Filter media for filtering matter from a fluid

Abstract

A filter medium for filtering matter from a fluid and the manufacture thereof are provided. In one exemplary embodiment, a method may be performed by a filter medium for filtering particulate matter from a fluid. Further, the filter medium may include a nonwoven sliver formed into a predetermined shape and composed of first synthetic staple fibers having a first denier, second synthetic staple fibers having a second denier, and third synthetic staple fibers having a third denier.

What is claimed is: 
     
         1 . A method performed by a filter medium for filtering particulate matter from a fluid, comprising:
 filtering, by the filter medium, the particulate matter from the fluid, wherein the filter medium includes a nonwoven sliver formed into a predetermined shape and composed of:
 first synthetic staple fibers having a first denier; 
 second synthetic staple fibers having a second denier; and 
 third synthetic staple fibers having a third denier. 
   
     
     
         2 . The method of  claim 1 , wherein the filter medium is capable of fiber migration of no more than about 100 fibers for a flush volume of about 18,990 milliliters applied to the filter medium having a volume of about 0.053 cubic feet. 
     
     
         3 . The method of  claim 1 , wherein the filter medium is capable of fiber migration of no more than about 500 fibers for a flush volume of about 18,990 milliliters applied to the filter medium having a volume of about 0.053 cubic feet. 
     
     
         4 . The method of  claim 1 , wherein the first denier is in a range from about 1 denier to about 10 denier, the second denier is in a range from about 10 denier to about 20 denier and the third denier is in a range from about 20 denier to about 50 denier. 
     
     
         5 . The method of  claim 1 , wherein the second denier is in a range from about 10 denier to about 20 denier, the first denier is less than the second denier and the third denier is more than the second denier. 
     
     
         6 . The method of  claim 1 , wherein a density of a core of the filter medium is greater than a density of an outer wrap of the filter medium. 
     
     
         7 . The method of  claim 1 , wherein a composition of the nonwoven sliver includes about 10% to about 60% of the first synthetic staple fibers, about 10% to about 60% of the second synthetic staple fibers and about 10% to about 40% of the third synthetic staple fibers. 
     
     
         8 . The method of  claim 1 , wherein a percentage of a volume of the first, second and third synthetic staple fibers in a volume of the filter medium is less than about 2%. 
     
     
         9 . The method of  claim 1 , wherein filtering includes filtering, by the filter medium, the particulate matter with a grain size in a range from about 5 microns to about 10 microns. 
     
     
         10 . The method of  claim 1 , wherein the filter medium has a flow resistance of no more than about 50 millibars. 
     
     
         11 . A filter medium for filtering particulate matter from a fluid, comprising:
 a nonwoven sliver formed into a predetermined shape, wherein the nonwoven sliver is composed of:
 first synthetic staple fibers having a first denier; 
 second synthetic staple fibers having a second denier; and 
 third synthetic staple fibers having a third denier; and 
   wherein the filter medium is capable of filtering the particulate matter from the fluid.   
     
     
         12 . The filter medium of  claim 11 , wherein the filter medium is capable of fiber migration of no more than about 100 fibers for a flush volume of about 18,990 milliliters applied to the filter medium having a volume of about 0.053 cubic feet. 
     
     
         13 . The filter medium of  claim 11 , wherein the filter medium is capable of fiber migration of no more than 500 fibers for a flush volume of about 18,990 milliliters applied to the filter medium having a volume of about 0.053 cubic feet. 
     
     
         14 . The filter medium of  claim 11 , wherein the first denier is in a range from about 1 denier to about 10 denier, the second denier is in a range from about 10 denier to about 20 denier and the third denier is in a range from about 20 denier to about 50 denier. 
     
     
         15 . The filter medium of  claim 11 , wherein the second denier is in a range from about 10 denier to about 20 denier, the first denier is less than the second denier and the third denier is more than the second denier. 
     
     
         16 . The filter medium of  claim 11 , wherein a density of a core of the filter medium is greater than a density of an outer wrap of the filter medium. 
     
     
         17 . The filter medium of  claim 11 , wherein a composition of the nonwoven sliver includes about 10% to about 60% of the first synthetic staple fibers, about 10% to about 60% of the second synthetic staple fibers and about 10% to about 40% of the third synthetic staple fibers. 
     
     
         18 . The filter medium of  claim 11 , wherein a percentage of a volume of the first, second and third synthetic staple fibers in a volume of the filter medium is less than about 2%. 
     
     
         19 . The filter medium of  claim 11 , wherein filtering includes filtering, by the filter medium, the particulate matter with a grain size in a range from about 5 microns to about 10 microns. 
     
     
         20 . The filter medium of  claim 11 , wherein the filter medium has a flow resistance of no more than about 50 millibars.