Filter media comprising a polyethersulfone-based fine fiber layer
Filter media comprising polyethersulfone, related components, and related methods are generally described.
1 . A filter media, comprising:
a PES-based fine fiber layer comprising a plurality of fine fibers comprising a polyethersulfone (PES) material;
wherein the PES material has a polydispersity index of greater than or equal to 1.9 and less than 2.6;
wherein the PES material has an intrinsic viscosity of greater than 0.3 dL/g and less than or equal to 2 dL/g;
wherein the PES-based fine fiber layer has a dust holding capacity of greater than or equal to 2 gsm and less than or equal to 300 gsm;
wherein the PES-based fine fiber layer has a surface area of greater than or equal to 4 m 2 /g and less than or equal to 10 m 2 /g;
wherein the filter media further comprises an additional layer;
wherein the additional layer comprises meltblown fibers;
wherein the additional layer comprises a pre-calendered additional layer; and
wherein the filter media has a thickness of greater than or equal to 0.001 mm and less than or equal to 0.5 mm.
2 . The filter media of claim 1 , wherein the PES material has an intrinsic viscosity of greater than or equal to 0.35 dL/g and less than or equal to 2 dL/g.
3 . The filter media of claim 2 , wherein the PES material has an intrinsic viscosity of greater than or equal to 0.4 dL/g and less than or equal to 2 dL/g.
4 . The filter media of claim 2 , wherein the PES material has a polydispersity index of greater than or equal to 2.0 and less than 2.6.
5 . The filter media of claim 2 , wherein the PES material has a polydispersity index of greater than or equal to 2.1 and less than 2.6.
6 . The filter media of claim 2 , wherein the fine fibers are electrospun.
7 . The filter media of claim 2 , wherein the PES-based fine fiber layer comprises less than 1,790 macro defects per square meter.
8 . The filter media of claim 2 , wherein the PES-based fine fiber layer comprises less than 107 macro defects per square meter.
9 . The filter media of claim 2 , wherein the PES-based fine fiber layer has an elongation at break of greater than or equal to 2% and less than or equal to 80%.
10 . The filter media of claim 2 , wherein the PES-based fine fiber layer has an elongation at break of greater than or equal to 10% and less than or equal to 80%.
11 . The filter media of claim 2 , wherein the PES-based fine fiber layer has a tensile strength of greater than or equal to 0.1 MPa and less than or equal to 5 MPa.
12 . The filter media of claim 2 , wherein the PES-based fine fiber layer has a tensile strength of greater than or equal to 0.1 MPa and less than or equal to 0.4 MPa.
13 . The filter media of claim 2 , wherein the PES-based fine fiber layer has a ratio of maximum pore size to mean flow pore size of less than or equal to 15:1.
14 . The filter media of claim 2 , wherein the PES-based fine fiber layer comprises anti-static PES material.
15 . The filter media of claim 2 , wherein the filter media further comprises a support layer.
16 . The filter media of claim 15 , wherein a ratio of the average fiber diameter of the PES-based fine fiber layer to a maximum pore size of the support layer is greater than or equal to 0.003:1 and less than or equal to 0.8:1.
17 . The filter media of claim 15 , wherein the support layer comprises fibers selected from the group consisting of synthetic fibers, cellulose fibers, and/or glass fibers.
18 . The filter media of claim 1 , wherein the PES material has an intrinsic viscosity of greater than or equal to 0.3 dL/g and less than or equal to 0.9 dL/g.
19 . The filter media of claim 1 , wherein the fine fibers have an average fiber diameter of greater than or equal to 300 nm and less than or equal to 6 microns.
20 . The filter media of claim 1 , wherein the filter media has a thickness of greater than or equal to 0.1 mm and less than or equal to 0.5 mm.
21 . The filter media of claim 1 , wherein the meltblown fibers comprise poly(olefin), poly(ester), poly(vinyl alcohol), poly(acrylic), fluorinated polymer, and/or cellulose acetate.