Three dimensional filter media for extended life filter

Abstract

(b) a plurality of mechanical cilia connected to and protruding outwardly and away from the base, the cilia having a length that is at least 10 times Z, Z being the thickness of the base set forth above, and having a density that is no greater than 5% of the density of the base.

What is claimed is: 
     
         1 . A method of removing airborne contaminants from an airflow stream which comprises:
 providing a three dimensional filter media in a filter and positioning said filter in a path of said airflow stream, said three dimensional filter media comprising:
 a filter media base made of fabric selected from the group consisting of synthetic fabric, natural fabric and combinations thereof, said fabric being made of a plurality of threads, each of said plurality of threads being formed by a plurality of joined twisted thread filaments, said fabric being selected from the group consisting of woven fabric, knitted fabric, and combinations thereof, said fabric having a thickness of Z, wherein Z is in the range of 0.020 to 0.075 inch, said fabric having a density, including interstices, of D wherein D is in the range of 0.25 to 0.50 gms/cubic inch, and 
 a plurality of mechanical cilia connected to and protruding outwardly and away from said base, said cilia having a length that is at least 10 times Z, Z being the thickness of said base set forth above, and having a density that is no greater than 5% of D, D being the density of said base set forth above; and 
   capturing a portion of said contaminants on said cilia away from said base and capturing another portion of said contaminants on said base, so as to allow extended use of said filter to capture airborne contaminants.   
     
     
         2 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said filter media base and said mechanical cilia are made of synthetic fabric selected from the group consisting of polyester, polypropylene, polyethylene, polyvinyl chlorides and combinations thereof. 
     
     
         3 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said base is a knitted fabric. 
     
     
         4 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia are one end severed filaments of said base. 
     
     
         5 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia have a length of at least 20 times Z, wherein Z is the thickness of said base set forth above. 
     
     
         6 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia have a density that is no greater than 2% of D, D being the density of said base set forth above. 
     
     
         7 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia are non-parallel and create passage areas in the range of one micron to 0.2 inch. 
     
     
         8 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia are non-parallel and create passage areas in the range of one micron to 0.01 inch. 
     
     
         9 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia have an average length of 0.065 to 0.3 inch. 
     
     
         10 . The method of removing airborne contaminants from an airflow stream of  claim 1 , wherein said cilia are located on only one side of said base.