Filter media, filters, and methods for making the same
Filter media and filters comprising a fibrous material, a bonding material, and a flame-resistant treatment composition are disclosed herein. Methods of making and using the same are also disclosed herein.
1. A filter media consisting of:
a single layer of 50% or greater of a cellulosic pulp fiber, by weight of the filter media, a bonding material, and 3% or greater of a flame-resistant treatment composition, by weight of the filter media, the flame-resistant treatment composition consisting of citric acid, sodium hypophosphite, and combinations thereof;
wherein the filter media has a MERV (ed. 2017) rating of 7 or greater,
wherein the filter media has an initial pressure drop from 0.02 inH 2 O to 0.45 inH 2 O at an air flow rate of 110 ft/min, a thickness of 800 μm to 3200 μm, a permeability of 200 cubic ft/min (CFM) to 1000 CFM at 0.5 inH 2 O, and a density of 0.03 g/cm 3 to 0.10 g/cm 3 ,
wherein the filter media has a dust holding capacity of 30 g/sq.ft. to 50 g/sq.ft. measured at an air flow rate of 110 ft/min and a final pressure drop of 1.0 inH 2 O, and
whereby, when the filter media is converted to a filter, the filter meets the flammability requirements defined by UL 900 (8 th ed. 2015).
2. The filter media of claim 1 , wherein the bonding material consists of a liquid binder and/or a bicomponent fiber.
3. The filter media of claim 1 , wherein the filter media comprises 70% or greater cellulosic pulp fiber, by weight of the filter media.
4. The filter media of claim 1 , wherein the filter media has an initial pressure drop from 0.02 inH 2 O to 0.37 inH 2 O measured at an air flow rate of 110 ft/min.
5. The filter media of claim 1 , wherein the filter media is biodegradable, recyclable, and/or compostable.
6. The filter media of claim 1 , wherein the filter media has a density of 0.03 to 0.06 g/cm 3 .
7. A filter comprising:
a filter media comprising the filter media of claim 1 ,
wherein the filter meets the flammability requirements defined by UL 900 (8 th ed. 2015),
wherein the filter has a MERV (8 th ed. 2015) rating of 7 or greater, and
wherein the filter has an initial pressure drop of 0.45 inH 2 O or less at an air flow rate of 492 ft/min, and a dust holding capacity of 21 g to 160 g at an air flow rate of 492 ft/min and a final pressure drop of 1.5 inH 2 O.
8. The filter of claim 7 , wherein the filter media is supported by a backing.
9. The filter of claim 7 , wherein the filter media is self-supporting.
10. The filter of claim 7 , wherein the filter has a dust-holding capacity of 30 grams to 160 grams for at least a 20 inch by 20 inch by 2 inch filter at an air flow rate of 492 ft/min and a final pressure drop of 1.5 inH 2 O.
11. The filter of claim 7 , wherein the filter is an HVAC filter.
12. The filter of claim 7 , wherein the bonding material consists of a liquid binder and/or a bicomponent fiber.
13. A method of making the filter media of claim 1 comprising:
blending the cellulosic pulp fiber with the bonding material;
forming an airlaid mat comprising the cellulosic pulp fiber and the bonding material;
heating the airlaid mat to bond the airlaid mat;
treating the bonded airlaid mat with the flame-resistant treatment composition to produce a treated airlaid mat; and
heating the treated airlaid mat to form a bonded or consolidated airlaid mat.
14. The method of making a filter media of claim 13 further comprising:
optionally heating the treated bonded airlaid mat; and
optionally repeating the heating step one or more times.
15. A method of making a filter, comprising:
laminating and/or pleating the filter media according to claim 1 .