US008950587B2
`
`(12) United States Patent
`Thomson et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,950,587 B2
`*Feb. 10, 2015
`
`(54)
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`(75)
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`(73)
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`(*)
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`(21)
`(22)
`(65)
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`(63)
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`(51)
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`(52)
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`(58)
`
`FILTER MEDIA SUITABLE FOR HYDRAULC
`APPLICATIONS
`Inventors: Cameron Thomson, Arlington, MA
`(US); Milind Godsay, Nashua, NH
`(US); Randall Keisler, Clifton Park, NY
`(US)
`Assignee: Hollingsworth & Vose Company, East
`Walpole, MA (US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 649 days.
`This patent is Subject to a terminal dis
`claimer.
`
`Notice:
`
`Appl. No.: 12/899,512
`
`Filed:
`
`Oct. 6, 2010
`
`Prior Publication Data
`US 2011 FOOT9553 A1
`Apr. 7, 2011
`Related U.S. Application Data
`Continuation-in-part of application No. 12/418,375,
`filed on Apr. 3, 2009.
`
`Int. Cl.
`BOID 29/01
`BOID 29/56
`
`(2006.01)
`(2006.01)
`(Continued)
`
`U.S. C.
`CPC ........ G06K 9/00335 (2013.01); B01D 39/1623
`(2013.01); B0ID 39/2017 (2013.01); B01D
`220 1/188 (2013.01); B01 D2239/065 (2013.01);
`BOID 2239/1233 (2013.01)
`USPC ................. 210/490; 55/488; 55/527: 55/528;
`210/503; 210/505; 210/509; 428/311.51;
`428/312.6; 428/426; 428/428
`Field of Classification Search
`CPC ... B01D 29/01; B01D 29/56; B01D 39/1607;
`B01D 39/1623; B01D 39/2003; B01D
`39/2017; B01D 2239/065; B01D 2239/069;
`
`B01D 2239/1225; B32B5/22; B32B5/26:
`B32B5/32: B32B 17/00; B32B 17/02: B32B
`17/06, B32B 17/064; B32B 17/10, B32B
`27/06, B32B 27/12
`USPC ............ 55/485 488, 527, 528: 162/141, 156,
`162/1571; 210/335, 488 490,500.26,
`210/503–505, 509; 428/300.7,308.4,
`428/304.4, 311.11, 311.51,315.5, 315.9,
`428/316.6, 210, 312.6, 426, 428
`See application file for complete search history.
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`3,353,682 A 11, 1967 Pall et al.
`3,849.241 A 11/1974 Butin et al.
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`CN
`CN
`
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`101.098.741 A
`(Continued)
`OTHER PUBLICATIONS
`International Search Report and Written Opinion for Application No.
`PCT/US2008/082759 mailed Aug. 4, 2009.
`(Continued)
`Primary Examiner — Joseph Drodge
`(74) Attorney, Agent, or Firm — Wolf, Greenfield & Sacks,
`P.C.
`ABSTRACT
`(57)
`Filter media, including those suitable for hydraulic applica
`tions, and related components, systems, and methods associ
`ated therewith are provided. The filter media described herein
`may include two or more layers, at least one of the layers
`having a relatively high percentage of microglass fibers.
`Additionally, the filter media may be designed such that the
`ratio of average fiber diameters between two layers is rela
`tively small, which can lead to a relatively low resistance ratio
`between the layers. In some embodiments, at least one layer
`of the filter media comprises synthetic polymer fibers. Certain
`filter media described herein may have desirable properties
`including high dirt holding capacity and a low resistance to
`fluid flow. The media may be incorporated into a variety of
`filter element products including hydraulic filters.
`40 Claims, 4 Drawing Sheets
`
`Layer3
`Layer3
`Sample Meltblown
`Meltblown
`Grammage Frazier Permeability
`gim
`ft/ft)
`19
`68.9
`19
`38.9
`s
`68.9
`19
`68.9
`19
`68.9
`s
`68.9
`19
`88.8
`2
`64
`20
`64
`20
`54
`2.
`6A.
`2
`64
`2
`54
`2.
`64
`2
`54
`2
`64
`23
`64
`
`Layer3
`Meltblown
`Thickness
`(mm)
`0.095
`0.095
`O95
`0.95
`0.095
`.095
`35
`.5
`0.095
`0.035
`35
`0.095
`0.095
`05
`3.95
`0.095
`0.095
`
`Layer3/Layer2
`Layer3
`Normalized
`Meltlin
`Avg. Fiber Diameter Resistance Ratio
`m)
`,095
`.036
`,096
`C,096
`0.036
`0.096
`,036
`3.096
`,095
`0.95
`.96
`0.096
`0.096
`.096
`8,096
`3.096
`0.096
`
`Layer3+layer2
`Composite
`Micron Rating
`cumc) Beta=200)
`10.4
`
`Layer3+layer2
`Composite
`DHC
`gfm
`42.70.
`
`10.9
`
`s.
`113
`14
`
`165.92
`
`164.94
`1883
`194.72
`
`layer2
`Layer2
`Glass
`Glass
`Grammage Frazier Permeability
`(gfm)
`tfifty
`55.1
`50
`32.5
`119
`32.5
`198
`32.5
`119
`85.1
`50
`55.1
`9s
`99
`55.1
`32.5
`115
`16.3
`30
`15.3
`3F
`16.3
`153
`16.3
`153
`48.8
`102
`48.8
`51
`32.5
`115
`48.8
`102
`48.8
`s
`
`Layer
`Layer2.jLayer1.
`layer2
`Glass
`Normalized
`Glass
`Awg, Fiber diameter Resistance Ratio Grammage
`m)
`(gfm)
`4.3
`32.5
`4.3
`65.1
`5.
`85.1
`43
`85.1
`4.3
`32.5
`5.
`32.5
`5.1
`32.5
`48.8
`4.
`85.1
`4.
`65.1
`4.
`85.1
`2.3
`55.1
`2.9
`32.5
`4.
`2.3
`32.5
`4.1.
`48.3
`32.5
`4.
`2.9
`32.3
`
`Philip Morris Products, S.A.
`Exhibit 1032
`Page 001
`
`

`

`US 8,950,587 B2
`Page 2
`
`(51) Int. Cl.
`B32B5/26
`B32B 7/02
`B32B 7/06
`G06K 9/00
`BOID 39/6
`BOID 39/20
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`(56)
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`- - -
`
`.
`
`.
`
`.
`
`.
`
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`
`.
`
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`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`.
`
`55,486
`
`210,489
`
`Philip Morris Products, S.A.
`Exhibit 1032
`Page 002
`
`

`

`US 8,950,587 B2
`Page 3
`
`(56)
`
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`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`
`10 2005 055 607 B3
`20 2005 O19 004 U1
`
`3, 2007
`4, 2007
`
`Philip Morris Products, S.A.
`Exhibit 1032
`Page 003
`
`

`

`US 8,950,587 B2
`Page 4
`
`(56)
`
`References Cited
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`OTHER PUBLICATIONS
`International Search Report and Written Opinion for PCT/US2011/
`Ola NaC ROOC. We COOO
`065499 mailed Apr. sign.
`p
`International Preliminary Reporton Patentability for Application No.
`for PCT/US2011/065499 mailed Jun. 27, 2013.
`International Preliminary Reporton Patentability for Application No.
`for PCT/US2011/054898 mailed Feb. 27, 2014.
`
`International Search Report and Written Opinion for PCT/US2013/
`046746 mailed Nov. 5, 2013.
`Berkalp. Air Permeability & Porosity in Spun-laced Fabrics. Fibres
`and Textiles in Eastern Europe. 2006; 14(3): 81-5.
`Dahiya et al., Melt Blown Technology. Apr. 2004. 13 pages.
`Keith et al., The Surface Area of Fibrous Filters. Tobacco Science.
`1977:68-72. Accessed Sep. 19, 2013.
`
`* cited by examiner
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`Exhibit 1032
`Page 004
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`U.S. Patent
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`Feb. 10, 2015
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`Sheet 1 of 4
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`US 8,950,587 B2
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`U.S. Patent
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`Feb. 10, 2015
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`Sheet 2 of 4
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`US 8,950,587 B2
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`Exhibit 1032
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`U.S. Patent
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`Feb. 10, 2015
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`Sheet 3 of 4
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`US 8,950,587 B2
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`U.S. Patent
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`US 8,950,587 B2
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`Philip Morris Products, S.A.
`Exhibit 1032
`Page 008
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`US 8,950,587 B2
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`1.
`FILTER MEDIA SUITABLE FOR HYDRAULC
`APPLICATIONS
`
`RELATED APPLICATIONS
`
`This application is a continuation-in-part of U.S. applica
`tion Ser. No. 12/418,375, filed Apr. 3, 2009 which is incor
`porated herein by reference in its entirety.
`
`FIELD OF INVENTION
`
`10
`
`The present invention relates generally to filter media
`which may be used in hydraulic applications and, more par
`ticularly, to multilayered filter media which have desirable
`performance characteristics.
`
`15
`
`BACKGROUND
`
`Filter media can be used to remove contamination in a
`variety of applications. Depending on the application, the
`filter media may be designed to have different performance
`characteristics. For example, filter media may be designed to
`have performance characteristics Suitable for hydraulic appli
`cations which involve filtering contamination in pressurized
`fluids.
`In general, filter media can beformed of a web offibers. For
`example, the web may include microglass fibers amongst
`other components. The fiber web provides a porous structure
`that permits fluid (e.g., hydraulic fluid) to flow through the
`filter media. Contaminant particles contained within the fluid
`may be trapped on the fibrous web. Filter media characteris
`tics, such as fiber diameter and basis weight, affect filter
`performance including filter efficiency, dirt holding capacity
`and resistance to fluid flow through the filter.
`There is a need for filter media that can be used in hydraulic
`applications which has a desirable balance of properties
`including a high dirt holding capacity and a low resistance to
`fluid flow (high permeability) across the filter media.
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`SUMMARY OF THE INVENTION
`
`2
`normalized resistance ratio of the second layer to the first
`layer is between 1:1 and 15:1.
`In another embodiment, a filter media includes at least
`three layers. A first layer of the filter media comprises glass
`fibers, the fibers in the first layer having a first average diam
`eter. A second layer of the filter media is adjacent the first
`layer and comprises glass fibers, the fibers in the second layer
`having a second average diameter. A third layer of the filter
`media is adjacent the second layer and comprises glass fibers,
`the fibers in the third layer having a third average diameter.
`The filter media has an absolute specific capacity at 10
`microns of greater than about 2.65.
`In another embodiment, a filter media includes at least
`three layers. A first layer of the filter media comprises glass
`fibers, the fibers in the first layer having a first average diam
`eter. A second layer of the media is adjacent the first layer
`comprising glass fibers, the fibers in the second layer having
`a second average diameter. The first and second layers have a
`combined basis weight of less than 75 g/m and an absolute
`specific capacity at 10 microns of greater than about 3.4.
`In another embodiment, a filter media includes at least
`three layers. A first layer of the filter media comprises at least
`90 wt % glass fibers, the first layer having a basis weight of
`greater than about 40 g/m. A second layer of the filter media
`is adjacent the first layer and comprises at least 90 wt % glass
`fibers, the second layer having a basis weight of less than
`about 40 g/m. A third layer of the filter media is adjacent the
`second layer and comprises at least 90 wt % glass fibers.
`In another embodiment, a filter media includes a first layer
`comprising glass fibers, wherein the fibers in the first layer
`have a first average diameter. The filter media also includes a
`second layer adjacent to the first layer, the second layer com
`prising glass fibers. The fibers in the second layer have a
`second average diameter, and the first average diameter is
`greater than the second average diameter. The filter media
`also includes a third layer adjacent to the second layer, the
`third layer comprising synthetic polymer fibers. The fibers in
`the third layer have a third average diameter, wherein the
`second average diameter is greater than the third average
`diameter. The third layer has a thickness of less than about
`200 microns.
`In another embodiment, a filter media includes a first layer
`comprising glass fibers, wherein the fibers in the first layer
`have a first average diameter. The filter media also includes a
`second layer adjacent to the first layer, the second layer com
`prising glass fibers. The fibers in the second layer have a
`second average diameter, and the first average diameter is
`greater than the second average diameter. The filter media
`also includes a third layer adjacent to the second layer. The
`third layer includes synthetic polymer fibers. The fibers in the
`third layer have a third average diameter, wherein the second
`average diameter is greater than the third average diameter.
`The filter media has an overall dirt holding capacity of at least
`about 150 g/m and an overall permeability of greater than
`about 25 cfm/sf.
`In some embodiments, the filter media described above and
`herein may have a normalized resistance ratio of the second
`layer to the first layer is 4:1 or greater, and a normalized
`resistance ratio of the third layer to the second layer is 4:1 or
`less. For instance, in some cases a normalized resistance ratio
`of the second layer to the first layer is between 4:1 and 6:1,
`and a normalized resistance ratio of the third layer to the
`second layer is between 2:1 and 4:1. The first layer may
`include less than about 20 wt % synthetic fibers. In some
`cases, the first layer is a pre-filter layer and has a basis weight
`greater than the basis weight of the second layer. At least one
`of the first and second layers may comprises at least about 80
`
`Filter media, including those suitable for hydraulic appli
`cations, and related components, systems, and methods asso
`ciated therewith are provided.
`In one set of embodiments, a series of filter media are
`provided. In one embodiment, a filter media includes at least
`two layers. A first layer of the filter media comprises at least
`80 wt % glass fibers, wherein the fibers in the first layer have
`a first average diameter. The filter media also includes a
`second layer directly adjacent the first layer, the second layer
`comprising glass fibers, wherein the fibers in the second layer
`have a second average diameter. The secondaverage diameter
`is Smaller than the first average diameter. A normalized resis
`tance ratio of the second layer to the first layer is between 1:1
`and 5:1.
`In another embodiment, a filter media includes at least
`three layers. A first layer of the filter media comprises glass
`fibers, the fibers in the first layer having a first average diam
`eter. A second layer of the filter media comprises glass fibers,
`the fibers in the second layer having a second average diam
`eter, wherein the second average diameter is Smaller than the
`first average diameter. A third layer of the filter media com
`prises glass fibers, the fibers in the third layer having a third
`average diameter, wherein the third average diameter is
`Smaller than the second average diameter. The second layer
`may be directly adjacent the first and third filter layers. A
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`US 8,950,587 B2
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`3
`wt % glass fibers. In other embodiments, at least one of the
`first and second layers comprises at least about 40 wt % or 60
`wt % microglass fibers. The microglass fibers may have an
`average diameter of between 1 um and 6 Lum. The ratio of the
`first and second average diameters may be less than 2:1.
`Optionally, the third average diameter may be less than about
`1 micron. In certain filter media, at least one of the first,
`second and third layers may have a basis weight of less than
`about 40 g/m.
`In certain embodiments, the synthetic polymer fibers of a
`layer may comprise meltblown fibers. The synthetic polymer
`fibers may comprise a material selected from the group con
`sisting of for example, polyester, nylon, and polyphenylene
`sulfide. The third layer may have a thickness of less than
`about 180 microns. The third layer may have a mean flow pore
`size of between about 8 microns and about 12 microns and a
`Betao at least 200. In some cases, the third layer may have
`a basis weight of from about 20 g/m to about 30 g/m.
`The filter media described above and herein may have an
`overall dirt holding capacity of at least about 180 g/m, or at
`least about 230 g/m. The filter media may have an overall
`permeability of greater than about 35 cfm/sf, or greater than
`about 40 cfm/sf. The filter media may have an efficiency of
`Beta at least 200 and a mean flow pore size of x+2 microns.
`The filter media may be used to form a hydraulic filter ele
`ment in some embodiments. In some Such embodiments, the
`third layer is downstream of the second layer, and the second
`layer is downstream of the first layer. Other configurations are
`also possible.
`30
`In one set of embodiments, methods are provided. A
`method of filtering a liquid comprising passing a liquid
`including particulates through a filter media. The filter media
`can include one of the filter media described above and/or
`herein. For instance, the filter media may include at least three
`layers. In one embodiment, a first layer of the filter media
`comprises glass fibers, the fibers in the first layer having a first
`average diameter. A second layer of the filter media comprises
`glass fibers, the fibers in the second layer having a second
`average diameter, wherein the second average diameter is
`Smaller than the first average diameter. In some embodiments,
`a third layer of the filter media comprises glass fibers, the
`fibers in the third layer having a third average diameter,
`wherein the third average diameter is smaller than the second
`average diameter. In other embodiments, the third layer may
`45
`comprise synthetic polymer fibers. The second layer may be
`directly adjacent the first and third filter layers. A normalized
`resistance ratio of the second layer to the first layer may be
`between 1:1 and 15:1.
`Other aspects, embodiments, advantages and features of
`the invention will become apparent from the following
`detailed description.
`
`4
`FIG. 2 shows a plot of absolute specific capacity at 10
`microns versus basis weight of the filter media for various
`samples, according to one set of embodiments; and
`FIGS. 3A and 3B are tables showing characteristics offilter
`media having a first layer including glass fibers, a second
`layer including glass fibers, and a third layer including melt
`blown fibers, according to one set of embodiments.
`
`DETAILED DESCRIPTION
`
`Filter media, including those suitable for hydraulic appli
`cations, and related components, systems, and methods asso
`ciated therewith are provided. The filter media described
`herein may include two or more layers, at least one of the
`layers having a relatively high percentage of microglass
`fibers. Additionally, the filter media may be designed such
`that the ratio of average fiber diameters between two layers is
`relatively small, which can lead to a relatively low resistance
`ratio between the layers. In some embodiments, at least one
`layer of the filter media comprises synthetic polymer fibers.
`Certain filter media described herein may have desirable
`properties including high dirt holding capacity and a low
`resistance to fluid flow. The media may be incorporated into a
`variety of filter element products including hydraulic filters.
`As shown in the embodiment illustrated in FIG. 1, a filter
`media 10 includes a first layer 20 adjacent a second layer 30.
`Optionally, filter media 10 can include a third layer 40 adja
`cent the second layer. Additional layers, e.g., fourth, fifth, or
`sixth layers, may also be included in Some cases. The orien
`tation of filter media 10 relative to fluid flow through the
`media can generally be selected as desired. As illustrated in
`FIG. 1, first layer 20 is upstream of second layer 30 in the
`direction offluid flow indicated by arrow 50. In other embodi
`ments, however, first layer 20 is downstream of the second
`layer in the direction of fluid flow through the filter media.
`As used herein, when a layer is referred to as being 'adja
`cent another layer, it can be directly adjacent the layer, oran
`intervening layer also may be present. A layer that is "directly
`adjacent” or “in contact with another layer means that no
`intervening layer is present.
`In some cases, each of the layers of the filter media has
`different characteristics and filtration properties that, when
`combined, result in desirable overall filtration performance,
`for example, as compared to a filter media having a single
`layered structure. For example, in one set of embodiments,
`first layer 20 is a pre-filter layer (also known as an “loading
`layer') and second layer 30 is a main filter layer (also known
`as an “efficiency layer'). Generally, a pre-filter layer is
`formed using coarser fibers, and therefore has a lower resis
`tance to fluid flow, than that of a main filter layer. The one or
`more main filter layers may include finer fibers and have a
`higher resistance to fluid flow than that of a pre-filter layer. As
`Such, a main filter layer can generally trap particles of smaller
`size compared to the pre-filter layer. Where third layer 40 is
`present, the third layer may be an additional main filter layer
`that has the same or different properties as second layer 30.
`For example, the third layer may have even finer fibers and a
`higher resistance to fluid flow than that of second layer 30. In
`Some embodiments, the third layer comprises synthetic poly
`mer fibers as described in more detail below.
`The filter media can also have other configurations of first,
`second, and optionally third or more layers. For instance, in
`some cases filter media 10 does not include a pre-filter layer.
`In Some such embodiments, first layer 20 is an upstream main
`filter layer and second layer 30 is a main filter layer down
`stream of the first layer. Optionally, the filter media can
`include third layer 40 (e.g., another main filter layer) posi
`
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`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Non-limiting embodiments of the present invention will be
`described by way of example with reference to the accompa
`nying figures, which are schematic and are not intended to be
`drawn to scale. In the figures, each identical or nearly identi
`cal component illustrated is typically represented by a single
`numeral. For purposes of clarity, not every component is
`labeled in every figure, nor is every component of each
`embodiment of the invention shown where illustration is not
`necessary to allow those of ordinary skill in the art to under
`stand the invention. In the figures:
`FIG. 1 shows an example of a filter media having multiple
`layers according to one set of embodiments;
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`5
`tioned downstream of the second layer. An upstream layer
`may have coarser fibers, and therefore a lower resistance to
`fluid flow, than that of a layer downstream of that layer. In
`Some cases, the resistance of each layer increases succes
`sively from the furthest upstream layer to the furthest down
`stream layer.
`In some embodiments, a layer having relatively coarse
`fibers may be positioned between two layers having relatively
`finer fibers. Other configurations are also possible. Addition
`ally, a filter media may include any suitable number of layers,
`e.g., at least 2, 3, 4, 5, 6, 7, 8, or 9 layers, depending on the
`particular application and performance characteristics
`desired.
`As noted above, each of the layers of the filter media can
`have different properties. For instance, the first and second
`layers can include fibers having different characteristics (e.g.,
`fiber diameters, fiber compositions, and fiber lengths). Fibers
`with different characteristics can be made from one material
`(e.g., by using different process conditions