Biodegradable filters
In order to address the sustainability and environmental issues associated with conventional HVAC filters, inventive HVAC filters have been developed that are completely biodegradable and compostable and exhibit Minimum Efficiency Reporting Value (MERV) ratings that are superior to conventional HVAC filters. More particularly, it has been discovered that biodegradable electrospun nanofibers can be used to produce biodegradable HVAC filters that exhibit superior filtration performance relative to conventional HVAC filters produced from polypropylene electrostatic media or triboelectric nonwoven media.
1 . A biodegradable filter consisting of:
(a) at least one biodegradable base media layer;
(b) at least one biodegradable nanofiber layer disposed on a surface of the at least one biodegradable base media layer comprising a plurality of electrospun nanofibers; and
(c) an optional biodegradable plastic scrim disposed on an effluent surface of the at least one biodegradable nanofiber layer,
wherein the electrospun nanofibers, the at least one biodegradable base media layer, and the optional biodegradable plastic scrim are formed from polycaprolactone, polyvinyl alcohol, polybutylene succinate, polybutylene adipate terephthalate, polylactic acid, a polyhydroxyalkanoate, a polyhydroxybutyrate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), a cellulose derivative, poly(butylene succinate-co-butylene adipate), or a combination thereof,
wherein the biodegradable filter exhibits a filtration efficiency of at least MERV 11, as measured according to the ASHRAE 52.2 standard,
wherein the at least one biodegradable nanofiber layer has a basis weight of 0.01 to 2.0 gsm,
wherein the at least one biodegradable base media layer has a basis weight of 10 to 150 gsm.
2 . The biodegradable filter according to claim 1 , wherein the electrospun nanofibers have an average diameter of 10 to 500 nm.
3 . The biodegradable filter according to claim 1 , wherein the at least one biodegradable base media layer and the at least one biodegradable nanofiber layer are home compostable as measured by Australian Standard AS5810, French Standard NF T51800, or German Standard prEN 17427.
4 . The biodegradable filter according to claim 1 , wherein the at least one biodegradable base media layer and the at least one biodegradable nanofiber layer are industrial compostable as measured using ASTM D6400.
5 . The biodegradable filter according to claim 1 , wherein the biodegradable filter consists of biodegradable and home compostable components.
6 . The biodegradable filter according to claim 1 , wherein the at least one biodegradable nanofiber layer consists of the electrospun nanofibers.
7 . The biodegradable filter according to claim 1 , wherein the electrospun nanofibers and the at least one biodegradable base media layer are formed entirely from polylactic acid, a polyhydroxyalkanoate, or a combination thereof.
8 . The biodegradable filter according to claim 1 , wherein biodegradable filter consists of one biodegradable nanofiber layer and one biodegradable base media layer.
9 . A biodegradable and compostable HVAC filter consisting essentially of:
(a) at least one biodegradable base media layer;
(b) at least one biodegradable nanofiber layer disposed on a surface of the at least one biodegradable base media layer comprising a plurality of electrospun nanofibers having an average diameter of 10 to 500 nm;
(c) at least one biodegradable pre-filter layer disposed on an influent surface of the at least one biodegradable base media layer; and
(d) an optional biodegradable plastic scrim disposed on an effluent surface of the at least one biodegradable nanofiber layer,
wherein the electrospun nanofibers, the at least one biodegradable base media layer, the at least one biodegradable pre-filter layer, and the optional biodegradable plastic scrim are formed from polycaprolactone, polyvinyl alcohol, polybutylene succinate, polybutylene adipate terephthalate, polylactic acid, a polyhydroxyalkanoate, a polyhydroxybutyrate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), a cellulose derivative, poly(butylene succinate-co-butylene adipate), or a combination thereof,
wherein the biodegradable and compostable HVAC filter exhibits a filtration efficiency of at least MERV 11, as measured according to the ASHRAE 52.2 standard,
wherein the at least one biodegradable base media layer, the at least one biodegradable nanofiber layer, the at least one biodegradable pre-filter layer, and the optional biodegradable plastic scrim are home compostable as measured by Australian Standard AS5810, French Standard NF T51800, or German Standard prEN 17427,
wherein the at least one biodegradable nanofiber layer has a basis weight of 0.01 to 2.0 gsm.
10 . The biodegradable and compostable HVAC filter according to claim 9 , wherein the electrospun nanofibers and the at least one biodegradable base media layer are formed from polylactic acid, a polyhydroxyalkanoate, or a combination thereof.
11 . The biodegradable and compostable HVAC filter according to claim 9 , wherein the at least one biodegradable base media layer has a basis weight of 10 to 150 gsm.
12 . The biodegradable and compostable HVAC filter according to claim 9 , wherein the at least one biodegradable base media layer, the at least one biodegradable nanofiber layer, and the at least one biodegradable pre-filter layer are bonded via a biodegradable adhesive.
13 . The biodegradable and compostable HVAC filter according to claim 9 , wherein the at least one biodegradable nanofiber layer consists of the electrospun nanofibers.
14 . The biodegradable and compostable HVAC filter according to claim 9 , further comprising a biodegradable and compostable outer boxing that encases the at least one biodegradable nanofiber layer, the at least one biodegradable base media layer, the at least one biodegradable pre-filter layer, and the optional biodegradable plastic scrim.
15 . The biodegradable and compostable HVAC filter according to claim 14 , wherein the biodegradable and compostable HVAC filter consists of the at least one biodegradable nanofiber layer, the at least one biodegradable base media layer, the at least one biodegradable pre-filter layer, the optional biodegradable plastic scrim, and the biodegradable and compostable outer boxing.