FORMED FILTER ELEMENT
First Claim
1. A filter medium comprising:
- a bicomponent fiber; and
a particle, the particle comprising at least one of a metal oxide, a metal, a ceramic, a zeolite, a carbon, an ion exchange resin, or a nanotube,wherein the filter medium has a basis weight at least about 500 gram/meter2, a permeability of about 0.5 to 200 fpm inclusive, a thickness equal to or greater than 8 millimeters, and a solidity of less than about 25%.
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Accused Products
Abstract
A filter medium for use in filtering a mobile fluid made from at least a bicomponent fiber. Other fibers, particles, or other materials can also be entrained in the filter medium. The filter medium has a substantial thickness compared to filters of the prior art. The fiber length and diameter dimensions are selected to obtain desired filter characteristics including thickness, basis weight, pore size, filtration efficiency, pressure drop, burst strength, and manufacturing efficiency. Further, a multilayer filter medium can be provided with ease. Each layer can have a different composition, pore size, basis weight, and so forth, thus providing the ability to build multiple functionality into the filter media of the invention.
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Citations
83 Claims
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1. A filter medium comprising:
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a bicomponent fiber; and a particle, the particle comprising at least one of a metal oxide, a metal, a ceramic, a zeolite, a carbon, an ion exchange resin, or a nanotube, wherein the filter medium has a basis weight at least about 500 gram/meter2, a permeability of about 0.5 to 200 fpm inclusive, a thickness equal to or greater than 8 millimeters, and a solidity of less than about 25%. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A process to form a filter medium, comprising the steps of:
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blending a first mixture of fibers comprising a bicomponent fiber to form a first aqueous slurry; applying the first aqueous slurry to a support to form a first wet layer; removing sufficient water from the first wet layer to make a first formed layer; blending a second mixture of fibers to form a second aqueous slurry, wherein the composition of the second mixture of fibers differs from the composition of the first mixture of fibers; applying the second aqueous slurry to the first formed layer to form a second wet layer; removing sufficient water to form a second formed layer; and heating the first and second formed layers to a temperature sufficient to melt one component of the bicomponent fiber. - View Dependent Claims (41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67)
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68. A method of removing an impurity from a fluid stream comprising:
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contacting a stream containing an impurity with a filter medium comprising a bicomponent fiber, wherein the filter medium has a basis weight at least about 500 gram/meter2, a permeability of about 0.5 to 200 fpm inclusive, a thickness equal to or greater than 8 millimeters, and a solidity of less than 25%; and passing the stream through the filter medium such that the impurity is removed from the fluid stream. - View Dependent Claims (69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83)
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Specification