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WO2018193165A1 - Unités filtrantes pourvues d'un milieu de filtration de carburant sans verre à efficacité et capacité élevées - Google Patents

Unités filtrantes pourvues d'un milieu de filtration de carburant sans verre à efficacité et capacité élevées Download PDF

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Publication number
WO2018193165A1
WO2018193165A1 PCT/FI2018/050285 FI2018050285W WO2018193165A1 WO 2018193165 A1 WO2018193165 A1 WO 2018193165A1 FI 2018050285 W FI2018050285 W FI 2018050285W WO 2018193165 A1 WO2018193165 A1 WO 2018193165A1
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WO
WIPO (PCT)
Prior art keywords
filter unit
fibrillated
filtration media
media
filtration
Prior art date
Application number
PCT/FI2018/050285
Other languages
English (en)
Inventor
Ina PARKER
Original Assignee
Ahlstrom-Munksjö Oyj
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US15/493,683 external-priority patent/US10357729B2/en
Application filed by Ahlstrom-Munksjö Oyj filed Critical Ahlstrom-Munksjö Oyj
Publication of WO2018193165A1 publication Critical patent/WO2018193165A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/18—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0654—Support layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1225—Fibre length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1233—Fibre diameter

Definitions

  • the embodiments disclosed herein relate generally to filtration units.
  • the embodiments herein relate to filtration units which include a high efficiency and high capacity glass-free fuel filtration media, e.g., filtration units that may usefully be employed as fuel filters.
  • Filtration media possessing high filtration efficiency of small sized particulates generally requires small pores in the media so that the particulates to be filtered cannot pass through the media.
  • Small pores in a media however generally result in low permeability and therefore cause high fluid pressure drop through the media.
  • When particulates are captured physically on the upstream side of the media they will over time gradually block the pores of the media which in turn cause the fluid pressure drop across the media to gradually increase.
  • the quality of any filtration media is thus characterized by the amount of particulates that are capable of being captured (also known as "media capacity"), which occurs at a specific predetermined pressure drop. If the specific predetermined pressure is reached too rapidly, the resulting media capacity will thus be low.
  • High efficiency filtration media such as required for fuel filtration, often contain staple glass microfibers. Glass microfibers possess unique filtration properties due to their needle-like fiber shape, rigidity and small size. Glass microfibers are therefore widely used in conventional filtration media to provide both high efficiency and high capacity.
  • a filter unit could be provided containing an inlet, an outlet and a filtration media which is glass-free (i.e., does not contain any glass fibers) but yet exhibits high filtration capacity and efficiency.
  • a filtration media should also possess a minimum strength sufficient to be further processed and/or pleated (e.g., so as to allow for the formation of filter units comprising such media). It is therefore towards fulfilling such desirable attributes that the present invention is directed.
  • the embodiments disclosed herein provide for a filter unit comprising the glass-free non-woven filtration media.
  • the filter unit exhibits a very high filtration efficiency and capacity, with an overall filtration efficiency at 4 microns of about 95% or higher, preferably about 97% or higher and more preferably about 99% or higher
  • a glass-free non-woven filtration media may be employed in such filter units which is comprised of a blend of staple synthetic fibers and fibrillated cellulosic fibers.
  • the staple synthetic fibers will most preferably comprise or consist of synthetic microfibers.
  • the filtration media of certain other embodiments may contain non-fibrillated cellulosic fibers in an amount which does not significantly adversely affect the filtration efficiency and/or capacity of the media.
  • Certain embodiments will be in the form of high efficiency and high capacity glass-free non-woven filtration media comprising a blend of synthetic non-fibrillated staple fibers and fibrillated cellulosic staple fibers, wherein the fibrillated cellulosic fibers are present in the media in an amount to achieve a multipass filtration efficiency at 1.5 microns of greater than 50%, an overall filtration efficiency at 4 microns of about 95% or higher and a ratio of filtration capacity to media caliper of 0.5 mg/in 2 /mils and greater.
  • the synthetic non-fibrillated stable fibers may be formed of a thermoplastic polymer selected from the group consisting of polyesters, polyalkylenes, poyacrylonitriles, and polyamides. Polyesters, especially polyalkylene
  • terephthalates are especially desirable. Some embodiments will include non- fibrillated polyethylene terephthalate (PET) stable microfibers having an average fiber diameter of less than about 10 microns and an average length of less than about 25 millimeters.
  • PET polyethylene terephthalate
  • the synthetic staple fibers may be present in an amount between about 50 wt.% to about 99.5 wt.% ODW.
  • the fibrillated cellulosic staple fibers may comprise fibrillated lyocell nanofibers. Certain embodiments will include fibrillated lyocell nanofibers in an amount of between about 0.5 to about 50 wt.% ODW.
  • the fibrillated cellulosic staple fibers may possess a Canadian Standard Freeness (CSF) of about 300 ml_ or less, for example between about 1 ml_ and about 300 ml_.
  • CSF Canadian Standard Freeness
  • Certain embodiments will include a blend of staple polyethylene
  • terephthalate microfibers having an average fiber diameter of less than about 10 microns and an average length of less than about 25 millimeters which are present in an amount of between about 50 wt.% to about 99.5 wt.% ODW, and fibrillated lyocell staple fibers having a Canadian Standard Freeness (CSF) of about 300 ml_ or less which are present in an amount of at least about 0.5 to about 50 wt.% ODW.
  • the fibrillated cellulosic fibers may have an average diameter of about 1000 nanometers or less and an average length between about 1 mm to about 8 mm.
  • the filtration media according to the embodiments disclosed herein will also possess the following properties:
  • SD machine direction (MD) stiffness SD MD Gurley Stiffness
  • MD machine direction stiffness
  • md x 2in. sample size and a test weight of 25 g placed at 4 in. from the pivot;
  • a SD machine direction (MD) tensile strength of greater than about 20 lb/in, for example between about 20 to about 35 lb/in, according to TAPPI Standard T494 (the entirety of which is expressly incorporated by reference herein); and [0017] (3) a SD dry burst strength (SD MD Mullen Burst) of greater than about 30 psi, for example between about 30 psi to about 70 psi, according to TAPPI Standard T403 om-02 (the entirety of which is expressly incorporated by reference herein).
  • MD machine direction
  • some embodiments may include natural wood pulp blended with the synthetic non-fibrillated staple fibers and fibrillated cellulosic staple fibers. If employed, the natural wood pulp may be present in an amount of about 25 wt.% ODW or less.
  • Wet strength additives, optical brighteners, fiber retention agents, colorants, fuel-water separation aides (e.g., silicone additives and associated catalyzers), water or oil repellants (e.g., fluorocarbons), fire or flame retardants, and the like may also be employed as may be desired.
  • Resin binders may also be added to the filtration media to achieve desired physical properties. If employed, such binder resins may be present in an amount between about 2 to about 50 wt.% SDC.
  • the filtration media may be formed by a wet-laid slurry process.
  • the filtration media may be made by forming a wet laid sheet from a fibrous slurry comprised of a blend of synthetic non-fibrillated staple fibers and fibrillated cellulosic staple fibers, and drying the sheet to obtain the filtration media.
  • the filtration media may be grooved and/or pleated or spirally wound so as to facilitate its use in filtration devices (e.g., filter units associated with on-board fuel filtration systems).
  • the filtration media of the present disclosure may be pleated and subsequently wrapped around a cylindrical core such that the pleats fan out around the circumference, perpendicular to the core in order to form a filter unit.
  • the filter unit may then be provided as a component part of a filtration system.
  • the filter unit may further be incorporated in any
  • Filters containing the high efficiency and high capacity media in accordance with the embodiments disclosed herein advantageously have a lower pressure drop than comparative prior art filters. The lower pressure build-up across filters with the inventive media also results in longer filter life.
  • FIG. 1 is a schematic cross-sectional view of a filtration system that may embody the high efficiency filtration media of the embodiments disclosed herein;
  • FIG. 2 is an enlarged schematic cross-sectional view of an exemplary filtration media embodiment as taken along line 2-2 in FIGURE 1 ;
  • FIG. 3 is a plot of multipass (MP) efficiency (%) at 4 microns versus the content of fibrillated Lyocell nanofibers (wt.%) present in the filtration media; and
  • FIG. 4 is a plot of multipass (MP) efficiency (%) at 4 microns versus time (min.) for Examples 6-9 below.
  • Fiber is a fibrous or filamentary structure having a high aspect ratio of length to diameter.
  • “Staple fiber” means a fiber which naturally possesses or has been cut or further processed to definite, relatively short, segments or individual lengths.
  • “Nanofibers” mean fibers having an average diameter of less than about 1000 nanometers.
  • Fibrous means a material that is composed predominantly of fiber and/or staple fiber.
  • Non-woven means a collection of fibers and/or staple fibers in a web or mat which are randomly interlocked, entangled and/or bound to one another so as to form a self-supporting structural element.
  • Synthetic fiber and/or "man-made fiber” refers to chemically produced fiber made from fiber-forming substances including polymers synthesized from chemical compounds and modified or transformed natural polymer. Such fibers may be produced by conventional melt-spinning, solution- or solvent-spinning and like filament production techniques.
  • a "cellulosic fiber” is a fiber composed of or derived from cellulose.
  • Multipass Dust Holding Capacity and “Multipass Filtration Efficiency” filtration performance parameters measured using a multipass (MP) test according to ISO 19438:2003, "Diesel fuel and petrol filters for internal combustion engines - Filtration efficiency using particle counting and contaminant retention capacity” (incorporated hereinto by reference).
  • the media disclosed herein will possess a Multipass Dust Holding Capacity (DHC) of greater than about 10 mg/in 2 , for example from about 15 mg/in 2 up to about 30 mg/in 2 , and will possess Multipass Filtration Efficiencies of >95% at 4 ⁇ or greater, >80% at 2.5 ⁇ or greater, >70% at 2 ⁇ or greater and >50% at 1.5 ⁇ or grater.
  • DHC Multipass Dust Holding Capacity
  • Freeness is the measure, in ml_, of the rate in which a dilute suspension of staple fiber may be drained, as described in TAPPI Canadian standard method T 227 om-94 (1994) (hereinafter sometimes referred to as “Canadian Standard Freeness” or “CSF”), the entire content of which is expressly incorporated hereinto by reference.
  • CSF Canadian Standard Freeness
  • Fibrils are tiny, minute irregular threadlike elements associated with a staple fiber.
  • Fibrillated means staple fibers that have been further acted upon to form numerous fibrils and which exhibit a Canadian Standard Freeness of about 300 ml_ or less, preferably about 200 ml_ or less, typically between about 10 to about 200 ml_.
  • Non-fibrillated means unprocessed staple fibers having essentially no fibrils and which exhibit a Canadian Standard Freeness of greater than about 500 ml_.
  • Fibrillatable means non-fibrillated staple fibers that inherently possess the ability to be fibrillated using standard mechanical beaters, refiners and the like employed in the paper-making industry.
  • Oven-dry weight or "ODW” means the total weight of fibers or fabric after drying in a hot air oven at 350°F (177 °C) for 5 minutes.
  • SDC saturated dry cured
  • “Saturated Dry” or “SD” means a media saturated with resin and dried for a time sufficient to evaporate solvent from the resin but not fully cured, for example a sample having between about 20% to about 95% of cured resin for typical SD media as determined by the "Wet Mullen Ratio” (%) of the media.
  • Weight Mullen Ratio is used to indicate the resin cure level of media and is calculated by dividing the wet SD Mullen burst strength of the sample by the wet SDC Mullen burst strength of the sample and expressing such ratio as a percentage.
  • the fully cured (SDC) sample of the filtration media will exhibit the highest Wet Mullen burst strength that the media is capable of exhibiting.
  • Wet Mullen burst strength is measured on a sample saturated with water having a concentration of ionic surfactant in the amount of approximately 0.03 wt%, according to TAPPI Standard T403 om-02.
  • FIG. 1 depicts a schematic exemplary filtration system 10 in which the filtration media as disclosed herein may be employed.
  • the system 10 is provided with a housing 12 having ports 12-1 and 12-2 through which a liquid flow of a fluid (e.g., liquid or gas) to be filtered can be introduced or discharged.
  • a fluid e.g., liquid or gas
  • the port 12-1 or the port 12-2 may serve as an inlet port while the other of port 12-1 or port 12-2 serves as a discharge port depending on the fluid flow within the system 10 that may be desired for any end use application.
  • the housing 12 includes an interior space 12-3 for holding the filtration media 14.
  • the filtration media 14 is in the form of a generally cylindrical structure comprised of a number of longitudinally oriented pleats. Other structural forms of the separation media 14 are of course possible, for example, spirally wound sheets.
  • the fluid to be filtered may therefore enter the core 14-1 of the media 14 and then pass therethrough in the event that the fluid enters the port 12-1 with the filtered fluid then being discharged through port 12-2.
  • a reverse flow may also be practiced, e.g., the fluid to be filtered may enter the port 12-2 so as to then pass from the outside periphery of the media 14 towards the core 14-1 whereby the filtered fluid then is discharged through port 12-1.
  • the housing 12 may optionally be provided with a tubular core element
  • the filtration media 14 may be a multilayer structure comprised of at least a filtration media layer 16 in accordance with the embodiments disclosed herein positioned downstream of a fibrous woven or nonwoven layer 18.
  • one or more intermediate layer(s) 20 may optionally be interposed between the upstream filtration media layer 16 and the downstream layer 18, if present.
  • the layers 18 and/or 20 if present may be provided so as to impart additional functional attributes to the media, e.g., pre-filtration, structural support, water droplet separation and the like.
  • Such layers 18, 20 may be positioned immediately adjacent one another and may if desired be physically laminated or physically connected to one another (e.g., by any suitable technique known in the art such as needle punching, adhesives, air jet entanglement and the like).
  • one or more face layers 22 may be provided upstream of the filtration media layer 16, while one or more backing layers 24 may be provided downstream of the fibrous layer 18.
  • Layers 22 and 24 may be selected for various functional attributes and do not necessarily need to be nonwoven or woven fibrous structures, for example, one or both such layers may be metal mesh or perforated film structures to serve various functions in the media 14.
  • any such additional layers 18, 20, 22 and/or 24 must not affect adversely the high efficiency filtration functionality of the filtration media layer 16.
  • the additional layers 18, 20 and/or 22 may be formed of virtually any woven or nonwoven (e.g., melt-blown) fibrous thermoplastic materials such as polyolefins (e.g., polypropylenes, polyethylenes, polybutylenes or the like), polyamides (PA) (e.g., PA-6, PA-6,6, PA-6,12 and the like), polyesters (e.g., polybutylene terephthalates (PBT), polyethylene terephthalates (PET),
  • polyolefins e.g., polypropylenes, polyethylenes, polybutylenes or the like
  • PA polyamides
  • polyesters e.g., polybutylene terephthalates (PBT), polyethylene terephthalates (PET)
  • the layers may alternatively or additionally be provided with cellulosic materials, such as regenerated cellulose.
  • Any one or all of the additional layers, if present, could alternatively be the same as the filtration media layer 16 in accordance with the embodiments disclosed herein.
  • multiple filtration media layers 16 may be immediately adjacent to one another or may include one or more layers of the types disclosed above interposed therebetween.
  • Filtration systems in which the filtration media layer 16 as described herein may be employed are well known in the art.
  • US Pat. No. 8,287,727 and US Pat no. 8,096,423 describe replaceable filter elements inside a fuel filter housings comprising annularly arranged filter media that is sealed at the end faces.
  • U.S. Pat. No. 6,814,243 and U.S. Pat. No. 8,501 ,003 are additional examples of filter systems, which have a removable filter element inside and also incorporate a drain in the canister.
  • any conventional synthetic non-fibrillated staple fibers may be employed in the filtration media of this invention.
  • Especially preferred embodiments will include synthetic non-fib llated staple fibers formed of a thermoplastic polymer, such as polyesters (e.g., polyalkylene terephthalates such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT) and the like), polyalkylenes (e.g., polyethylenes, polypropylenes and the like),
  • PAN poyacrylonitriles
  • polyamides for example, nylon-6, nylon 6,6, nylon-6,12, and the like.
  • Preferred are staple PET fibers.
  • the synthetic staple fibers are most preferably microfibers, that is staple fibers which possess average fiber diameters of less than about 10 microns, sometimes less than about 8 microns or even less than about 5 microns, and lengths of less than about 25 millimeters, sometimes less than about 10 millimeters, such as less than about 6.5 millimeters (e.g., less than about 3.5 millimeters).
  • Particularly preferred synthetic staple microfibers are water dispersible polyalkylene terephthalate microfibers.
  • Preferred are staple polyethylene terephthalate (PET) microfibers.
  • the staple PET microfibers are the result of water-washing of water non-dispersible sulfopolyester fibers having a glass transition temperature (Tg) of at least 25°C, the sulfopolyester comprising: (i) about 50 to about 96 mole% of one or more residues of isophthalic acid or terephthalic acid; (ii) about 4 to about 30 mole%, based on the total acid residues, of a residue of sodiosulfoisophthalic acid; (iii) one or more diol residues wherein at least 25 mole%, based on the total diol residues, is a poly(ethylene glycol) having a structure H-(OCH2-CH2) n -OH, wherein n is an integer
  • the synthetic staple fibers will be employed in the filtration media in an amount between about 50 wt.% to about 99.5 wt.% ODW, preferably between 75 wt.% to about 97.5 wt.% ODW. Especially preferred embodiments will include the synthetic staple fibers in an amount between about 80 wt.% to about 90 wt.% ODW.
  • the filtration media will necessarily include fibrillated cellulosic staple fibers which possess a Canadian Standard Freeness (CSF) of about 300 ml_ or less, preferably about 200 ml_ or less, typically between about 10 to about 200 ml_.
  • CSF Canadian Standard Freeness
  • Preferred fibrillatable cellulosic staple fibers are those made by direct dissociation and spinning of wood pulp in an organic solvent, such as an amine oxide, and are known as lyocell staple fibers.
  • the fibrillatable cellulose staple fibers may thus be fibrillated by being subjected to standard mechanical beaters, refiners and the like employed in the paper-making industry.
  • the fibrillated cellulosic staple fibers will be employed in the filtration media in an amount between about 0.5 to about 50 wt.% ODW, preferably between 2.5 to about 25 wt.% ODW. Especially preferred embodiments will include the fibrillated cellulosic staple fibers in an amount between about 10 to about 20 wt.% ODW.
  • Especially preferred fibrillated cellulosic staple fibers include lyocell staple fibers.
  • the lyocell staple fibers are most preferably nanofibers, that is staple fibers having an average diameter of about 1000 nanometers or less, or sometimes about 400 nanometers or less, for example about 100 nanometers.
  • Some especially preferred embodiments will include fibrillated cellulosic staple fibers of about 250 nanometers.
  • the average length of the Lyocell staple nanofibers is typically between about 1 mm to about 8 mm, or between about 2 mm to about 6 mm, or about 3 mm to about 4 mm.
  • Preferred fibrillated lyocell nanofibers are commercially available from Engineered Fibers Technology, LLC under the tradename EFTecTM Nanofibrillated Fibers.
  • Preferred commercially available forms of the fibrillated lyocell nanofibers include EFTecTM L010-4, L040-4 and L200-6 Nanofibrillated fibers having degrees of fibrillation at 4 mm or 6 mm fiber length of ⁇ 10 CSF, 40 CSF and 200 CSF, respectively.
  • non-fibrillated cellulosic staple fibers may optionally be blended with the non-fibrillated synthetic staple fibers and the fibrillated cellulosic staple fibers so as to impart additional stiffness to the filtration media. According to some embodiments, therefore, the addition of from 0 up to about 25 wt.% ODW, for example, from 0 wt.% to about 20 wt.% ODW or to about 15 wt.% ODW, of natural wood pulp (non-lyocell) staple fibers may be desired.
  • a variety of non-lyocell non- fibrillated cellulosic staple fibers are commercially available and may be blended with the other components of the filter media disclosed herein as may be desired.
  • the filtration media may include a resin binder to achieve desired physical properties. Any suitable resin binders may be added to the filtration media for such a purpose. Suitable examples of binder resins that may optionally be employed include polymers such as styrene acrylic, acrylic, polyethylene vinyl chloride, styrene butadiene rubber, polystyrene acrylate, polyacrylates, polyvinyl chloride, polynitriles, polyvinyl acetate, polyvinyl alcohol derivates, starch polymers, epoxy, phenolics and combinations thereof, including both waterborne or solvent versions. In some cases, the binder resin may be in the form of a latex, such as a water-based emulsion.
  • the resin binder may be present in amounts between about 2 to about 50 wt.% SDC, preferably between 10 to about 30 wt.% SDC. Especially preferred embodiments will include the resin binder in an amount between about 12 to about 25 wt.% SDC.
  • Preferred resin binders include phenolic resins, acrylic resins (e.g., vinyl acrylic latex resins), melamine resins, silicone resins, epoxy resins and the like.
  • phenolic (phenolformaldehyde) resin that may be employed includes
  • DURITE ® SL161A commercially available from Momentive Specialty Chemicals Inc. of Louisville, KY.
  • One suitable latex based resin binder that may be employed is PD 0458 M1 (a polyoxymethylene nonylphenol branched ether phosphate dispersed in formaldehyde) commercially available from HB Fuller Co. of St. Paul, MN.
  • a suitable melamine binder resin may be ASTRO ® Celrez PA-70 methylated melamine resin system commercially available from Momentive Specialty
  • Suitable acrylic resins include ACRODUR® formaldehyde-free water-based acrylic resins commercially available from BASF Corporation.
  • the filtration media may also contain additives conventionally employed in wet-laid filtration media, such as for example, wet strength additives, optical brighteners, fiber retention agents, colorants, fuel-water separation aides (e.g., silicone additives and associated catalyzers), water or oil repellants (e.g., fluorocarbons), fire or flame retardants, and the like. If present, these additives may be included in amounts of up to about 20 wt.% ODW, preferably up to about 10 wt.% ODW, for example between about 1 to about 10 wt.%.
  • wet strength additives e.g., optical brighteners, fiber retention agents, colorants, fuel-water separation aides (e.g., silicone additives and associated catalyzers), water or oil repellants (e.g., fluorocarbons), fire or flame retardants, and the like.
  • these additives may be included in amounts of up to about 20 wt.% ODW, preferably up to about
  • the filtration media described herein may be made by any conventional "wet-laid" paper-making technology.
  • predetermined amounts of the non-fibrillated synthetic staple fibers and the fibrillated cellulosic staple fibers (along with any optional components, such as the natural wood pulp fibers and/or additives) and water may be placed in a pulper or beater.
  • the fibers are mixed and dispersed by the pulper or beater evenly in the water to form a slurry batch.
  • Some mechanical work can also be performed on the fibers to affect physical parameters, such as permeability, surface properties and fiber structure.
  • the slurry batch may thereafter be transferred to a mixing chest where additional water is added and the fibers are homogenously blended.
  • the blended slurry may then be transferred to a machine chest where one or more slurry batches can be combined, allowing for a transfer from a batch to a continuous process.
  • Slurry consistency is defined and maintained by agitation to assure even dispersion of fibers.
  • the slurry may optionally be passed through a refiner to adjust physical parameters.
  • the slurry is then transferred to a moving wire screen where water is removed by means of gravity and suction.
  • the fibers form into a fibrous nonwoven mat or sheet having characteristics determined by a number of process variables, including for example, the slurry flow rate, machine speed, and drainage parameters.
  • the formed sheet may optionally be
  • the wet paper mat is then moved through a drying section comprised of heated rollers (or "cans" in art parlance) where most of the remaining entrained water is removed.
  • the dried web may then have a binder applied by any conventional means, such as dipping, spray coating, roller (gravure) application and the like. Heat may then subsequently be applied to dry the web.
  • the dried web may be any suitable material.
  • the dried web may be any suitable material.
  • the media may have about 50
  • Each groove will thus preferably have a nominal width of about 4 mm.
  • a typical grooved glass- containing high-efficiency fuel grade has dimensions such as overall SD
  • the finished (optionally grooved) filtration media may then be taken up on a roll for further processing into finished filter products.
  • one or more finished filtration media sheets may be laminated with one or more other sheets of material (e.g., at least one additional filtration media layer, supporting layer and the like) to achieve desired physical and performance characteristics.
  • the filtration media may also be pleated and formed into a cylindrical filter cartridge that may then be provided as a component part of a filtration unit (e.g., an onboard fuel filter unit). Co-pleating of the filtration media with a supporting wire mesh layer may be desirable in certain end use applications.
  • the basis weight of the finished filtration media is not critical.
  • the finished filtration media may have a basis weight of at least about 15 grams per square meter (gsm), more preferably at least about 35 gsm up to about 300 gsm.
  • Some embodiments of the filtration media may possess a basis weight of between about 50 up to about 200 gsm.
  • the media according to the embodiments disclosed herein may be partially cured so as to exhibit a Wet Mullen Ratio of >50%, preferably >70%. Such embodiments result in energy savings when manufacturing filters since less energy is required to cure the media.
  • PET Microfibers Non-fibrillated PET staple microfibers having an average diameter of 2.5 microns, commercially available from Eastman Chemical Company,
  • Fibrillated Lyocell Fibrillated lyocell nanofibers commercially available from Engineered Fibers Technology LLC under the tradename EFTecTM fibers with Lyocell L010 having a CSF of ⁇ 10 mL; Lyocell L040 having a CSF of 40 mL; and Lyocell L200 having a CSF of 200 mL.
  • Sodra Red Chemi-Thermal-Mechanical (CTM) Softwood pulp with a Freeness of 600-700ml and SR of 15, and a pH of 7.5, manufactured by Sodra, Sweden. Bulk is 4 cm3/g.
  • HPZIII Mercerized southern softwood from Buckeye Technologies, Inc. having an average fiber length of 1.8 mm and 7.3 cm 3 /g bulk
  • GRAND PRAIRIE Northern softwood from Weyerhaeuser Co. having average fiber length of 2.3 mm, CSF ranges from 648 - 300, bulk ranges from 1.52 - 1.24 cm 3 /g.
  • FIBRIA Fibria ECF Bleached Eucalyptus Pulp from Aracruz Cellulose (USA) Incorporated having a drainability of 22-55 SR and a fiber length of about 0.70mm
  • KYMENE A wet strength additive consisting of 12-13% solids of an aqueous solution of a cationic amine polymer-epichlorohydrin adduct having specific gravity is 1.03, pH is 3.5-4.5 and the solution contains 12-13% solids.
  • MOMENTIVE 161 A EPON Resin 161 , a multifunctional epoxidized phenolic novolac resin binder commercially available from Momentive Specialty Chemicals, Inc. and having a epoxide equivalent weight of 169-178 g/eq (ASTM D1652), a viscosity (25°C) of 18,000-28,000 cP (ASTM D2196) and a density (25°C) of 10.0 lb/gal.
  • the furnish was then poured into the wetlaid mold and diluted with approx. 25 liters of tap water, stirred 3 times with a pedal stir, and drained through a standard paper machine wire.
  • SDC Caliper The caliper (thickness) of SDC media was measured using a 89-100 Thickness Tester from Thwing-Albert Instrument Company according to TAPPI Standard T41 1 , "Thickness (caliper) of paper, paperboard and combined board” (incorporated fully by reference herein).
  • SDC Air Permeability The air permeability of SDC media was tested with a FX3300 LabAir IV Air Permeability Tester from TexTest, according to ASTM D737, "Standard Test Method for Air Permeability of Textile Fabrics" incorporated fully by reference herein). Measurements were recorded at 125 Pa in Cubic Feet per Minute (cfm) per area of one square foot.
  • Filtration performance was measured using a multipass (MP) test according to ISO 19438:2003 which specifies a multi-pass filtration test, with continuous contaminant injection using the on-line particle counting method, for evaluating the performance of fuel filters for internal combustion engines submitted to a constant flow rate of test liquid.
  • the test procedure determines the contaminant capacity of a filter, its particulate removal characteristics and differential pressure.
  • ISO 19438:2003 is applicable to filter elements having a rated flow of between 50 l/h and 800 l/h; however, by agreement between filter manufacturer and customer, and with some modification, the procedure is permitted for application to fuel filters with higher flow rates.
  • the parameters employed in the MP Test are:
  • Hand sheets were made using 2.5 micron PET microfiber (Eastman Chemical Company), different grades of fibrillated lyocell (Grades L010, L040, L200 from Engineered Fibers Technology, LLC), and three different types of wood pulp. Most hand sheets also contained Kymene, a wet strength additive, to imitate production conditions, in amounts noted in the tables below.
  • the "Capacity/Caliper Ratio” was calculated by dividing the media capacity (mg/in 2 ) by the media caliper (mils) in order to normalize the capacity data to account for different sheet caliper thickness. Overall efficiency at 4 microns” was determined using the multipass (MP) filtration test described previously.
  • Example 1 was repeated except that filtration media was formed on a standard Fourdrinier wet-laid paper line. The results of these trials are shown in Table 2 below.
  • Example 1 was repeated with different amounts of natural wood pulp blended with the PET microfibers and fibrillated lyocell microfibers in varying amounts.
  • the data appear in Table 3 below.
  • Example 1 was repeated with different amounts of fibrillated lyocell.
  • the data appear in Table 4 below.
  • the data also show that, although the relative amounts of the PET nanofibers and fibrillated lyocell nanofibers can be varied, generally it is the fibrillated lyocell nanofibers that contribute to an increased efficiency, while the PET nanofibers contribute to an increased filtration capacity.
  • the fibrillated lyocell nanofiber content With higher basis weight, the filtration media generally exhibits higher capacity due to increase in caliper, and the pore structure gets smaller and more compact due to more filtration depth. Therefore, using the very same two components, the fibrillated lyocell nanofiber content must be decreased with an increase in basis weight in order to maintain the same efficiency level (which in this case, means that capacity will increase).
  • different grades that is, different CSF
  • the absolute amount of the fibers will vary greatly.
  • the data show that substantially double the amount of the EFTecTM L200 Lyocell nanofibers yields the same efficiency level as compared to the EFTecTM L010 Lyocell nanofibers.
  • the data in general show that a minimum amount of about 2.5 wt.% EFTecTM L010 fibrillated Lyocell nanofibers would be required while a maximum of 50 wt.% EFTecTM L200 fibrillated Lyocell nanofibers was required to achieve acceptable efficiency performance
  • Example 1 was repeated using a media formed of the following
  • PET Microfibers non-fibrillated PET staple microfibers having an average diameter of 2.5 microns, commercially available from Eastman Chemical
  • Fibrillated Cellulose Fibrillated cellulose nanofibers commercially available from International Paper (formerly owned by Weyerhaeuser NR Co) under the tradename InterlaceTM having a CSF of ⁇ 10 ml_.
  • KYMENETM wet strength additive A wet strength additive consisting of 12- 13% solids of an aqueous solution of a cationic amine polymer- epichlorohydrin adduct having specific gravity is 1.03, pH is 3.5-4.5 and the solution contains 12-13% solids commercially available from Solenis International, L.P.
  • MOMENTIVE 161 a EPONTM Resin 161 , a multifunctional epoxidized phenolic novolac resin binder commercially available from Momentive Specialty Chemicals, Inc. and having a epoxide equivalent weight of 169-178 g/eq (ASTM D1652), a viscosity (25°C) of 18,000-28,000 cP (ASTM D2196) and a density (25°C) of 10.0 lb/gal.
  • EPONTM Resin 161 a multifunctional epoxidized phenolic novolac resin binder commercially available from Momentive Specialty Chemicals, Inc. and having a epoxide equivalent weight of 169-178 g/eq (ASTM D1652), a viscosity (25°C) of 18,000-28,000 cP (ASTM D2196) and a density (25°C) of 10.0 lb/gal.
  • MOMENTIVE PA-70 ASTRO ® Celrez PA-70, a methylated melamine resin system commercially available from Momentive Specialty Chemicals Inc.
  • Acid may be added to keep the pH of the resin system below 5
  • a suitable acid catalyst is PTSA (Para Toulene Sulfonic Acid) 65, containing 65% active ingredient, supplied by Brenntag.
  • the samples were produced using a conventional "wet-laid" paper making process as described previously.
  • the media samples were subject to longitudinal machine-direction (MD) grooving using mated male/female rollers as also described previously.
  • MD longitudinal machine-direction
  • SD MD Gurley Stiffness The machine-direction bending resistance of SD media was measured using Gurley Stiffness Tester 4171 E from Thwing-Albert Instrument Company, according to TAPPI Standard T543 "Bending resistance of paper (Gurley-type tester)" (incorporated fully by reference herein). Test specimens were cut to a length of 3.5 in in the machine-direction and a width of 2 in. Test parameters: the test was conducted using a 25g weight attached at a distance of 4in from the pivot.
  • SD Mullen Burst The bursting strength of SD media was measured using a Mullen tester, according to TAPPI Standard T403 om-02.
  • SD MD Tensile Strength The machine-direction tensile strength of SD media was measured using QC-1000 Tensile tester from Thwing-Albert
  • Test specimens were cut to a length of 8 in in the machine-direction and a width of 1 in. Test parameters: rate of separation of the jaws was controlled at 1 in/min.
  • Each of the filtration media samples of Examples 6-9 was subjected to multipass test according to ISO 19438:2003 using the same parameters as described in Example 1 above except that ISO medium test dust was used.
  • the multipass test was conducted with a test stand manufactured by GMN provided with sensors that are capable of detecting particles as low as 1.5 ⁇ .
  • the data for such multipass testing is presented in FIG. 4 as a function of test time. The first few minutes of test data are not included in the data plots. The downstream particle counts measured initially are considered to be unreliable as the test fluid (containing the dust) has not circulated completely through the fluid test loop.
  • the filtration media of Examples 6-9 were able to maintain filtration efficiency over a longer period of time (i.e., the filtration efficiency did not drop significantly over time during test, which is common in other cellulose-based filtration products).
  • Prototype filter elements were made from the Roll 7A and Roll 14B filtration media made in Example 2.
  • the filtration media was slit to a desired width and subsequently pleated.
  • the pleated media was wrapped around a cylindrical center tube such that the pleats were fanned out around the circumference, perpendicular to the tube. End caps were glued to each end of the tube to hold the pleated media in place and form a filter element.
  • the slit width, pleat height and number of pleats were varied in order to produce filter elements with various filter areas, as shown below in Table 7. Comparative filter elements were also made with standard cellulose and glass media.
  • the filter elements were each placed in a filter housing and subjected to multipass test according to ISO 19438:2003, with the following test conditions:
  • Inventive Filters 4 and 6 have about 30% less filter area compared to Comparative Filter 1 but are able to match or surpass the filtration performance of the comparative filter.
  • Filters containing the inventive media can be optimized to have smaller area (e.g. reduction in filter height) whist still meeting the filtration requirements, which is an important cost-saving measure for filter manufacturers and end-users (e.g. vehicles).

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Filtering Materials (AREA)

Abstract

L'invention concerne des unités filtrantes qui incluent un logement définissant un espace intérieur et des orifices d'entrée et de sortie respectivement pour l'introduction d'un fluide à filtrer et pour la décharge d'un fluide filtré de l'espace intérieur. Un milieu de filtration sans verre à efficacité et capacité élevées est positionné au sein de l'espace intérieur du logement et inclut un mélange de fibres discontinues non fibrillées synthétiques et de fibres discontinues cellulosiques fibrillées, les fibres cellulosiques fibrillées étant présentes dans le milieu en une quantité permettant d'obtenir une capacité de rétention de poussière à plusieurs passages d'au moins 10 mg/po2 et une efficacité de filtration à 1,5 micromètre à plusieurs passages, supérieure à 50 %. Le milieu de filtration est fabriqué par formage d'une feuille appliquée par voie humide à partir d'un mélange de bouillie fibreuse des fibres discontinues non fibrillées synthétiques et des fibres discontinues cellulosiques fibrillées, suivi par un séchage de la feuille pour obtenir le milieu de filtration. Éventuellement, le milieu de filtration peut être pourvu d'un liant résineux et peut être rainuré et/ou plissé.
PCT/FI2018/050285 2017-04-21 2018-04-20 Unités filtrantes pourvues d'un milieu de filtration de carburant sans verre à efficacité et capacité élevées WO2018193165A1 (fr)

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US8293103B2 (en) 2005-12-08 2012-10-23 Donaldson Company, Inc. Spin-on filter assembly and methods
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US5643446A (en) 1985-05-14 1997-07-01 Parker Hannifin Corporation Fuel filter and priming pump
US6328883B1 (en) 2000-05-31 2001-12-11 Parker-Hannifin Corporation Fuel filter assembly with priming pump
US6814243B2 (en) 2000-08-23 2004-11-09 Caterpillar Inc Replaceable filter with locking mechanism
US20080311815A1 (en) 2003-06-19 2008-12-18 Eastman Chemical Company Nonwovens produced from multicomponent fibers
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Publication number Priority date Publication date Assignee Title
US12251654B2 (en) 2019-10-08 2025-03-18 Donaldson Company, Inc. Filter medium comprising a fine fiber layer

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