USRE47737EExpiredUtilityPatentIndex 83
Filter medium and structure

Assignee: DONALDSON CO INCPriority: Nov 5, 2004Filed: Jun 19, 2017Granted: Nov 26, 2019
Est. expiryNov 5, 2024(expired)· nominal 20-yr term from priority
Inventors:KAHLBAUGH BRAD E DEMA KEH B OLSON LINDA M ISRAEL JOE JONES DEREK O LAVALLEE GREGORY L MADDEN MICHAEL A YANG CHUANFANG ROGERS ROBERT M KOJETIN PAUL L SPORRE TIMOTHY D
B01D 46/10B01D 2275/10B01D 39/2024B01D 46/521B01D 46/2411B01D 39/2089B01D 46/0068B01D 46/71B01D 39/20
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Cited by
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References
Claims
Abstract

Thermoplastic bicomponent binder fiber can be combined with other media, fibers and other filtration components to form a thermally bonded filtration media. The filtration media can be used in filter units. Such filter units can be placed in the stream of a mobile fluid and can remove a particulate load from the mobile stream. The unique combination of media fiber, bicomponent binder fiber and other filtration additives and components provide a filtration media having unique properties in filtration applications.
Claims

exact text as granted — not AI-modified
We claim: 
     
       1. A filtration medium comprising a thermally bonded sheet, the sheet comprising:
 (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and   (b) an effective amount of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers, an aspect ratio of about 10 to 10,000 to obtain a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min −1 ;   wherein the media has a thickness of about 0.2 to 50 mm, a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m −2 .   
     
     
       2. The medium of  claim 1  wherein the media comprises about 0.1 to 10 wt % of a binder resin. 
     
     
       3. The medium of  claim 1  wherein the media comprises about 0.5 to 15 wt % of a secondary fiber. 
     
     
       4. The medium of  claim 3  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 
     
     
       5. The medium of  claim 1  comprising two or more layers. 
     
     
       6. The medium of  claim 1  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       7. The medium of  claim 1 , wherein the bicomponent binder fiber comprises a blend of two or more fibers having different average diameters. 
     
     
       8. The medium of  claim 1 , wherein the bicomponent binder fiber comprises a blend of two or more fibers comprising different materials. 
     
     
       9. The medium of  claim 8  wherein the different materials comprise two or more of a vinyl acetate polymer, poly(vinyl chloride), polyvinyl alcohol, polyvinyl acetate, polyvinyl acetyl, acrylic polymer, methacrylic polymer, polyamide, polyethylene vinyl acetate copolymer, urea phenol resin, urea formaldehyde resin, a polyolefin, a polyester, a nylon, polytetrafluoroethylene, polyvinyl chloride acetate, polyvinyl butyral, polyvinylidene chloride, polystyrene, a cellulosic resin, or blends or copolymers thereof. 
     
     
       10. A liquid filtration medium comprising a thermally bonded sheet, the sheet comprising:
 (a) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and   (b) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m −2 , a pore size of about 0.2 to 50 micrometers and a permeability of about 2 to 200 ft-min −1 .   
     
     
       11. The medium of  claim 10  wherein the media comprises a secondary fiber. 
     
     
       12. The medium of  claim 10  wherein the media fiber comprises a glass fiber. 
     
     
       13. The medium of  claim 12  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       14. The medium of  claim 10  also comprising a 0.1 to 25 wt % of a binder resin. 
     
     
       15. The medium of  claim 10  comprising two or more layers. 
     
     
       16. The medium of  claim 10  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       17. A method of filtering a liquid stream, the method comprising:
 (a) placing a filter unit into the stream and   (b) retaining particulate entrained in the filter in the stream using filter media within the filter unit, the filter media comprising a thermally bonded sheet comprising:
 (i) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and 
 (ii) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; 
   wherein the medium has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m −2 , a pore size of about 0.2 to 50 micrometers and a permeability of about 2 to 200 ft-min −1 .   
     
     
       18. The method of  claim 17  wherein the liquid is an aqueous liquid. 
     
     
       19. The method of  claim 17  wherein the liquid is a non-aqueous liquid. 
     
     
       20. The method of  claim 19  A method of filtering a liquid stream, the method comprising:
 (a) placing a filter unit into the stream and 
 (b) retaining particulate entrained in the filter in the stream using filter media within the filter unit, the filter media comprising a thermally bonded sheet comprising:
 (i) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and 
 (ii) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; 
 
 wherein the medium has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m −2 , a pore size of about 0.2 to 30 micrometers and a permeability of about 2 to 200 ft-min −1 ; 
 wherein the liquid is a non-aqueous liquid; and  
 wherein the medium also comprises 0.1 to 25 wt % of a binder resin. 
 
     
     
       21. The method of  claim 17  comprising two or more layers. 
     
     
       22. A gaseous filtration medium for removing mist from air comprising a thermally bonded sheet, the sheet comprising:
 (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;   (b) about 20 to 80 wt % of a media fiber a fiber diameter of about 0.1 to 20 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 20 to 200 grams-m −2 , a pore size of about 5 to 100 micrometers and a permeability of about 5 to 500 ft-min −1 .   
     
     
       23. The medium of  claim 22  wherein the media comprises about 0.1 to 10 wt % of a secondary fiber having a fiber diameter of 0.1 to 15 microns. 
     
     
       24. The medium of  claim 22  wherein the media fiber comprises a glass fiber. 
     
     
       25. The medium of  claim 24  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       26. The medium of  claim 22  comprising two or more layers. 
     
     
       27. The medium of  claim 22  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       28. A gaseous filtration medium for removing particulate from air comprising a thermally bonded sheet, the sheet comprising:
 (a) about 80 to 98 wt % of a bicomponent binder fiber having a fiber diameter of about 10 to 15 micrometers and a fiber length of about 0.1 to 15 cm;   (b) about 2 to 20 wt % of a media fiber a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 10 to 25%, a basis weight of about 40 to 400 grams-m −2 , a pore size of about 10 to 30 micrometers and a permeability of about 20 to 200 ft-min −1 .   
     
     
       29. The medium of  claim 28  wherein the media comprises a secondary fiber. 
     
     
       30. The medium of  claim 28  wherein the media fiber comprises a glass fiber. 
     
     
       31. The medium of  claim 30  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       32. The medium of  claim 28  comprising two or more layers. 
     
     
       33. The medium of  claim 30  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       34. A gaseous filtration medium for removing an entrained liquid from blow-by gases comprising a thermally bonded sheet, the sheet comprising:
 (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 5 to 15 cm;   (b) about 0.5 to 15 wt % of a media fiber or a secondary fiber having a fiber diameter of about 0.5 to 15 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 1 to 10%, a basis weight of about 20 to 80 grams-m −2 , a pore size of about 5 to 50 micrometers and a permeability of about 50 to 500 ft-min −1 .   
     
     
       35. The medium of  claim 34  wherein the media comprises a secondary fiber. 
     
     
       36. The medium of  claim 34  wherein the media fiber comprises a glass fiber. 
     
     
       37. The medium of  claim 36  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       38. The medium of  claim 34  comprising two or more layers. 
     
     
       39. The medium of  claim 37  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       40. A filtration medium for filtering a lubricant oil comprising a thermally bonded sheet, the sheet comprising:
 (a) about 1 to 40 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 0.1 to 15 cm; and   (b) about 60 to 99 wt % of a glass fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.2 to 2 mm, a solidity of about 2 to 10%, a basis weight of about 10 to 50 g-m −2 , a pore size of about 0.5 to 10 micrometers and a permeability of about 0.1 to 30 ft-min −1 .   
     
     
       41. The medium of  claim 40  wherein the media comprises a binder resin. 
     
     
       42. The medium of  claim 40  wherein the media fiber comprises a glass fiber. 
     
     
       43. The medium of  claim 42  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 
     
     
       44. The medium of  claim 40  comprising two or more layers. 
     
     
       45. The medium of  claim 44  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       46. A filtration medium for filtering a hydraulic oil comprising a thermally bonded sheet, the sheet comprising:
 (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 0.1 to 15 cm; and   (b) about 80 to 20 wt % of a media fiber having a fiber diameter of about 0.1 to 2 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.2 to 2 mm, a basis weight of about 40 to 350 g-m −2 , a pore size of about 0.5 to 30 micrometers and a permeability of about 5 to 200 ft-min −1 .   
     
     
       47. The medium of  claim 46  wherein the media comprises a binder resin. 
     
     
       48. The medium of  claim 46  wherein the media fiber comprises a glass fiber. 
     
     
       49. The medium of  claim 48  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 
     
     
       50. The medium of  claim 46  comprising two or more layers. 
     
     
       51. The medium of  claim 46  wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 
     
     
       52. A method of filtering a heated fluid, the method comprises the steps of:
 (a) passing a mobile fluid phase containing a contaminant through a filter medium, the medium having a thickness of about 0.2 to 50 mm, the medium comprising a thermally bonded sheet, the sheet comprising:
 (i) about 20 to 80 wt % of a bicomponent binder fiber having a first component with a melting point and a second component with a lower melting point, the fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and 
 (ii) about 20 to 80 wt % of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers and an aspect ratio of about 10 to 10,000; 
 
 wherein the media has a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m −2 , a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min −1 , the mobile fluid phase having a temperature greater than the melting point of the second component; and 
 (b) removing the contaminant. 
 
     
     
       53. The method of  claim 52  wherein the fluid is a gas. 
     
     
       54. The method of  claim 52  wherein the contaminant is a liquid. 
     
     
       55. The method of  claim 52  wherein the contaminant is a solid. 
     
     
       56. The method of  claim 52  wherein the fluid is a liquid. 
     
     
       57. The method of claim  52  56 wherein the liquid is an aqueous liquid. 
     
     
       58. The method of claim  52  56 wherein the liquid is a fuel. 
     
     
       59. The method of claim  52  56 wherein the liquid is a lubricant oil. 
     
     
       60. The method of claim  52  56 wherein the liquid is a hydraulic fluid. 
     
     
       61. A filtration medium comprising a thermally bonded sheet, the sheet comprising:
 (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm:   (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and   (c) about 20 to 80 wt % of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.2 to 50 mm, a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m −2 , a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min −1 .   
     
     
       62. The medium of  claim 61  wherein the media comprises about 0.1 to 10 wt % of a binder resin. 
     
     
       63. The medium of  claim 61  wherein the media comprises an effective amount of the secondary binder fiber to bind the sheet and the media is substantially free of a residue from an aqueous binder resin. 
     
     
       64. The medium of  claim 61  wherein the media comprises 0.5 to 15 wt % of the secondary binder fiber and the media is substantially free of a residue from an aqueous binder resin. 
     
     
       65. The medium of  claim 63  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 
     
     
       66. The medium of  claim 61  comprising two or more layers. 
     
     
       67. A liquid filtration medium comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising:
 (a) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;   (b) an effective medium binding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and   (c) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m −2 , a pore size of about 0.2 to 50 micrometers and a permeability of about 1 to 200 ft-min −1 .   
     
     
       68. The medium of  claim 67  wherein the media comprises about 0.5 to 15 wt % of the secondary binder fiber and the media fiber comprises a glass fiber. 
     
     
       69. The medium of  claim 68  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       70. The medium of  claim 67  comprising two or more layers. 
     
     
       71. A method of filtering a liquid stream, the method comprising:
 (a) placing a filter unit comprising the medium of  claim 67  into the stream; and   (b) retaining particulate entrained within the filter from the stream using filter media within the filter unit.   
     
     
       72. A gaseous filtration medium for removing mist from air comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising:
 (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm;   (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and   (c) about 20 to 80 wt % of a media fiber with a diameter of about 0.1 to 20 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 20 to 200 g-m −2 , a pore size of about 5 to 20 micrometers and a permeability of about 5 to 500 ft-min −1 .   
     
     
       73. The medium of  claim 72  wherein the secondary binder fiber is present in an effective amount to bind the sheet and the fiber has a fiber diameter of about 0.1 to 15 microns. 
     
     
       74. The medium of  claim 72  wherein the media comprises about 0.5 to 15 wt % of the secondary binder fiber having a diameter of about 0.1 to 15 microns and the media fiber comprises a glass fiber. 
     
     
       75. The medium of  claim 74  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       76. A method of filtering a gaseous stream, the method comprising:
 (a) placing a filter unit comprising the medium of  claim 72  into the stream; and   (b) retaining particulate entrained within the filter from the stream using filter media within the filter unit.   
     
     
       77. A gaseous filtration medium for removing particulate from air comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising:
 (a) about 80 to 98 wt % of a bicomponent binder fiber having a fiber diameter of about 10 to 15 micrometers and a fiber length of about 0.1 to 15cm;   (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and   (c) about 2 to 20 wt % of a media fiber with a diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000;   wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 10 to 25%, a basis weight of about 40 to 400 g-m −2 , a pore size of about 10 to 30 micrometers and a permeability of about 20 to 200 ft-min −1 .   
     
     
       78. The medium of  claim 77  wherein the secondary binder fiber is present in an effective amount to bind the sheet and the fiber has a fiber diameter of 0.1 to 15 microns. 
     
     
       79. The medium of  claim 77  wherein the secondary binder fiber is present in an amount of about 0.01 to 10 wt % and the fiber has a fiber diameter of 0.1 to 15 microns. 
     
     
       80. The medium of  claim 79  wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 
     
     
       81. The medium of  claim 77  comprising two or more layers. 
     
     
       82. A method of filtering a gaseous stream, the method comprising:
 (a) placing a filter unit comprising the medium of  claim 77  into the stream and   (b) retaining particulate entrained within the filter from the stream using filter media within the filter unit.
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