Filter media comprising a pre-filter layer
Filter media comprising a pre-filter layer and related components, systems, and methods associated therewith are provided. In some embodiments, the pre-filter layer may be designed to impart desirable properties to the filter media, such as a high gamma and/or long service life, while having relatively minimal or no adverse effects on another property of the filter media that is important for a given application. For instance, a pre-filter layer may be used to improve the upstream removal of fine particulate matter, which may clog a downstream efficiency layer comprising submicron fibers and reduce filtration performance. The pre-filter layer may be configured to increase service life and/or increase the gamma of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.
1. A filter media, comprising:
a pre-filter layer comprising first fibers having a median diameter of less than or equal to about 2 microns, the pre-filter layer having a thickness greater than or equal to about 20 microns and less than or equal to about 1 mm, wherein the pre-filter layer has a basis weight of less than about 30 g/m 2 and an initial DOP efficiency of less than or equal to about 90%; and
a second layer comprising second fibers having a median diameter of less than or equal to about 1 micron, wherein the second layer has an initial DOP efficiency of greater than or equal to about 60% and wherein the initial DOP efficiency of the second layer is greater than the pre-filter layer.
2. A filter media, comprising:
a pre-filter layer comprising first fibers having a median diameter of less than or equal to about 2 microns, the pre-filter layer having a thickness greater than or equal to about 20 microns and less than or equal to about 1 mm, wherein the pre-filter layer has a basis weight of less than about 30 g/m 2 and an initial DOP efficiency of less than or equal to about 90%; and
a polymeric membrane having an initial DOP efficiency of greater than or equal to about 60% and wherein the initial DOP efficiency of the polymeric membrane is greater than the pre-filter layer.
3. A filter media as in claim 1 , wherein a surface area of the pre-filter layer is greater than or equal to about 1.75 m 2 /g and less than or equal to about 45 m 2 /g.
4. A filter media as in claim 1 , wherein the initial DOP efficiency of the pre-filter layer is greater than or equal to about 10%.
5. A filter media as in claim 1 , wherein the pre-filter layer has a solidity of less than or equal to about 25%.
6. A filter media as in claim 1 , wherein the pre-filter layer has a pressure drop of less than 35 mm H 2 O.
7. A filter media as in claim 1 , wherein the first fibers have a median diameter of less than or equal to about 1 micron.
8. A filter media as in claim 1 , wherein the first fibers are continuous fibers.
9. A filter media as in claim 1 , wherein the first fibers are synthetic fibers.
10. A filter media as in claim 1 , wherein the second fibers have a median fiber diameter of less than or equal to about 0.5 microns.
11. A filter media as in claim 1 , wherein the median diameter of the first fibers is greater than the median diameter of the second fibers.
12. A filter media as in claim 2 , wherein the polymeric membrane comprises a fluorinated polymer.
13. A filter media as in claim 1 , wherein the pre-filter has a gamma of greater than or equal to about 7.
14. A filter element comprising the filter media of claim 1 .
15. A filter element as in claim 14 , wherein the filter element is a HEPA filter, ULPA filter, HVAC filter, or a face mask.
16. A filter media as in claim 1 , wherein the pre-filter layer comprises continuous fibers and the second layer comprises synthetic fibers.
17. A filter media as in claim 1 , wherein the pre-filter layer and the second layer comprise synthetic fibers.
18. A filter media as in claim 1 , wherein the pre-filter layer comprises synthetic fibers and the second layer comprises continuous fibers.
19. A filter media as in claim 1 , wherein the pre-filter layer and/or the second layer comprise electrospun fibers.
20. A filter media as in claim 1 , wherein the pre-filter layer and/or the second layer comprise meltblown fibers.
21. A method comprising:
passing a fluid through the filter media of claim 1 .
22. A filter media as in claim 2 , wherein the polymeric membrane is non-fibrous.
23. A method comprising:
passing a fluid through the filter element of claim 14 .