Coalescing media
Some embodiments relate to a filter material for coalescing a dispersed phase in a continuous phase. The filter material has binder fibers and irregular rayon fibers distributed among the binder fibers. The filter material lacks non-fibrous resin. Some embodiments relate to a filter assembly. The filter assembly has a particle filtration layer, a coalescing layer downstream of the particle filtration layer, and a growth media downstream of the coalescing layer. The coalescing layer is coupled to the particle filtration layer. The growth media has irregular rayon fibers and binder fibers distributed among the irregular rayon fibers. The growth media lacks non-fibrous resin.
1 . A filter material comprising:
binder fibers;
irregular rayon fibers distributed among the binder fibers; and
fibrillated rayon fibers, wherein the filter material lacks non-fibrous resin, wherein the filter material is 30% to 75% by weight total rayon fibers including at least the irregular rayon fibers and the fibrillated rayon fibers.
2 . The filter material of claim 1 , having an air permeability between 100-500 ft 3 -min −1 -ft −2 at 125 Pa.
3 . The filter material of claim 1 , having a thickness of at least 0.25 mm.
4 . The filter material of claim 1 , further comprising polyester fibers, wherein the filter material is up to 70% by weight polyester fibers.
5 . The filter material of claim 1 , wherein the filter material lacks a support layer.
6 . The filter material of claim 1 , wherein the filter material lacks glass.
7 . The filter material of claim 1 , wherein the filter material comprises natural cellulose fibers.
8 . The filter material of claim 1 , wherein the irregular rayon fibers are multi-lobed rayon fibers.
9 . The filter material of claim 1 , wherein the irregular rayon fibers have a linear mass density from 1 den to 7 den.
10 . The filter material of claim 1 , having variations in flow resistance through the filter material across a surface area of the filter material.
11 . A filter assembly comprising:
a particle filtration layer;
a coalescing layer downstream of the particle filtration layer, wherein the coalescing layer is coupled to the particle filtration layer; and
a growth media downstream of the coalescing layer, the growth media is filter material comprising:
irregular rayon fibers;
binder fibers distributed among the irregular rayon fibers, wherein the filter material lacks non-fibrous resin; and
fibrillated rayon fibers, wherein the filter material is 30% to 75% by weight total rayon fibers including at least the irregular rayon fibers and the fibrillated rayon fibers.
12 . The filter assembly of claim 11 , wherein the particle filtration layer, coalescing layer, and growth media are pleated and collectively define a tubular structure.
13 . The filter assembly of claim 11 , wherein the particle filtration layer and coalescing layer are pleated and collectively define a tubular structure having a central opening, and wherein the growth media forms a non-pleated tube within the central opening.
14 . The filter assembly of claim 11 , wherein the particle filtration layer and coalescing layer are pleated and collectively define a tubular structure having a central opening, and the growth media is pleated and defines a tubular structure, and wherein a radial gap is defined between the growth media and the coalescing layer.
15 . The filter assembly of claim 11 , further comprising a porous barrier downstream of the growth media.
16 . The filter assembly of claim 15 , wherein the porous barrier forms a tubular structure.