Composite filter media utilizing bicomponent fibers
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.
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.