# US 11,896,921 B2 · Nonwoven sliver-based filter medium for filtering particulate matter > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,896,921 B2 - Document ID: US11896921B2 - Status: Granted - Kind: B2 - Application number: 17/704,174 - Filed: 2022-03-25 - Published: 2022-07-07 - Granted: 2024-02-13 - Earliest claimed: 2015-01-23 - Applicants: Kirk S. Morris - Inventors: Kirk S. Morris - Web page: https://patentgrep.com/patent/US11896921B2 ## CPC - B01D 39/1623: {of synthetic origin} - D04H 1/5418: {Mixed fibres, e.g. at least two chemically different fibres or fibre blends} - B01D 2239/02: Types of fibres, filaments or particles, self-supporting or supported materials - B01D 2239/0618: Non-woven - B01D 2239/0636: Two or more types of fibres present in the filter material - B01D 2239/064: The fibres being mixed - B01D 2239/065: More than one layer present in the filtering material - B01D 2239/0695: Wound layers - B01D 2239/1233: Fibre diameter - B01D 2239/1291: Other parameters - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) ## Abstract A filter medium for filtering matter from a fluid and the manufacture thereof are provided. In one exemplary embodiment, a method may be performed by a filter medium for filtering particulate matter from a fluid. Further, the filter medium may include a nonwoven sliver formed into a predetermined shape and composed of first synthetic staple fibers having a first denier, second synthetic staple fibers having a second denier, and third synthetic staple fibers having a third denier. ## Claims ### Claim 1 A filter medium for filtering particulate matter from a liquid, the filter medium comprising: a nonwoven sliver formed into a predetermined shape, wherein the nonwoven sliver comprises: first synthetic staple fibers having a first denier; second synthetic staple fibers having a second denier; and third synthetic staple fibers having a third denier; wherein the filter medium has a substantially cylindrical or spherical shape and comprises a core and an outer wrap, a density of the core being greater than a density of the outer wrap, wherein the filter medium is configured to filter particulate matter from a liquid, with a fiber migration of about 100 fibers or less for a flush volume of about 19,000 milliliters at a flow rate of about 600 cubic centimeters per minute; wherein: the nonwoven sliver is a first nonwoven sliver comprising synthetic staple fibers having a first density, the filter medium further comprises a second nonwoven sliver comprising synthetic staple fibers having a second density, the core comprises the first nonwoven sliver, and the outer wrap comprises the second nonwoven sliver. ### Claim 2 (depends on 1) The filter medium of claim 1, wherein the filter medium has a volume of about 0.05 cubic feet. ### Claim 3 (depends on 1) The filter medium of claim 1, wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers comprise fibers having a fiber length ranging from about two inches to about six inches. ### Claim 4 (depends on 1) The filter medium of claim 1, wherein the first denier ranges from about 1 denier to about 10 denier, the second denier ranges from about 10 denier to about 20 denier, and the third denier ranges from about 20 denier to about 50 denier. ### Claim 5 (depends on 1) The fitter medium of claim 1, wherein the second denier ranges from about 10 denier to about 20 denier, the first denier is less than the second denier, and the third denier is greater than the second denier. ### Claim 6 (depends on 1) The filter medium of claim 1, wherein a composition of the nonwoven sliver comprises from about 10% to about 60% of the first synthetic staple fibers, from about 10% to about 60% of the second synthetic staple fibers, and from about 10% to about 50% of the third synthetic staple fibers. ### Claim 7 (depends on 1) The filter medium of claim 1, wherein the filter medium has a total volume, including a volume of the first synthetic staple fibers, a volume of the second synthetic staple fibers, and a volume of the third synthetic staple fibers, wherein the volume of the third synthetic fibers comprises less than about 2% of the total volume of the filter medium. ### Claim 8 (depends on 1) The filter medium of claim 1, wherein the filter medium is configured to filter particulate matter having a grain size ranging from about 5 microns to about 10 microns. ### Claim 9 (depends on 1) The filter medium of claim 1, wherein the filter medium has a flow resistance of no more than about 50 millibars. ### Claim 10 (depends on 1) The filter medium of claim 1, wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers are crimped and folded. ### Claim 11 (depends on 1) The filter medium of claim 1, wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers comprise bi-component fibers. ### Claim 12 (depends on 1) The filter medium of claim 1, wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers comprise fibers that are one or more of oleophilic, oleophobic, hydrophilic, or hydrophobic. ### Claim 13 A filter medium for filtering particulate matter from a liquid, the filter medium comprising: a nonwoven sliver formed into a predetemined shape, wherein the nonwoven sliver comprises: first synthetic staple fibers having a first denier; second synthetic staple fibers having a second denier; and third synthetic staple fibers having a third denier; wherein the filter medium is configured to filter particulate matter from a liquid, and wherein the first denier ranges from about 1 denier to about 10 denier, the second denier ranges from about 10 denier to about 20 denier, and the third denier ranges from about 20 denier to about 50 denier; wherein the filter medium comprises a core and an outer wrap; wherein: the nonwoven sliver is a first nonwoven sliver comprising synthetic staple fibers having a first density, the filter medium further comprises a second nonwoven sliver comprising synthetic staple fibers having a second density, the core comprises the first nonwoven sliver, and the outer wrap comprises the second nonwoven sliver. ### Claim 14 (depends on 13) The fitter medium of claim 13, wherein the filter medium is configured to filter particulate matter from a liquid, with a fiber migration of about 100 fibers or less for a flush volume of about 19,000 milliliters at a flow rate of about 600 cubic centimeters per minute. ### Claim 15 (depends on 13) The filter medium of claim 13, wherein a density of the core is greater than a density of the outer wrap. ### Claim 16 (depends on 13) The filter medium of claim 13, wherein a composition of the nonwoven sliver comprises from about 10% to about 60% of the first synthetic staple fibers, from about 10% to about 60% of the second synthetic staple fibers, and from about 10% to about 50% of the third synthetic staple fibers. ### Claim 17 (depends on 13) The filter medium of claim 13, wherein the filter medium has a total volume, including a volume of the first synthetic staple fibers, a volume of the second synthetic staple fibers, and a volume of the third synthetic staple fibers, wherein the volume of the third synthetic fibers comprises less than about 2% of the total volume of the filter medium. ### Claim 18 (depends on 13) The filter medium of claim 13, wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers are crimped and folded. ### Claim 19 (depends on 13) The filter medium of claim 13, wherein the filter medium has a volume of about 0.05 cubic feet.