Filter media suitable for hydraulic applications
Filter media, including those suitable for hydraulic applications, and related components, systems, and methods associated therewith are provided. The filter media described herein may include two or more layers, at least one of the layers having a relatively high percentage of microglass fibers. Additionally, the filter media may be designed such that the ratio of average fiber diameters between two layers is relatively small, which can lead to a relatively low resistance ratio between the layers. In some embodiments, at least one layer of the filter media comprises synthetic polymer fibers. Certain filter media described herein may have desirable properties including high dirt holding capacity and a low resistance to fluid flow. The media may be incorporated into a variety of filter element products including hydraulic filters.
1. A filter media comprising:
a first layer comprising fibers, wherein the fibers in the first layer comprise synthetic polymer fibers, and wherein the fibers in the first layer have a first average diameter;
a second layer adjacent to the first layer, the second layer comprising fibers, wherein the fibers in the second layer comprise synthetic polymer fibers, wherein the fibers in the second layer have a second average diameter, and wherein the first average diameter is greater than the second average diameter; and
a third layer adjacent to the second layer, the third layer comprising fibers, wherein the fibers in the third layer comprise synthetic polymer fibers, wherein the fibers in the third layer have a third average diameter, wherein the second average diameter is greater than the third average diameter, wherein the third layer has a mean flow pore size of between about 1 micron and about 50 microns,
wherein the filter media has a thickness of between about 5 mils and about 300 mils,
wherein at least one layer of the filter media comprises at least about 97 wt. % synthetic fibers, and
wherein a normalized resistance ratio of the second layer to the first layer is between 1:1 and 5:1, wherein the normalized resistance ratio is a ratio of a resistance of the second layer, divided by a basis weight of the second layer, to a resistance of the first layer, divided by a basis weight of the first layer.
2. The filter media of claim 1 , wherein the first layer has a basis weight of between about 10 gsm and about 100 gsm as measured by TAPPI Standard T410.
3. The filter media of claim 1 , wherein the first layer has a thickness of between about 3 mils and about 40 mils.
4. The filter media of claim 1 , wherein the first average diameter is between about 1.0 micron and about 10.0 microns.
5. The filter media of claim 1 , wherein the second layer has a basis weight of between about 10 gsm and about 100 gsm as measured by TAPPI Standard T410.
6. The filter media of claim 1 , wherein the second layer has a thickness of between about 3 mils and about 40 mils.
7. The filter media of claim 1 , wherein the second average diameter is between about 1.0 micron and about 10.0 microns.
8. The filter media of claim 1 , wherein the ratio of basis weights as measured by TAPPI Standard T410 between the second layer and the first layer is less than 2:1.
9. The filter media of claim 1 , wherein the third layer has a basis weight of at least about 1 gsm and less than about 90 gsm as measured by TAPPI Standard T410.
10. The filter media of claim 1 , wherein the third layer has a thickness of less than about 500 microns.
11. The filter media of claim 1 , wherein the third average diameter is between about 0.1 microns and about 5.0 microns.
12. The filter media of claim 1 , wherein the mean flow pore size of the third layer is between about 1 micron and about 30 microns.
13. The filter media of claim 1 , wherein the normalized resistance ratio of the second layer to the first layer is between 1:1 and 3:1.
14. The filter media of claim 1 , wherein the third layer comprises fibers selected from the group consisting of polyester, polyamide, polyvinyl alcohol, acrylic, rayon, polycarbonate, polyphenylene sulfide, polybutylene terephthalate, and polyurethane fibers.
15. The filter media of claim 1 , wherein the fibers in the third layer have an average length of at least about 1 inch.
16. The filter media of claim 15 , wherein the third layer has a basis weight of at least about 1 gsm and less than about 90 gsm as measured by TAPPI Standard T410, wherein the mean flow pore size of the third layer is between about 1 microns and about 30 microns, and wherein the third average diameter is between about 0.1 microns and about 5.0 microns.
17. The filter media of claim 1 , wherein the fibers in the third layer have an average length of from about 0.1 inches to about 1,000 inches.
18. The filter media of claim 1 , wherein the third layer has an air permeability of from about 3 cfm/sf to about 700 cfm/sf as measured by TAPPI Method T251.
19. The filter media of claim 1 , wherein the first layer has a basis weight of between about 10 gsm and about 100 gsm as measured by TAPPI Standard T410 and a thickness of between about 3 mils and about 30 mils, and wherein the second layer has a basis weight of between about 10 gsm and about 100 gsm as measured by TAPPI Standard T410 and a thickness of between about 3 mils and about 30 mils.
20. The filter media of claim 1 , wherein the synthetic polymer fibers of the third layer comprise meltblown, meltspun, melt electrospun, and/or solvent electrospun fibers.
21. The filter media of claim 1 , wherein at least one layer of the filter media is a wet laid layer.
22. The filter media of claim 1 , wherein the first and second layers are wet laid layers.