Abstract:
Disclosed is a method of producing a non-woven web of fibrous or particulate material comprising: formation of a foam slurry; deposition of that slurry onto a foraminous element having a three-dimensional mold; and formation of a web having a three-dimensional shape that is not substantially planar by removal of foam from the slurry through the foraminous element and drying the web. An apparatus therefor is also disclosed. The method may be used in production a variety of products, including automotive pleated fluid and air filters, pleated heating and/or air conditioning (HVAC) filters, shaped breathing mask filters and bacterial filters, laminated cleaning products with super-absorbent middle layers, such as a mop wipe shape to fit a cleaning mop head, and other products.
Abstract:
Disclosed is a method of producing a non-woven web of fibrous or particulate material comprising: formation of a foam slurry; deposition of that slurry onto a foraminous element having a three-dimensional mold; and formation of a web having a three-dimensional shape that is not substantially planar by removal of foam from the slurry through the foraminous element and drying the web. An apparatus therefor is also disclosed. The method may be used in production a variety of products, including automotive pleated fluid and air filters, pleated heating and/or air conditioning (HVAC) filters, shaped breathing mask filters and bacterial filters, laminated cleaning products with super-absorbent middle layers, such as a mop wipe shape to fit a cleaning mop head, and other products.
Abstract:
Disclosed is a method of producing a non-woven web of fibrous or particulate material comprising: formation of a foam slurry; deposition of that slurry onto a foraminous element having a three-dimensional mold; and formation of a web having a three-dimensional shape that is not substantially planar by removal of foam from the slurry through the foraminous element and drying the web. An apparatus therefor is also disclosed. The method may be used in production a variety of products, including automotive pleated fluid and air filters, pleated heating and/or air conditioning (HVAC) filters, shaped breathing mask filters and bacterial filters, laminated cleaning products with super-absorbent middle layers, such as a mop wipe shape to fit a cleaning mop head, and other products.
Abstract:
A non-woven filter material of fibrous material containing a reactive particulate material is made using the foam process. First and second fibrous webs are made using the foam process, and a foam slurry including reactive particulate material is provided between the webs so as to provide a composite web. Foam and liquid are withdrawn from the composite web and then the composite web is dried so as to produce a final non-woven filter material with reactive material having substantially optimum reactivity (that is the reactive material loses a minimum amount of reactivity during the web production process). The webs and slurry may be made using substantially pure water, and the particulate part of the reactive material is mixed with the foam no more than about ten seconds before the foam is withdrawn from the composite web. Activated carbon and titanium dioxide are two particularly desirable reactive particulates; the reactive loading is at least 0.01 g/cm , and the air permeability of the final filter material is at least 3000 liters per square meter per second.