Aerosol separator
An arrangement separating a hydrophobic liquid phase from gaseous stream, for crankcase ventilation arrangements as described. The arrangement includes a media stage including media formed from a vacuum forming process and including at least 50%, by weight, bi-component fiber therein. Useable media formulations and arrangements are described.
1. A filter for liquid entrained in a gas; the filter including:
(a) a vacuum formed media stage comprising:
(i) at least 50% by weight, based on total weight of fiber material in the vacuum formed media stage, bi-component fiber material having an average fiber largest cross-sectional dimension of at least 10 microns and an average length of 120 mm, inclusive; and,
(ii) at least 20%, by weight, based on total weight of fiber material in the vacuum formed media stage, secondary fiber material having an average fiber largest cross-sectional dimension of no more than 10 micron; and
(b) the vacuum formed media stage having:
(i) a calculated pore size, X-Y direction, of 12-50 microns, inclusive; and,
(ii) an added binder resin content, if any, of no greater than 7% by total weight of fiber material.
2. A filter according to claim 1 wherein:
(a) the vacuum formed media stage has a thickness of at least 1.5 mm.
3. A filter according to claim 1 wherein:
a) the vacuum formed media stage is positioned secured to a first end cap.
4. A filter according to claim 3 wherein:
(a) the vacuum formed media stage is a tubular construction positioned in extension between the first end cap and a second end cap.
5. A filter according to claim 1 wherein:
(a) the vacuum formed media stage has a fiber treatment therein selected from the group consisting essentially of silicone and fluorochemical fiber treatment materials.
6. A filter according to claim 1 wherein:
(a) the secondary fiber material comprises glass fibers; and,
(b) the fiber matrix includes no more than 3%, by weight, added binder resin, if any.
7. A filtration assembly for liquid entrained in a gas comprising:
(a) a housing including a gas flow inlet arrangement, a gas flow outlet arrangement and a liquid drain outlet arrangement; and,
(b) a serviceable filter for liquid entrained in a gas operably positioned within the housing and comprising:
(i) a vacuum formed media stage comprising:
(A) at least 50% by weight, based on total weight of fiber material in the vacuum formed media stage, bi-component fiber material having an average fiber largest cross-sectional dimension of at least 10 microns and an average length of1-20 mm, inclusive; and,
(B) at least 20%, by weight, based on total weight of fiber material in the vacuum formed media stage, secondary fiber material having an average fiber largest cross-sectional dimension of no more than 10 micron; and
(ii) the vacuum formed media stage having:
(A) a calculated pore size, X-Y direction, of 12-50 microns, inclusive; and,
(B) an added binder resin content, if any, of no greater than 7% by total weight of fiber material.
8. A filtration assembly according to claim 7 wherein:
(a) the vacuum formed media stage is tubular, is positioned for in-to-out filtering flow and has a height of 101 to 305 mm.
9. A filtration assembly according to claim 8 wherein:
(a) the liquid drain outlet is configured for liquid flow through a portion of the gas flow inlet arrangement.
10. A filtration assembly according to claim 7 wherein:
(a) the housing is configured as a crankcase ventilation filter housing.