High speed rotating crankcase ventilation filter media and media pack
Filter media and media packs that provide robust performance in high-speed rotating coalescer (HSRC) elements for crankcase ventilation systems are described. The filter media is HSRC filter media. As such, the filter media has a higher resistance to compressibility than traditional coalescer filter media, such as filter media used in low-speed rotating coalescer arrangements or stationary coalescer arrangements.
1. Filter media comprising:
fibers having a geometric mean fiber diameter between 5 to 40 μm, the fibers having a solidity between 5% and 30%, and about three percent of the fibers have a diameter greater than 20 μm;
wherein the filter media has a compressibility of less than 25% at pressures greater than 20 kPa.
2. The filter media of claim 1 , wherein the fibers are comprised of a polymeric material.
3. The filter media of claim 2 , wherein the polymeric material is a needle-punched polyphenylene sulfide filter media.
4. The filter media of claim 1 , wherein the filter media is formed into a cylindrical filter media pack.
5. The filter media of claim 4 , wherein the filter media has a compressibility of less than 25% at 200 G, where G is defined by the equation
G
=
ω
2
R
9.81
,
where ω is a rotational speed of the filter media pack in radians per second and R is a radius of the filter media pack in meters.
6. The filter media of claim 5 , wherein the filter media has a compressibility of less than 25% at 1000 G.
7. The filter media of claim 2 , wherein the polymer material is a single polymer material, a single copolymer material, or a single polymer blend.
8. The filter media of claim 1 , wherein the filter media has a Frazier permeability of less than or equal to 250 cubic feet per minute at 0.5 inches of water pressure drop.
9. The filter media of claim 1 , wherein the fibers are first fibers and the geometric mean fiber diameter is a first geometric mean fiber diameter, wherein the filter media further comprises second fibers having a second geometric mean fiber diameter, the second geometric mean fiber diameter different than the first geometric fiber diameter.
10. The filter media of claim 9 , wherein the second fibers are layered over the first fibers forming a multi-layer filter media.
11. The filter media of claim 9 , wherein the second fibers are positioned with respect to the first fibers such that the filter media has a varying filtering efficiency across a depth of the filter media thereby forming a gradient efficiency filter media.
12. The filter media of claim 9 , wherein the filter media is a composite filter media comprising the first fibers and the second fibers.
13. The filter media of claim 1 , wherein the compressibility is at 20 degrees Celsius.
14. The filter media of claim 1 , wherein the compressibility is at 120 degrees Celsius.
15. A high-speed rotating coalescer element comprising:
a first endplate;
a second endplate;
a filter media pack comprising filter media positioned between the first endplate and the second endplate, the filter media comprising fibers having a geometric mean fiber diameter between 5 to 40 μm, the fibers having a solidity between 5% and 30%, the filter media has a compressibility of less than 25% at pressures greater than 20 kPa.
16. The high-speed rotating coalescer element of claim 15 , wherein the filter media has a Frazier permeability of less than or equal to 250 cubic feet per minute at 0.5 inches of water pressure drop.
17. The high-speed rotating coalescer element of claim 15 , further comprising a support cage extending between the first and second endplates, the support cage positioned adjacent to the filter media pack such that the support cage provides a support surface for the filter media pack during rotation of the coalescer element.
18. The high-speed rotating coalescer element of claim 15 , wherein the polymeric material is a needle-punched polyphenylene sulfide filter media.
19. The high-speed rotating coalescer element of claim 15 , wherein the filter media pack is cylindrical in shape.
20. The high-speed rotating coalescer element of claim 19 , wherein the filter media has a compressibility of less than 25% at 200 G, where G is defined by the equation
G
=
ω
2
R
9
.
8
1
,
where ω is a rotational speed of the filter media pack in radians per second and R is a radius of the filter media pack in meters.
21. The high-speed rotating coalescer element of claim 20 , wherein the filter media has a compressibility of less than 25% at 1000 G.
22. The high-speed rotating coalescer element of claim 15 , wherein about three percent of the fibers have a diameter greater than 20 μm.
23. The high-speed rotating coalescer element of claim 15 , wherein the filter media has a Frazier permeability of less than or equal to 250 cubic feet per minute at 0.5 inches of water pressure drop.
24. The high-speed rotating coalescer element of claim 15 , wherein the fibers are first fibers and the geometric mean fiber diameter is a first geometric mean fiber diameter, wherein the filter media further comprises second fibers having a second geometric mean fiber diameter, the second geometric mean fiber diameter different than the first geometric fiber diameter.
25. The high-speed rotating coalescer element of claim 24 , wherein the second fibers are layered over the first fibers forming a multi-layer filter media.
26. The high-speed rotating coalescer element of claim 24 , wherein the second fibers are positioned with respect to the first fibers such that the filter media has a varying filtering efficiency across a length of the filter media thereby forming a gradient efficiency filter media.
27. The high-speed rotating coalescer element of claim 24 , wherein the filter media is a composite filter media comprising the first fibers and the second fibers.
28. The high-speed rotating coalescer element of claim 15 , wherein the fibers are comprised of a polymeric material.
29. A filter media pack for use in a high-speed rotating coalescer, the filter media pack comprising:
filter media formed into a cylindrical filter media pack, the filter media having fibers of a polymeric material, the fibers having a geometric mean fiber diameter between 5 to 40 μm, the fibers having a solidity between 5% and 30%, the filter media has a compressibility of less than 25% at pressures greater than 20 kPa, and about three percent of the fibers have a diameter greater than 20 μm.
30. The filter media pack of claim 29 , wherein the fibers having a Frazier permeability of less than or equal to 250 cubic feet per minute at 0.5 inches of water pressure drop.
31. The filter media pack of claim 29 , wherein the fibers are comprised of a polymeric material.
32. The filter media pack of claim 31 , wherein the polymeric material is a needle-punched polyphenylene sulfide filter media.
33. The filter media pack of claim 29 , wherein the filter media has a compressibility of less than 25% at 200 G, where G is defined by the equation
G
=
ω
2
R
9.81
,
where ω is a rotational speed of the filter media pack in radians per second and R is a radius of the filter media pack in meters.
34. The filter media pack of claim 33 , wherein the filter media has a compressibility of less than 25% at 1000 G.
35. The filter media pack of claim 29 , wherein the fibers are first fibers and the geometric mean fiber diameter is a first geometric mean fiber diameter, wherein the filter media further comprises second fibers having a second geometric mean fiber diameter, the second geometric mean fiber diameter different than the first geometric fiber diameter.
36. The filter media pack of claim 35 , wherein the second fibers are layered over the first fibers forming a multi-layer filter media.
37. The filter media pack of claim 35 , wherein the second fibers are positioned with respect to the first fibers such that the filter media has a varying filtering efficiency across a length of the filter media thereby forming a gradient efficiency filter media.
38. The filter media pack of claim 35 , wherein the filter media is a composite filter media comprising the first fibers and the second fibers.
39. Filter media comprising:
fibers having a geometric mean fiber diameter between 5 to 30 μm, the fibers having a solidity between 5% and 25%, and about three percent of the fibers have a diameter greater than 20 μm,
wherein the filter media has a Frazier permeability of less than or equal to 250 cubic feet per minute at 0.5 inches of water pressure drop.
40. The filter media of claim 39 , wherein the filter media has a compressibility of less than 25% at pressures greater than 20 kPa.
41. The filter media of claim 40 , wherein the fibers are of a polymeric material.
42. The filter media of claim 41 , wherein the filter media is formed into a cylindrical filter media pack.
43. The filter media of claim 42 , wherein the filter media has a compressibility of less than 25% at 200 G, where G is defined by the equation
G
=
ω
2
R
9.81
,
where ω is a rotational speed of the filter media pack in radians per second and R is a radius of the filter media pack in meters.
44. The filter media of claim 43 , wherein the filter media has a compressibility of less than 25% at 1000 G.