Nonwoven sliver-based filter medium for filtering particulte matter

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 filter for filtering particulate matter from a liquid, the filter comprising:
 a housing comprising an inlet port configured to receive liquid and an outlet port configured to discharged at least partially filtered liquid; and   a filter medium associated with the housing to filter particulate matter from liquid entering the inlet port, the filter medium comprising:
 a nonwoven sliver having a substantially cylindrical shape or a substantially spherical shape, and comprising a core having a first density and an outer wrap having a second density less than the first density, wherein the nonwoven sliver comprises:
 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; 
 
   wherein the filter medium is configured to filter particulate matter from a liquid, with a fiber migration of about 500 fibers or less for a flush volume ranging from about 17,500 milliliters to about 20,000 milliliters at a flow rate ranging from about 500 cubic centimeters per minute to about 750 cubic centimeters per minute.   
     
     
         2 . The filter of  claim 1 , wherein the second denier ranges from about 10 denier to about 20 denier, the first denier is less than the second denier, and the third denier is greater than the second denier. 
     
     
         3 . The filter of  claim 1 , wherein a composition of the nonwoven sliver comprises from about 10% to about 60% of the first synthetic staple fibers, from about 10% to about 60% of the second synthetic staple fibers, and from about 10% to about 50% of the third synthetic staple fibers. 
     
     
         4 . The filter of  claim 1 , wherein the filter medium is configured to filter particulate matter having a grain size ranging from about 5 microns to about 10 microns. 
     
     
         5 . The filter of  claim 1 , wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers are crimped and folded to form a cross-locking characteristic. 
     
     
         6 . The filter of  claim 1 , wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers comprise at least one bi-component fiber. 
     
     
         7 . The filter of  claim 1 , wherein one or more of the first synthetic staple fibers, the second synthetic staple fibers, or the third synthetic staple fibers comprise fibers that are one or more of oleophilic, oleophobic, hydrophilic, or hydrophobic.