Composite filter media utilizing bicomponent fibers

Patent metadata

Field	Value
Publication number	US-10058808-B2
Application number	US-201313827968-A
Country	US
Kind code	B2
Filing date	Mar 14, 2013
Priority date	Oct 22, 2012
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

Disclosed is composite media that may be utilized in coalescing elements, coalescing cartridges, coalescing systems, and coalescing methods. The disclosed media typically is a composite or laminate material formed by bonding adjacent layers of media material comprising bicomponent fibers.

First claim

We claim:

1. A composite media comprising:
at least three layers of media material, the at least three layers of media material bonded together and include, from an upstream direction to a downstream direction, a Layer A, a Layer C, and a Layer D,
wherein one or more layers adjacent to the Layer C consists of bicomponent polymeric fibers,
wherein the Layer A comprises polymeric media material having a nominal mean fiber diameter of greater than about 10 μm; the Layer C comprises polymeric media material comprising nanofibers and having a mean pore size of 0.2-10 μm; and the Layer D comprises polymeric media material having a nominal mean fiber diameter greater than about 10 μm and provides support for the preceding layers,
wherein the composite media is configured as a pleated filter media,
wherein the pleated filter media has a pleat density that exceeds 1/(2H), wherein H is a thickness of the composite media, and
wherein the polymeric media material of Layer D is textured and comprises grooves in a direction perpendicular to bend lines in pleats of the Layer D.

2. The composite media claim 1 , wherein the bicomponent polymeric fibers comprise two different polymeric materials, wherein one of the two different polymeric materials has a different onset melting point than an onset melting point of another of the two different polymeric materials.

3. The composite media of claim 2 , wherein the onset melting points of the one of the two polymeric materials and the other of the two different polymeric materials differ by at least 10° C.

4. The composite media of claim 1 , wherein the bicomponent polymeric fibers comprise a core and sheath in cross-section, the core and sheath each comprise a polymeric material, wherein the polymeric material of the core is a different polymeric material than the polymeric material of the sheath, and wherein the polymeric material of the sheath has a melting temperature that is lower than a melting temperature of the polymeric material of the core.

5. The composite media of claim 4 , wherein the Layer A consists of the bicomponent polymeric fibers, and the melting temperature of the polymeric material of the sheath is lower than a melting temperature of the polymeric media material of the Layer C.

6. The composite media of claim 4 , further comprising a Layer B disposed between the Layer A and the Layer C, wherein the Layer B consists of the bicomponent polymeric fibers, and the melting temperature of the polymeric material of the sheath is lower than a melting temperature of the polymeric media material of the Layer C.

7. The composite media of claim 4 , wherein the Layer D consists of the bicomponent polymeric fibers, and the melting temperature of the polymeric material of the sheath is lower than a melting temperature of the polymeric material of the Layer C.

8. The composite media of claim 4 , wherein the Layer A and the Layer D consist of the bicomponent polymeric fibers, and the melting temperature of the polymeric material of the sheath is lower than a melting temperature of the polymeric material of the Layer C.

9. The composite media of claim 4 , further comprising a Layer B disposed between the Layer A and the Layer C, wherein the Layer A, the Layer B, and the Layer D consist of the bicomponent polymeric fibers, and the melting temperature of the polymeric material of the sheath is lower than a melting temperature of the polymeric material of Layer C.

10. The composite media of claim 1 , wherein one or more layers are bonded to one or more adjacent layers via ultrasonic bonding.

11. The composite media of claim 1 , wherein the Layer A comprises polymeric media material having a mean pore size of greater than about 25μm.

12. The composite media of claim 1 , wherein the Layer A comprises polymeric media material having a maximum pore size of greater than about 30 μm.

13. The composite media of claim 1 , wherein the Layer A comprises polymeric media material having a permeability of 80-325 cfm.

14. The composite media of claim 1 , wherein the Layer A comprises polymeric media material having a thickness of 0.1-0.5 mm.

15. The composite media of claim 1 , wherein the Layer A comprises polymeric media material having a basis weight of 20-60 gsm.

16. The composite media of claim 1 , wherein the Layer C comprises polymeric media material having a nominal mean fiber diameter of 0.1-5 μm.

17. The composite media of claim 1 , wherein the Layer C comprises polymeric media material having a maximum pore size of 1-25 μm.

18. The composite media of claim 1 , wherein the Layer C comprises polymeric media material having a permeability of about 3-55 cfm.

19. The composite media of claim 1 , wherein the Layer C comprises polymeric media material having a thickness of 0.1-0.5 mm.

20. The composite media of claim 1 , wherein the Layer C comprises polymeric media material having a basis weight of 8-50 gsm.

21. The composite media of claim 1 , wherein the Layer D comprises polymeric media material having a nominal mean fiber diameter greater than 15 μm.

22. The composite media of claim 1 , wherein the Layer D comprises polymeric media material having a mean pore size greater than 20 μm.

23. The composite media of claim 1 , wherein the Layer D comprises polymeric media material having a maximum pore size greater than 40 μm.

24. The composite media of claim 1 , wherein the Layer D comprises polymeric media material having a permeability of 40-200 cfm.

25. The composite media of claim 1 , wherein the Layer D comprises polymeric media material having a thickness of 0.1-0.56 mm.

26. The composite media of claim 1 , wherein the Layer D comprises polymeric media material having a basis weight of 40-180 gsm.

27. The composite media of claim 1 , further comprising a Layer B disposed between the Layer A and the Layer C, wherein the Layer B comprises polymeric media material having one or more of the following characteristics: (a) a nominal mean fiber diameter of 1-5 μm; (b) a mean pore size of 5-15 μm; (c) a maximum pore size of 10-25 μm; (d) a permeability of 25-55 cfm; (e) a thickness of 0.1-0.5 mm; and (f) a basis weight of 15-50 gsm.

28. The composite media of claim 1 , further comprising a Layer B disposed between the Layer A and the Layer C, wherein at least one of the Layer A, the Layer B, the Layer C, and the Layer D comprises polymeric material selected from a group consisting of polyamide material, polybutylene terephthalate material, polyethylene terephthalate material, and polyester material.

29. The composite media of claim 1 , wherein the one or more layers adjacent to the Layer C consists of bicomponent polymeric fibers that have been meltspun or meltblown.

30. The composite media of claim 1 , wherein the Layer C comprises polyamide material.

31. The composite media of claim 1 , further comprising a Layer B disposed between the Layer A and the Layer C, wherein at least one of the Layer A and the Layer B comprise polybutylene terephthalate material.

32. The composite media of claim 1 , wherein the Layer D comprises polyethylene terephthalate material.

Assignees

• Cummins Filtration Ip Inc

Inventors

• Haberkamp William C
• Janikowski Eric A
• Ellison Kyle
• Verdegan Barry Mark
• Holm Christopher E

Classifications

• B01D2239/1216

  Pore size · CPC title

• B01D2239/0668

  The layers being joined by heat or melt-bonding · CPC title

• B01D39/163 Primary

  sintered or bonded · CPC title

• B01D39/1623 Primary

  of synthetic origin · CPC title

• B01D2239/1233

  Fibre diameter · CPC title