Antimicrobial filter media
A product and method of manufacturing and producing antimicrobial fibers using an antimicrobial additive material. The method comprising using various antimicrobial metals incorporated and embedded into an inorganic material as metal ions within the additive material that can be formulated into a masterbatch precursor material and processed to manufacture fine or synthetic fibers using standard manufacturing processes for use in applications from face masks and respirators to air filters for HVAC and higher efficiency HEPA applications.
1 . An air filtration filter media comprising: a nonwoven mixture of a plurality of at least three different fibers, including (1) functional antimicrobial fibers, (2) functional antimicrobial binder fibers and (3) non-functional fibers, wherein the functional antimicrobial fibers and the functional antimicrobial binder fibers each include an active inorganic-based ingredient comprising a zeolite additive which is dispersed within an outer layer of each of the functional antimicrobial fibers and the functional antimicrobial binder fibers for an antimicrobial effect, wherein the zeolite additive is between 1% to 5% w/w of each of the functional antimicrobial fibers and the functional antimicrobial binder fibers and the zeolite additive includes a mixture of copper and silver ions having an active metal ion content between 0.01% and 0.5% w/w of the zeolite additive.
2 . The air filtration filter media of claim 1 , wherein the combination of the functional antimicrobial fibers and the functional antimicrobial binder fibers comprise 20%-100% of the content of the non-woven mixture.
3 . The air filtration filter media of claim 1 , wherein the functional antimicrobial binder fiber content comprises 20%-100% of the content of the non-woven mixture.
4 . The air filtration filter media of claim 1 , wherein the non-woven mixture has a weight between 40 gsm to 250 gsm.
5 . The air filtration filter media of claim 1 , wherein the non-woven mixture has a thickness between 0.4 mm to 20 mm.
6 . The air filtration filter media of claim 1 , wherein the non-woven mixture has a permeability between 500 l/m 2 s to 6,000 l/m 2 s at 200 Pa.
7 . The air filtration filter media of claim 1 , wherein the active inorganic-based ingredient within the non-woven mixture is between 10% to 30% w/w.
8 . The air filtration filter media of claim 1 , wherein the non-woven mixture has an efficiency range from ASHRAE 52.2 MERV 8 to MERV 15 and an equivalent filtration efficiency range from EN779:2012 G4 to F9.
9 . The air filtration filter media of claim 1 , wherein the functional antimicrobial fibers and functional antimicrobial binder fibers are configured as monofilament fibers or bicomponent fibers.
10 . The air filtration filter media of claim 9 , the bicomponent fiber comprising a non-functional core and a functional sheath, wherein the active inorganic-based ingredient is loaded into the polyester mix of the sheath.
11 . The air filtration filter media of claim 1 , wherein the air filtration filter media comprises:
a basis weight of 101 g/m 2 ; and
a thickness of 1.3 mm (0.052 in);
an efficiency of ASHRAE 52.2 MERV 8; and
an air permeability of 3500 L/m 2 s at 200 Pa or 430 cubic feet per minute (cfm) at 0.5 in water gauge (WG).
12 . The air filtration filter media of claim 1 , wherein the antimicrobial effect comprises a reduction of greater than 99% of viral load when tested by the Spearman-Karber method at 50% TCID 50 /ml.