Nonwoven Filter Fabric Composition And Method of Use

Abstract

A nonwoven filter fabric composition may comprise a blend of at least one thermoplastic and at least one naturally-derived fiber. In some embodiments, a method of using a nonwoven filter fabric composition made according to at least one composition disclosed herein may comprise providing a first filter fabric, configuring the first filter fabric, applying one or more reinforced seams to the first filter fabric thereby creating a first filter bag, inserting one or more substances suitable for steeping into first filter bag, and steeping the first filter bag in a liquid. In some embodiments, the method may comprise steeping the first filter bag in a cold brew system.

Claims

1. A nonwoven filter fabric composition, comprising: at least one naturally-derived fiber; and at least one thermoplastic polymer.

2. The composition of claim 1, wherein the at least one thermoplastic comprises polypropylene and a polyester.

3. The composition of claim 2, comprising: 55-68% polypropylene; 20-30% polyester; and 2-10% viscose fiber.

4. The composition of claim 2, comprising one or more of: polypropylene up to 68% of the composition; polyester up to 28% of the composition; and viscose fiber up to 8% of the composition.

5. The composition of claim 2, wherein the polyester is polyethylene terephthalate.

6. The composition of claim 5, comprising: 55-68% polypropylene; 20-30% polyethylene terephthalate; and 2-10% viscous fiber.

7. The composition of claim 6, comprising one or more of: polypropylene up to 68% of the composition; polyethylene terephthalate up to 28% of the composition; and viscose fiber up to 8% of the composition.

8. The composition of claim 1, wherein the at least one naturally-derived fiber is cellulose and the at least one thermoplastic polymer is polyethylene terephthalate.

9. The composition of claim 8, comprising: 85% cellulose; and 15% polyethylene terephthalate.

10. A method of using a nonwoven filter fabric composition, comprising: providing a first filter fabric piece made in accordance with the composition of claim 3, wherein the first filter fabric has at least a first edge, a second edge, a first side and a second side; folding the first filter fabric so as to overlay the first edge onto the second edge; applying at least one reinforced seam to the first filter fabric, wherein the at least one reinforced seam is configured to transverse the filter fabric; providing a cold brew filtering system having a cold brew filter basket and a cold brew filtering container; inserting the first filter fabric into the filter basket; filling the filtering container with a liquid; inserting a substance suitable for steeping into the first filter fabric; and steeping the substance suitable for steeping in the liquid.

11. The method of claim 10, wherein the at least one reinforced seam is a first reinforced seam and a second reinforced seam, and wherein the step of applying at least one reinforced seam to the first filter fabric comprises applying the first reinforced seam and the second reinforced seam to the first filter fabric, wherein the first reinforced seam and the second reinforced seam are configured to transverse the filter fabric.

12. The method of claim 10, wherein the at least one reinforced seam further comprises a third reinforced seam, and wherein the step of applying at least one reinforced seam to the first filter fabric further comprises applying a third reinforced seam configured to transverse the filter fabric.

13. A method of using a nonwoven filter fabric composition, comprising: providing a first filter fabric piece made in accordance with the composition of claim 9, wherein the first filter fabric has at least a first edge, a second edge, a first side and a second side; folding the first filter fabric so as to overlay the first edge onto the second edge; applying at least one reinforced seam to the first filter fabric, wherein the at least one reinforced seam is configured to transverse the filter fabric; providing a cold brew filtering system having a cold brew filter basket and a cold brew filtering container; inserting the first filter fabric into the filter basket; filling the filtering container with a liquid; inserting a substance suitable for steeping into the first filter fabric; and steeping the substance suitable for steeping in the liquid.

14. The method of claim 13, wherein the at least one reinforced seam is a first reinforced seam and a second reinforced seam, and wherein the step of applying at least one reinforced seam to the first filter fabric comprises applying the first reinforced seam and the second reinforced seam to the first filter fabric, wherein the first reinforced seam and the second reinforced seam are configured to transverse the filter fabric.

15. The method of claim 13, wherein the at least one reinforced seam further comprises a third reinforced seam, and wherein the step of applying at least one reinforced seam to the first filter fabric further comprises applying a third reinforced seam configured to transverse the filter fabric.

Description

DETAILED DESCRIPTION

[0028] Having summarized various aspects of the present disclosure, reference will now be made in detail to that which is illustrated in the drawings. While the disclosure will be described in connection with these drawings, there is no intent to limit it to the embodiment or embodiments disclosed herein. Rather, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the disclosure as defined by the appended claims.

[0029] Having summarized various aspects of the present disclosure, reference will now be made in detail to that which is illustrated in the drawings. While the disclosure will be described in connection with these drawings, there is no intent to limit it to the embodiment or embodiments disclosed herein. Rather, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the disclosure as defined by the appended claims.

[0030] The nonwoven filter fabric composition of the present invention may comprise a first material, a second material, a third material. In some embodiments, the nonwoven filter fabric composition may further comprise a fourth or more material. The first material, second material, third material, and fourth or more material may be comprised of at least one plastic, such as but not limited to at least one thermoplastic. The first material, second material, third material, and fourth or more material may be comprised of at least one naturally-derived fibers or materials, synthetic fibers or materials, and semi-synthetic fibers or materials. In some embodiments, one or more of the first material, second material, third material, and/or fourth or more material may be comprised of more than one or a combination of naturally-derived fibers or materials, synthetic fibers or materials, and semi-synthetic fibers or materials.

[0031] A naturally-derived fiber may be any fiber wherein the majority of the fiber came from one or more natural sources. In some embodiments, a naturally-derived fiber may be comprised entirely or substantially entirely of an element found in nature, such as by way of illustration and not limitation, untreated cotton. In some embodiments, a naturally derived fiber may comprise a chemically-treated natural fiber that was harvested as a natural source material and has been chemically altered.

[0032] Non-limiting examples of the natural fibers or natural source materials used to comprise one or more naturally-derived fibers include such materials as flax, hemp, cotton, abaca, jute, white jute, seacell/seaweed, bamboo, kenaf, coir, sisal, wheat, corn, corn starch, sunflower, silk, sugarcane, soybean, wool, ramie, other plants of the boehmeria genus, kapok tree, palm trees, cellulose, cassava roots, cassava chips, cassava starch, natural viscose fibers, and any other plant or natural fiber capable of use as a paper or filtering agent, or as providing cellulose for regenerated cellulose-based fibers. Other woods and papers, such as Kraft paper, are also contemplated.

[0033] The nonwoven filter fabric composition of the present invention may also be comprised in whole or in part of any synthetic fibers or materials such as plastics or thermoplastics. Example plastics and thermoplastics include polyethylene (PE), high density polyethylene (HDPE), polyvinyl chloride (PVC), low density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), polyurethane (PU), polyolefin, polyethylene isophthalate, high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyamide (nylon), or any synthetic or semi-synthetic plastic, thermoplastic, thermosetting polymer, or bioplastic.

[0034] Additional examples of plastics and thermoplastics include but are not limited to polyester, polyester-based resin, linear polyester, copolymerized polyesters, or other type of polyester. For example, in some embodiments, the polyester of the present invention may comprise polyethylene terephthalate (PET or PETE), polyglycolide or polyglycolic acid (PGA), polylactic acid (PLA), polycaprolactone (PCL), polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyethylene adipate (PEA), polybutylene succinate (PBS), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), Vectran, polycaprolactone diol (PCL), polyethylene adipate diol (PEA), or other type of polyester.

[0035] Naturally-derived fibers such as semi-synthetic fibers or materials may also comprise the nonwoven filter fabric composition of the present invention in part or in whole. Non-limiting examples of semi-synthetic fibers include cellulose regenerated fibers such as rayon, modal, bamboo fiber, semi-synthetic viscose fibers, cellulose acetate, cellulose diacetate, cellulose triacetate, and any other semi-synthetic fiber known in the art.

[0036] In some embodiments, the nonwoven filter fabric composition of the present invention may be comprised in whole or in part of a biodegradable materials such as but not limited to a bioplastic such as polylactic acid (PLA) or a biodegradable film or sheet material, which in some embodiments may be plant-based. By way of illustration and not limitation, the biodegradable material may be comprised of degradable polyethylene, biodegradable polyester amide, starch-based polymers, cellulose derivatives and polypeptides, naturally-occurring polyesters, specialty tree-based materials, other forms of biodegradable cellulose-based material, and other types of biodegradable polylactic acid-containing material. In some embodiments, the biodegradable material used for one or more elements of the nonwoven filter fabric composition of the present invention may be coated in an egg-based coating, paraffin spray, corn-based or soy-based substances, or beeswax to improve barrier resistance to oxygen and other atmospheric elements. In some embodiments, the coating may comprise in polyvinylidone chloride (PvdC), polyglycolic acid (PGA).

[0037] In some embodiments, the nonwoven filter fabric composition of the present invention may comprise first material and a second material. The first material may be a naturally-derived fiber and the second material may be a thermoplastic. In other embodiments, both the first material and the second material may be a natural-derived fiber. In some embodiments, more than two materials may comprise the nonwoven filter fabric composition. In embodiments having more than three materials, any or all of the materials may comprise a naturally-derived material, a plastic, a thermoplastic, a bioplastic, or any combination of any material or substance disclosed herein.

[0038] In some embodiments, the nonwoven filter fabric composition of the present invention may comprise 60% first material, 30% second material, and 10% third material. Relatedly, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 70% first material, 20% second material, and 10% third material. Moreover, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 65% first material, 25% second material, and 10% third material. As well, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% first material, 24% second material, 8% third material, and 4% fourth material. Or, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% first material, 28% second material, and 8% third material. In some embodiments, the nonwoven filter fabric composition of the present invention may comprise 68% first material, 24% second material, and 8% third material. Additionally, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% first material, 24% second material, and 12% third material.

[0039] In some embodiments, the first material may comprise a plastic, the second material may also comprise a plastic, and the third material may comprise a semi-synthetic fiber. By way of illustration and not limitation, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 65% first plastic, 25% second plastic, and 10% third semi-synthetic fiber. As well, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% first plastic, 24% second plastic, 8% semi-synthetic fiber, and 4% naturally-derived fiber. Or, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% first plastic, 28% second plastic, and 8% semi-synthetic fiber. In some embodiments, the nonwoven filter fabric composition of the present invention may comprise 68% first plastic, 24% second plastic, and 8% semi-synthetic fiber. Additionally, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% first plastic, 24% second plastic, and 12% semi-synthetic fiber.

[0040] Moreover, in some embodiments, the first material may comprise polypropylene, the second material may comprise a polyester, and the third material may comprise viscose fiber. By way of illustration and not limitation, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 65% polypropylene, 25% polyester, and 10% viscose fiber. As well, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% polypropylene, 24% polyester, 8% viscose fiber, and 4% naturally-derived fiber. Or, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% polypropylene, 28% polyester, and 8% viscose fiber. In some embodiments, the nonwoven filter fabric composition of the present invention may comprise 68% polypropylene, 24% polyester, and 8% viscose fiber. Additionally, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% polypropylene, 24% polyester, and 12% viscose fiber.

[0041] Additionally, in some embodiments, the first material may comprise polypropylene, the second material may comprise polyethylene terephthalate, and the third material may comprise viscose fiber. By way of illustration and not limitation, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 65% polypropylene, 25% polyethylene terephthalate, and 10% viscose fiber. As well, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% polypropylene, 24% polyethylene terephthalate, 8% viscose fiber, and 4% naturally-derived fiber. Or, in some embodiments, the nonwoven filter fabric composition of the present invention may comprise 64% polypropylene, 28% polyethylene terephthalate, and 8% viscose fiber. In some embodiments, the nonwoven filter fabric composition of the present invention may comprise 68% polypropylene, 24% polyethylene terephthalate, and 8% viscose fiber. Additionally, in some embodiments, the nonwoven filter fabric may comprise 64% polypropylene, 24% polyethylene terephthalate, and 12% viscose fiber.

[0042] In other or various embodiments, the nonwoven filter fabric composition of the present invention may comprise 1%-99% plastic(s) and 1%-99% natural material(s). By way of illustration and not limitation, in an embodiment, the nonwoven filter fabric composition of the present invention may comprise 25% plastic(s) and 75% natural material(s). Or, an example embodiment of the nonwoven filter fabric composition of the present invention may comprise 40% plastic(s) and 60% natural material(s). In some embodiments, the nonwoven filter fabric composition of the present invention may be comprised of 60% plastic(s) and 40% natural material(s). In yet another example embodiment, the nonwoven filter fabric composition of the present invention may be comprised of 75% plastic(s) and 25% natural material(s).

[0043] A nonwoven filter bag made in accordance with at least one embodiment of the nonwoven filter fabric composition of the present invention (hereinafter, a nonwoven filter bag) may be comprised of two pieces of nonwoven filter fabric having a first reinforced seam, a second reinforced seam, and an opening. In some embodiments, the nonwoven filter bag may be comprised of a single piece of nonwoven filter fabric having a first reinforced seam, a second reinforced seam, a third reinforced seam, and an opening.

[0044] Although generally anticipated in some embodiments to be configured as a flat, square-shaped bag, a nonwoven filter bag made in accordance with at least one embodiment of the nonwoven filter fabric composition of the present invention may be of any shape known in the art, including pyramidal, sack-shaped, multi-layered, spherical, or any other shape. In some embodiments, one or more sides of the nonwoven filter bag may be longer than one or more other sides of the nonwoven filter bag. In such embodiments, one or more sides of the nonwoven filter bag that bound or surround the opening may be longer or shorter than one or more other sides of the nonwoven filter bag that bound or surround the opening.

[0045] The first reinforced seam may, in some embodiments, comprise a permanent or temporary joining of two or more elements of the nonwoven filter fabric accomplished by hand, mechanical, chemical, thermal and/or other means, techniques or processes. In some embodiments, the first reinforced seam may comprise a permanent or temporary joining of two or more separate and otherwise unconnected elements of the nonwoven filter fabric by hand, mechanical, chemical, thermal and/or other means, techniques or processes.

[0046] Illustrative and non-binding examples of such hand, mechanical, chemical, thermal and other means, techniques or processes include but are not limited to manufacturing processed such as but not limited to interlocking the materials via needlework, by interlocking the materials via adhesives, or by four-step staple nonwoven processes, melt-blown techniques, spunlaid and spunbond processes, flashspun techniques and/or air-laid processes. Additionally, the materials may be bonded via thermal bonding, hydro-entanglement (spunlace), ultrasonic pattern bundong, needle punching and felting, chemical bonding (wetlaid processes), melt-blown bonding, and any other bonding or binding techniques or processes known in the art.

[0047] Likewise, in some embodiments, the second reinforced seam may comprise a permanent or temporary joining of two or more sides of a single piece of the nonwoven filter fabric by hand, mechanical, chemical, thermal and/or other means, techniques or processes. In such embodiments, the folding of the single piece of the nonwoven filter fabric may be accomplished by hand, mechanical, chemical, thermal and/or other means, techniques or processes.

[0048] Similarly, in some embodiments, the third reinforced seam may comprise a permanent or temporary joining of two or more sides of a single piece of nonwoven filter fabric by hand, mechanical, chemical, thermal and/or other means, techniques or processes. In such embodiments, the folding of the single piece of the nonwoven filter fabric may be accomplished by hand, mechanical, chemical, thermal and/or other means, techniques or processes.

[0049] In some embodiments, such as the flat square embodiment discussed herein, the opening may extend fully from side to side of the nonwoven filter bag. However, in some embodiments, the opening may be narrower or shaped differently than in the flat square embodiment. For example, in some embodiments, the general shape of the nonwoven filter bag may be pyramidal, and the opening may be narrower or smaller in size than one or more sides of the nonwoven filter bag. Conversely, would the nonwoven filter bag to be hourglass shaped, the opening may be wider than the middle portion of the nonwoven filter bag. In some embodiments, the sides of the nonwoven filter bag that surround the opening may be of unequal proportions, making the sides of the opening unequal as well.

[0050] Relatedly, in some embodiments the opening may be secured with a closure device (not shown) such as but not limited to a string, cable ties, zip-close string assembly, one or more clamps, or any other closure device known in the art.

[0051] In another embodiment of the nonwoven filter bag, the nonwoven filter bag may comprise a single piece of nonwoven filter fabric having a first reinforced seam, a second reinforced seam, a folded edge, and an opening.

[0052] The folded edge is generally contemplated to comprise one side of the nonwoven filter bag resulting from folding the single piece of nonwoven filter fabric back over itself and applying a first reinforced seam and a second reinforced seam to the piece of nonwoven filter fabric. Although likely relatively flat in some embodiments, the folded edge can be arcuate or creased to any degree or amount. As well, in some embodiments, one or more partial seams may transverse the folded edge. In such embodiments, the remaining un-seamed portions of the folded edge may serve to provide flexibility or additional filtering properties to the nonwoven filter bag.

[0053] It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

[0054] Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.

EXAMPLES OF PREFERRED EMBODIMENTS

[0055] The following examples are given in order to more fully teach what the Applicant regards as the invention. It should be understood that the compositions set forth in the Examples are not to be construed as limiting the scope of the invention, except so far as they yield a nonwoven filter fabric having the desired properties and characteristics.

[0056] The following compositions are examples of Applicant's invention with the percentages given by weight:

Example 1

[0057]

TABLE-US-00001 Percent. Percent. Percent. Percent. Percent. Comp. Comp. Comp. Comp. Comp. Material A B C D E polypropylene 55 60 65 68 64 polyester 20 30 25 24 24 viscose fiber 25 10 10 8 8 natural fiber 0 0 0 0 4

Example 2

[0058]

TABLE-US-00002 Percent. Percent. Percent. Percent. Percent. Comp. Comp. Comp. Comp. Comp. Material A B C D E polypropylene 55 60 65 68 64 polyethylene terephthalate 20 30 25 24 24 viscose fiber 25 10 10 8 8 natural fiber 0 0 0 0 4

Example 3

[0059]

TABLE-US-00003 Percent. Percent. Percent. Percent. Percent. Comp. Comp. Comp. Comp. Comp. Material A B C D E polypropylene 55 60 65 68 64 polyethylene terephthalate 20 30 25 24 24 viscose fiber 25 10 10 8 8 other polyester 0 0 0 0 4

CONCLUSIONS, RAMIFICATIONS, AND SCOPE

[0060] While certain embodiments of the invention have been illustrated and described, various modifications are contemplated and can be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention not be limited, except as by the appended claim(s).

[0061] The teachings disclosed herein may be applied to other systems, and may not necessarily be limited to any described herein. The elements and acts of the various embodiments described above can be combined to provide further embodiments. All of the above patents and applications and other references, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions and concepts of the various references described above to provide yet further embodiments of the invention.

[0062] Particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being refined herein to be restricted to any specific characteristics, features, or aspects of the present invention with which that terminology is associated. In general, the terms used in the following claims should not be constructed to limit the present invention to the specific embodiments disclosed in the specification unless the above description section explicitly define such terms. Accordingly, the actual scope encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the disclosed present invention. The above description of embodiments of the present invention is not intended to be exhaustive or limited to the precise form disclosed above or to a particular field of usage.

[0063] While specific embodiments of, and examples for, the present invention are described above for illustrative purposes, various equivalent modifications are possible for which those skilled in the relevant art will recognize.

[0064] While certain aspects of the present invention are presented below in particular claim forms, various aspects of the present invention are contemplated in any number of claim forms. Thus, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the present invention.