Fiber web having a high stiffness
The fiber webs described herein may be incorporated into filter media and filter elements. The webs may exhibit a high permeability and stiffness, at a low thickness. The stiffness can be sufficient for the webs to be pleated to include sharp, well-defined peaks which can be maintained in a stable configuration during use.
1. A fiber web having a permeability of greater than about 500 cfm/sf, a stiffness of greater than about 500 mg, and a thickness of less than about 25 mils.
2. The fiber web of claim 1 , wherein the fiber web is a nonwoven web.
3. The fiber web of claim 1 , wherein the fiber web includes synthetic fibers.
4. The fiber web of claim 1 , wherein the fiber web includes bicomponent fibers.
5. The fiber web of claim 4 , wherein the weight percent of the bicomponent fibers is greater than 50 percent by weight of the total weight percent of the fibers in the fiber web.
6. The fiber web of claim 1 , wherein the fiber web includes binder fibers and non-binder fibers.
7. The fiber web of claim 6 , wherein the binder fibers comprise greater than 50 percent by weight of the total weight of fibers in the fiber web.
8. The fiber web of claim 7 , wherein the binder fibers are multi-component fibers.
9. The fiber web of claim 1 , wherein the fiber web includes a resin.
10. The fiber web of claim 9 , wherein the resin is in latex form.
11. The fiber web of claim 9 , wherein the fiber web includes a binder comprising a polymer in the same class as the resin.
12. The fiber web of claim 11 , wherein the binder and the resin are a polyester.
13. The fiber web of claim 1 , wherein the fiber web has a permeability of between about 500 cfm/sf and about 1200 cfm/sf.
14. The fiber web of claim 1 , wherein the fiber web has a stiffness of between about 500 mg and about 1700 mg.
15. The fiber web of claim 1 , wherein the fiber web has a thickness of between about 12 mils and about 25 mils.
16. The fiber web of claim 1 , wherein the fiber web has a basis weight of between about 40 g/m 2 and about 300 g/m 2 .
17. The fiber web of claim 1 , wherein the fiber web has a SFI after 5 seconds of less than about 70°.
18. A filter media comprising the fiber web of claim 1 as a backing and a second fiber web attached to the backing.
19. A filter element comprising the fiber web of claim 18 .
20. A fiber web having a permeability of greater than about 500 cfm/sf, a thickness of less than about 25 mils, and a stiffness of greater than about 500 mg, the fiber web comprising multi-component fibers, wherein the multi-component fibers comprise greater than 50 percent by weight of the total weight of fibers in the fiber web.
21. A fiber web having a permeability of greater than about 500 cfm/sf, a stiffness of greater than about 500 mg and a thickness of less than about 25 mils, wherein the fiber web comprises binder fibers and a resin, wherein the binder fibers comprise a polymer and the resin comprises a polymer, and the polymer of the binder fibers is in the same class as the polymer of the resin.
22. A method of filtering a fluid, the method comprising:
filtering a fluid using a filter element comprising a fiber web, the fiber web having a permeability of greater than about 500 cfm/sf, a stiffness of greater than about 500 mg, and a thickness of less than about 25 mils.
23. A method of manufacturing a fiber web comprising:
forming a fiber web that has a permeability of greater than about 500 cfm/sf, a stiffness of greater than about 500 mg, and a thickness of less than about 25 mils.
24. The fiber web of claim 1 , wherein the fiber web has a permeability of between about 500 cfm/sf and about 1200 cfm/sf, a stiffness of between about 500 mg and about 1700 mg and a thickness of between about 12 mils and about 25 mils.
25. The fiber web of claim 24 , wherein the fiber web is a nonwoven web and the fiber web includes synthetic fibers, bicomponent fibers, and the weight percent of the bicomponent fibers is greater than 50 percent by weight of the total weight percent of the fibers in the fiber web.
26. The fiber web of claim 20 , wherein the fiber web has a permeability of between about 500 cfm/sf and about 1200 cfm/sf, a stiffness of between about 500 mg and about 1700 mg and a thickness of between about 12 mils and about 25 mils.
27. The fiber web of claim 21 , wherein the fiber web has a permeability of between about 500 cfm/sf and about 1200 cfm/sf, a stiffness of between about 500 mg and about 1700 mg and a thickness of between about 12 mils and about 25 mils.
28. The method of claim 22 , wherein the fiber web has a permeability of between about 500 cfm/sf and about 1200 cfm/sf, a stiffness of between about 500 mg and about 1700 mg and a thickness of between about 12 mils and about 25 mils.
29. The method of claim 28 , wherein the fiber web is a nonwoven web and the fiber web includes synthetic fibers, bicomponent fibers, and the weight percent of the bicomponent fibers is greater than 50 percent by weight of the total weight percent of the fibers in the fiber web.
30. The method of claim 28 , wherein the fiber web includes a resin in latex form and the fiber web includes a binder comprising a polymer in the same class as the resin.
31. The method of claim 30 , wherein the binder and the resin are a polyester.
32. The method of claim 31 , wherein the fiber web has a basis weight of between about 40 g/m 2 and about 300 g/m 2 .
33. The method of claim 23 , wherein the fiber web has a permeability of between about 500 cfm/sf and about 1200 cfm/sf, a stiffness of between about 500 mg and about 1700 mg and a thickness of between about 12 mils and about 25 mils.