Filter media and system and method for manufacture thereof

Abstract

A system and method for laminating filter media can include applying an adhesive to a layer of the filter media and curing the adhesive. A multilayer filter assembly can include a first and a second layer laminated together using an inorganic adhesive.

We claim: 
     
         1 . A method comprising:
 providing a first layer and a second layer;   applying an adhesive to a broad face of the first layer;   contacting the broad face of the first layer to a broad face of the second layer;   contemporaneously applying a predetermined pressure to and heating the first and second layers to cure a first portion of the adhesive; and   curing a remainder of the adhesive.   
     
     
         2 . The method of  claim 1 , wherein the adhesive consists essentially of inorganic adhesive. 
     
     
         3 . The method of  claim 2 , wherein the adhesive is applied as an aqueous solution. 
     
     
         4 . The method of  claim 1 , wherein the adhesive is applied at a temperature less than or equal to 50° C. 
     
     
         5 . The method of  claim 1 , wherein the predetermined force is applied, and the first and second layers are heated, using a set of perforated plates. 
     
     
         6 . The method of  claim 1 , wherein the remainder of the uncured adhesive is cured using an air knife. 
     
     
         7 . The method of  claim 1 , further comprising:
 applying the adhesive to a second broad face of the first layer; and   contacting the second broad face of the first layer to a broad face of a third layer;   
       wherein the pressure is applied to the second and third layers. 
     
     
         8 . A multi-layer air filter comprising:
 a photocatalytic layer comprising a photocatalytic material disposed on a fibrous substrate; and   an electrically conductive layer, wherein the photocatalytic material is in electrical contact with the electrically conductive layer;   
       wherein the photocatalytic layer is laminated to the electrically conductive layer using an inorganic adhesive. 
     
     
         9 . The air filter of  claim 8 , wherein the photocatalytic material is bound to the fibrous substrate using an inorganic binder. 
     
     
         10 . The air filter of  claim 8 , further comprising an activated carbon layer and an electrostatic layer, wherein the electrostatic layer is laminated to the electrically conductive layer using the inorganic adhesive. 
     
     
         10 . The air filter of  claim 10 , wherein the activated carbon layer and the electrostatic layer are fused together.