Filter medium and structure
AssigneeDonaldson Company, Inc.
InventorsBrad E. Kahlbaugh, Keh B. Dema, Linda M. Olson
Life of this patent
Estimating the term…
Abstract
Thermoplastic bicomponent binder fiber can be combined with other media, fibers and other filtration components to form a thermally bonded filtration media. The filtration media can be used in filter units. Such filter units can be placed in the stream of a mobile fluid and can remove a particulate load from the mobile stream. The unique combination of media fiber, bicomponent binder fiber and other filtration additives and components provide a filtration media having unique properties in filtration applications.
Claims82
A filtration medium comprising a thermally bonded sheet, the sheet comprising:
- (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- and
- (b) an effective amount of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers, an aspect ratio of about 10 to 10,000 to obtain a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min−1;
- wherein the media has a thickness of about 0.2 to 50 mm, a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m−2.
A liquid filtration medium comprising a thermally bonded sheet, the sheet comprising:
- (a) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- and
- (b) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m−2, a pore size of about 0.2 to 50 micrometers and a permeability of about 2 to 200 ft-min−1.
A method of filtering a liquid stream, the method comprising:
- (a) placing a filter unit into the stream and
- (b) retaining particulate entrained in the filter in the stream using filter media within the filter unit, the filter media comprising a thermally bonded sheet comprising:
- (i) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- and
- (ii) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the medium has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m−2, a pore size of about 0.2 to 50 micrometers and a permeability of about 2 to 200 ft-min−1.
A gaseous filtration medium for removing mist from air comprising a thermally bonded sheet, the sheet comprising:
- (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- (b) about 20 to 80 wt % of a media fiber a fiber diameter of about 0.1 to 20 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 20 to 200 grams-m−2, a pore size of about 5 to 100 micrometers and a permeability of about 5 to 500 ft-min−1.
A gaseous filtration medium for removing particulate from air comprising a thermally bonded sheet, the sheet comprising:
- (a) about 80 to 98 wt % of a bicomponent binder fiber having a fiber diameter of about 10 to 15 micrometers and a fiber length of about 0.1 to 15 cm;
- (b) about 2 to 20 wt % of a media fiber a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 10 to 25%, a basis weight of about 40 to 400 grams-m−2, a pore size of about 10 to 30 micrometers and a permeability of about 20 to 200 ft-min−1.
A gaseous filtration medium for removing an entrained liquid from blow-by gases comprising a thermally bonded sheet, the sheet comprising:
- (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 5 to 15 cm;
- (b) about 0.5 to 15 wt % of a media fiber or a secondary fiber having a fiber diameter of about 0.5 to 15 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 1 to 10%, a basis weight of about 20 to 80 grams-m−2, a pore size of about 5 to 50 micrometers and a permeability of about 50 to 500 ft-min−1.
A filtration medium for filtering a lubricant oil comprising a thermally bonded sheet, the sheet comprising:
- (a) about 1 to 40 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 0.1 to 15 cm;
- and
- (b) about 60 to 99 wt % of a glass fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.2 to 2 mm, a solidity of about 2 to 10%, a basis weight of about 10 to 50 g-m−2, a pore size of about 0.5 to 10 micrometers and a permeability of about 0.1 to 30 ft-min−1.
A filtration medium for filtering a hydraulic oil comprising a thermally bonded sheet, the sheet comprising:
- (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 0.1 to 15 cm;
- and
- (b) about 80 to 20 wt % of a media fiber having a fiber diameter of about 0.1 to 2 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.2 to 2 mm, a basis weight of about 40 to 350 g-m−2, a pore size of about 0.5 to 30 micrometers and a permeability of about 5 to 200 ft-min−1.
A method of filtering a heated fluid, the method comprises the steps of:
- (a) passing a mobile fluid phase containing a contaminant through a filter medium, the medium having a thickness of about 0.2 to 50 mm, the medium comprising a thermally bonded sheet, the sheet comprising:
- (i) about 20 to 80 wt % of a bicomponent binder fiber having a first component with a melting point and a second component with a lower melting point, the fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- and
- (ii) about 20 to 80 wt % of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m−2, a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min−1, the mobile fluid phase having a temperature greater than the melting point of the second component;
- and
- (b) removing the contaminant.
A filtration medium comprising a thermally bonded sheet, the sheet comprising:
- (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm:
- (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin;
- and
- (c) about 20 to 80 wt % of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.2 to 50 mm, a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m−2, a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min−1.
A liquid filtration medium comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising:
- (a) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- (b) an effective medium binding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin;
- and
- (c) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m−2, a pore size of about 0.2 to 50 micrometers and a permeability of about 1 to 200 ft-min−1.
A gaseous filtration medium for removing mist from air comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising:
- (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;
- (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin;
- and
- (c) about 20 to 80 wt % of a media fiber with a diameter of about 0.1 to 20 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 20 to 200 g-m−2, a pore size of about 5 to 20 micrometers and a permeability of about 5 to 500 ft-min−1.
A gaseous filtration medium for removing particulate from air comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising:
- (a) about 80 to 98 wt % of a bicomponent binder fiber having a fiber diameter of about 10 to 15 micrometers and a fiber length of about 0.1 to 15cm;
- (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin;
- and
- (c) about 2 to 20 wt % of a media fiber with a diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;
- wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 10 to 25%, a basis weight of about 40 to 400 g-m−2, a pore size of about 10 to 30 micrometers and a permeability of about 20 to 200 ft-min−1.
Dependencies are inferred from the claim text.