Gas filter

Claim 2

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said first surface of said microporous membrane being pretreated with a solvent selected from the group consisting of alcohol, ethyl, ethyl ketone, carbon tetrachloride, and acetone whereby the adhesion of said water repellent layer will be enhanced.

Claim 3

The gas filter of claim 1 wherein said deodorizing agent is activated carbon.

Claim 4

The gas filter of claim 1 wherein the filter is comprised of a foam pad consisting of reticulated polyurethane foam carrying particles of a deodorizing agent.

Claim 5

The gas filter of claim 3 further comprising a filter housing for containing said gas filter, said filter housing being comprised of a plastic housing having a base wall with a hole formed therethrough for entry of gas to be deodorized and a peripheral wall of which traps said filter pad within said housing.

Claim 6

The gas filter of claim 1 in which said second surface of said pad is laminated to a second microporous membrane which is made of substantially the same material as said first microporous membrane.

Claim 7

The gas filter of claim 1 in which said water repellent layer is comprised of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, or wax.

Claim 8

The gas filter of claim 1 in which the membrane is a 0.1-0.15 mm thick polyurethane foil with controlled microporous holes of predetermined size therein, obtained by adding preground soluble material (e.g., rock salt) to a solution of polyurethane which is then extrusion calendered to thickness and width and then passed through hot water baths to dissolve said soluble material, thereby leaving minute holes.

Claim 9

The gas filter of claim 1 in which said microporous membrane is selected from the group consisting of PTFE and FEP.

Claim 10

The gas filter of claim 1 in which said microporous membrane is polyethylene or polyurethane or ethyl vinyl acetate (EVA) into which is mixed a controlled pore size of chalk (calcium carbonate) which remains in situ and, being porous, allows gas to flow therethrough.

Claim 11

The gas filter of claim 1 in which said foam pad is of an open cell polyurethane foam carrying substantially 180 to 220 grams of carbon per square meter, and has a thickness in the manufactured state of the filter of approximately 1 millimeter.

Claim 12

The gas filter of claim 10 in which said second surface of said pad is laminated to a second microporous membrane which is substantially the same as said first microporous membrane.

Claim 13

The gas filter of claim 1 in which said pad is of reticulated polyurethane foam having the characteristics indicated in the following Table A: TABLE A ______________________________________ Density 27-30 kg/m.sup.3 Compression Resistance 3.4-4.6 KPA Ultimate elongation 350% Tensile strength 200 KPA Tear strength 6 N/cm Porosity 65-85 (PPI) ______________________________________

Claim 14

The gas filter of claim 12 in which said water repellent layer comprises a material selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, and wax.

Claim 15

The gas filter of claim 13 in which said microporous membrane is a 0.1-0.15 mm thick polyurethane foil with controlled microporous holes of predetermined size therein, obtained by adding preground soluble material (e.g., rock salt) to a solution of polyurethane which is then extrusion calendered to thickness and width, then passed through hot water baths to dissolve the soluble material, thereby leaving minute holes.

Claim 16

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said microporous membrane being a 0.1-0.15 mm thick polyurethane foil with controlled microporous holes of predetermined size therein, obtained by adding preground soluble material (e.g., rock salt) to a solution of polyurethane which is then extrusion calendered to thickness and width and then passed through hot water baths to dissolve said soluble material, thereby leaving minute holes.

Claim 17

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said microporous membrane being a 0.1-0.15 mm thick polyurethane foil with controlled microporous holes of predetermined size therein, obtained by adding preground soluble material (e.g., rock salt) to a solution of polyurethane which is then extrusion calendered to thickness and width and then passed through hot water baths to dissolve said soluble material, thereby leaving minute holes.

Claim 18

The gas filter of claim 15 wherein said deodorizing agent is activated carbon.

Claim 19

The gas filter of claim 15 wherein the filter is comprised of a foam pad consisting of reticulated polyurethane foam carrying particles of a deodorizing agent.

Claim 20

The gas filter of claim 17 further comprising a filter housing for containing said gas filter, said filter housing being comprised of a plastic housing having a base wall with a hole formed therethrough for entry of gas to be deodorized and a peripheral wall of which traps said filter pad within said housing.

Claim 21

The gas filter of claim 15 in which said second surface of said pad is laminated to a second microporous membrane which is made of substantially the same material as said first microporous membrane.

Claim 22

The gas filter of claim 15 in which said water repellent layer is comprised of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, or wax.

Claim 23

The gas filter of claim 15 in which said foam pad is of an open cell polyurethane foam carrying substantially 180 to 220 grams of carbon per square meter, and has a thickness in the manufactured state of the filter of approximately 1 millimeter.

Claim 24

The gas filter of claim 15 in which said pad is of reticulated polyurethane foam having the characteristics indicated in the following Table A: TABLE A ______________________________________ Density 27-30 kg/m.sup.3 Compression Resistance 3.4-4.6 KPA Ultimate elongation 350% Tensile strength 200 KPA Tear strength 6 N/cm Porosity 65-85 (PPI) ______________________________________

Claim 25

The gas filter of claim 22 in which said water repellent layer comprises a material selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, and wax.

Claim 26

The gas filter of claim 23 in which said second surface of said microporous membrane, to which the water repellent layer is applied, is pretreated by a solvent selected from the group consisting of alcohol, ethyl, ethyl ketone, carbon tetrachloride, and acetone, whereby the adhesion of the layer will be enhanced.

Claim 27

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said microporous membrane consisting of polyethylene, polyurethane, or ethyl vinyl acetate (EVA) into which is mixed a controlled pore size of chalk (calcium carbonate) which remains in situ and, being porous, allows gas to flow therethrough.

Claim 28

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said microporous membrane consisting of polyethylene, polyurethane, or ethyl vinyl acetate (EVA) into which is mixed a controlled pore size of chalk (calcium carbonate) which remains in situ and, being porous, allows gas to flow therethrough.

Claim 29

The gas filter of claim 25 wherein said deodorizing agent is activated carbon.

Claim 30

The gas filter of claim 25 wherein the filter is comprised of a foam pad consisting of reticulated polyurethane foam carrying particles of a deodorizing agent.

Claim 31

The gas filter of claim 27 further comprising a filter housing for containing said gas filter, said filter housing being comprised of a plastic housing having a base wall with a hole formed therethrough for entry of gas to be deodorized and a peripheral wall of which traps said filter pad within said housing.

Claim 32

The gas filter of claim 25 in which said second surface of said pad is laminated to a second microporous membrane which is made of substantially the same material as said first microporous membrane.

Claim 33

The gas filter of claim 25 in which said water repellent layer is comprised of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, or wax.

Claim 34

The gas filter of claim 25 in which said second surface of said microporous membrane is pretreated with a solvent selected from the group consisting of alcohol, ethyl, ethyl ketone, carbon tetrachloride, and acetone whereby the adhesion of said water repellent layer will be enhanced.

Claim 35

The gas filter of claim 25 in which said foam pad is of an open cell polyurethane foam carrying substantially 180 to 220 grams of carbon per square meter, and has a thickness in the manufactured state of the filter of approximately 1 millimeter.

Claim 36

The gas filter of claim 25 in which said pad is of reticulated polyurethane foam having the characteristics indicated in the following Table A: TABLE A ______________________________________ Density 27-30 kg/m.sup.3 Compression Resistance 3.4-4.6 KPA Ultimate elongation 350% Tensile strength 200 KPA Tear strength 6 N/cm Porosity 65-85 (PPI) ______________________________________

Claim 37

The gas filter of claim 33 in which said water repellent layer comprises a material selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, and wax.

Claim 38

The gas filter of claim 34 in which said second surface of said microporous membrane, to which the water repellent layer is applied, is pretreated by a solvent selected from the group consisting of alcohol, ethyl, ethyl ketone, carbon tetrachloride, and acetone, whereby the adhesion of the layer will be enhanced.

Claim 39

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said pad being comprised of reticulated polyurethane foam having the characteristics indicated in the following Table A: TABLE A ______________________________________ Density 27-30 kg/m.sup.3 Compression Resistance 3.4-4.6 KPA Ultimate elongation 350% Tensile strength 200 KPA Tear strength 6 N/cm Porosity 65-85 (PPI) ______________________________________ said water repellent layer comprising a material selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, and wax, and said second surface of said microporous membrane, to which said water repellent layer is applied, is pretreated by a solvent selected from the group consisting of alcohol, ethyl, ethyl ketone, carbon tetrachloride, and acetone, whereby the adhesion of the layer will be enhanced.

Claim 40

A gas filter comprising a pad impregnated with a deodorizing agent and made of an open cell plastic foam material having a first surface and a second surface, said pad being laminated together with a first microporous membrane having a first surface and a second surface, said first surface of said foam material being laminated to said first surface of said microporous membrane, there being a layer of water repellent material on said second surface of said membrane, said layer of water repellent material being sufficiently thin that the pores in said microporous membrane are not blocked against gas flow, said pad being comprised of reticulated polyurethane foam having the characteristics indicated in the following Table A: TABLE A ______________________________________ Density 27-30 kg/m.sup.3 Compression Resistance 3.4-4.6 KPA Ultimate elongation 350% Tensile strength 200 KPA Tear strength 6 N/cm Porosity 65-85 (PPI) ______________________________________ said water repellent layer comprising a material selected from the group consisting of polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), silicone, and wax, and said second surface of said microporous membrane, to which said water repellent layer is applied, is pretreated by a solvent selected from the group consisting of alcohol, ethyl, ethyl ketone, carbon tetrachloride, and acetone, whereby the adhesion of the layer will be enhanced.

Claim 41

The gas filter of claim 36 wherein said deodorizing agent is activated carbon.

Claim 42

The gas filter of claim 36 further comprising a filter housing for containing said gas filter, said filter housing being comprised of a plastic housing having a base wall with a hole formed therethrough for entry of gas to be deodorized and a peripheral wall of which traps said filter pad within said housing.

Claim 43

The gas filter of claim 36 in which said second surface of said pad is laminated to a second microporous membrane which is made of substantially the same material as said first microporous membrane.

Claim 44

The gas filter of claim 36 in which the membrane is a 0.1-0.15 mm thick polyurethane foil with controlled microporous holes of predetermined size therein, obtained by adding preground soluble material (e.g., rock salt) to a solution of polyurethane which is then extrusion calendered to thickness and width and then passed through hot water baths to dissolve said soluble material, thereby leaving minute holes.

Claim 45

The gas filter of claim 36 in which said microporous membrane is selected from the group consisting of PTFE and FEP.

Claim 46

The gas filter of claim 36 in which said microporous membrane is polyethylene or polyurethane or ethyl vinyl acetate (EVA) into which is mixed a controlled pore size of chalk (calcium carbonate) which remains in situ and, being porous, allows gas to flow therethrough.

Claim 47

The gas filter of claim 36 in which said foam pad carries substantially 180 to 220 grams of carbon per square meter, and has a thickness in the manufactured state of the filter of approximately 1 millimeter.