg/cm 2 and a thickness of less than about 30 mils, wherein the dust holding capacity is measured by Palas filtration performance according to ISO Procedure 5011:2000 when a pressure drop across the fiber web reaches 1,500 Pa with a test face velocity of 20.0 cm/sec and using SAE fine dust at a dust mass concentration of 200.0 mg/m 3 , wherein the frequency of the flutes is between about 1 flute/inch and about 20 flutes/inch.
2. The fiber web of claim 1 , wherein the fiber web has a dust holding capacity of greater than about 3.5 mg/cm 2 .
3. The fiber web of claim 1 , wherein the fiber web has a dust holding capacity of between about 3 mg/cm 2 and about 8 mg/cm 2 .
4. The fiber web of claim 1 , wherein the fiber web includes cellulose fibers.
5. The fiber web of claim 1 , wherein the fiber web includes synthetic fibers.
6. The fiber web of claim 5 , wherein the weight percentage of synthetic fibers is greater than 50% of the total weight percentage of fibers in the fiber web.
7. The fiber web of claim 5 , wherein the synthetic fibers comprise at least one of the materials selected from the group consisting of polyaramid, polypropylene, polyethylene, polyamide, polyether ether ketone, polyester, lyocell, rayon, and PET.
8. The fiber web of claim 1 , wherein the fiber web includes a resin formulation.
9. The fiber web of claim 8 , wherein the resin formulation comprises between about 1% and about 50% by weight of the fiber web.
10. The fiber web of claim 1 , wherein the fiber web includes a dry Mullen burst of greater than about 15 psi.
11. The fiber web of claim 1 , wherein the fiber web includes an as is wet Mullen burst of between about 5 psi and about 80 psi.
12. The fiber web of claim 1 , wherein the fiber web includes a fully cured wet Mullen burst of between about 10 psi and about 100 psi.
13. The fiber web of claim 1 , wherein the fiber web has a tensile elongation in the machine direction of greater than about 2%.
14. The fiber web of claim 1 , wherein the fiber web has a tensile elongation in the cross-machine direction of greater than about 2%.
15. The fiber web of claim 1 , wherein the fiber web has a tensile strength in the machine direction of greater than about 10 lb/in.
16. The fiber web of claim 1 , wherein the fiber web has a tensile strength in the cross-machine direction of greater than about 3 lb/in.
17. The fiber web of claim 1 , wherein the fiber web has a permeability of between about 5 cfm/sf and about 100 cfm/sf.
18. The fiber web of claim 1 , wherein the fiber web has a basis weight of between about 20 g/m 2 and about 150 g/m 2 .
19. The fiber web of claim 1 , wherein the fiber web has a basis weight of between about 60 g/m 2 and about 80 g/m 2 .
20. The fiber web of claim 1 , wherein the fiber web has a mean pore size of greater than about 5 microns.
21. A filter element comprising the fiber web of claim 1 .
22. The fiber web of claim 3 , wherein the fiber web has a thickness of between about 2 mils and about 25 mils.
23. The fiber web of claim 22 , wherein the frequency of the flutes is between about 4 flutes/inch and about 8 flutes/inch.
24. The fiber web of claim 22 , wherein the amplitude of the flutes is between about 5 mils and about 75 mils.
25. The fiber web of claim 22 , wherein the fiber web includes cellulose fibers.
26. The fiber web of claim 22 , wherein the fiber web includes synthetic fibers.
27. The fiber web of claim 26 , wherein the synthetic fibers comprise at least one of the materials selected from the group consisting of polyaramid, polypropylene, polyethylene, polyamide, polyether ether ketone, polyester, lyocell, rayon, and PET.
28. The fiber web of claim 22 , wherein the fiber web includes a resin formulation.
29. The fiber web of claim 28 , wherein the resin formulation comprises between about 1% and about 50% by weight of the fiber web.
30. The fiber web of claim 22 , wherein the fiber web includes a dry Mullen burst of between about 15 psi and about 90 psi.
31. The fiber web of claim 22 , wherein the fiber web includes an as is wet Mullen burst of between about 5 psi and about 80 psi.
32. The fiber web of claim 22 , wherein the fiber web has a tensile elongation in the cross-machine direction of between about 2% and about 8%.
33. The fiber web of claim 22 , wherein the fiber web has a tensile strength in the machine direction of between about 10 lb/in and about 50 lb/in.
34. The fiber web of claim 22 , wherein the fiber web has a tensile strength in the cross-machine direction of between about 7 lb/in and about 30 lb/in.
35. The fiber web of claim 22 , wherein the fiber web has a mean pore size of between about 5 microns and about 50 microns.
36. The fiber web of claim 22 , wherein the fiber web has a permeability of between about 5 cfm/sf and about 100 cfm/sf.
37. The fiber web of claim 22 , wherein the fiber web has a basis weight of between about 20 g/m 2 and about 150 g/m 2 .
38. A filter element comprising the fiber web of claim 22 .
39. A fiber web having a machine direction and a cross-machine direction, the fiber web including a series of flutes that extend in the cross-machine direction, the fiber web having a dust holding capacity of greater than about 3 mg/cm 2 and a thickness of less than about 30 mils, wherein the dust holding capacity is measured by Palas filtration performance according to ISO Procedure 5011:2000 when a pressure drop across the fiber web reaches 1,500 Pa with a test face velocity of 20.0 cm/sec and using SAE fine dust at a dust mass concentration of 200.0 mg/m 3 , wherein the fiber web has a thickness of between about 5 mils and about 15 mils.
40. The fiber web of claim 39 , wherein the fiber web has a dust holding capacity of between about 3 mg/cm 2 and about 8 mg/cm 2 .
41. The fiber web of claim 39 , wherein the fiber web has a tensile elongation in the machine direction of between about 2% and about 8%.
42. The fiber web of claim 39 , wherein the fiber web has a permeability of between about 5 cfm/sf and about 100 cfm/sf.
43. The fiber web of claim 39 , wherein the fiber web includes synthetic fibers and the weight percentage of synthetic fibers is greater than 50% of the total weight percentage of fibers in the fiber web.
44. A fiber web having a machine direction and a cross-machine direction, the fiber web including a series of flutes that extend in the cross-machine direction, the fiber web having a dust holding capacity of greater than about 3 mg/cm 2 and a thickness of less than about 30 mils, wherein the dust holding capacity is measured by Palas filtration performance according to ISO Procedure 5011:2000 when a pressure drop across the fiber web reaches 1,500 Pa with a test face velocity of 20.0 cm/sec and using SAE fine dust at a dust mass concentration of 200.0 mg/m 3 , wherein the amplitude of the flutes is between about 1 mil and about 100 mils.
45. The fiber web of claim 44 , wherein the fiber web has a dust holding capacity of between about 3 mg/cm 2 and about 8 mg/cm 2 .
46. The fiber web of claim 44 , wherein the fiber web has a tensile elongation in the machine direction of between about 2% and about 8%.
47. The fiber web of claim 44 , wherein the fiber web has a permeability of between about 5 cfm/sf and about 100 cfm/sf.
48. The fiber web of claim 44 , wherein the fiber web includes synthetic fibers and the weight percentage of the synthetic fibers is greater than 50% of the total weight percentage of fibers in the fiber web.
49. The fiber web of claim 44 , wherein the fiber web has a basis weight of between about 60 g/m 2 and about 80 g/m 2 .
50. A fiber web having a machine direction and a cross-machine direction, the fiber web including a series of flutes that extend in the cross-machine direction, the fiber web having a dust holding capacity of greater than about 3 mg/cm 2 and a thickness of less than about 30 mils, wherein the dust holding capacity is measured by Palas filtration performance according to ISO Procedure 5011:2000 when a pressure drop across the fiber web reaches 1,500 Pa with a test face velocity of 20.0 cm/sec and using SAE fine dust at a dust mass concentration of 200.0 mg/m 3 , wherein the fiber web has a dry Gurley stiffness in the machine direction of greater than about 200 mg.
51. A fiber web having a machine direction and a cross-machine direction, the fiber web including a series of flutes that extend in the cross-machine direction, the fiber web having a dust holding capacity of greater than about 3 mg/cm 2 and a thickness of less than about 30 mils, wherein the dust holding capacity is measured by Palas filtration performance according to ISO Procedure 5011:2000 when a pressure drop across the fiber web reaches 1,500 Pa with a test face velocity of 20.0 cm/sec and using SAE fine dust at a dust mass concentration of 200.0 mg/m 3 , wherein the fiber web has a wet Gurley stiffness in the machine direction of greater than about 10 mg.