Apparatus and method for filtering fluids with multi-material filter media

Abstract

An apparatus and method for filtering fluids with a multi-material filter media. Multi-component fibers where two or more materials are used in the same fiber to achieve desired physical characteristics, such as specific gravity, resilience, chemical resistance, stiffness and fiber diameter. Based on the particular application and fluid to be filtered, component materials provide desired performance characteristics such as specific particle size and/or specific pollutant removal capabilities and desired backwash cleaning characteristics.

1 . An apparatus for filtering fluids comprising: 
 a housing;    a fluid inlet for providing fluid into the housing;    a filtered fluid outlet for filtered effluent to exit the housing; and    compressible fibrous filter media dispersed within the housing for filtering fluid, wherein the filter media includes at least one fiber comprising at least two different component materials, and wherein the filter media includes one or more detached fibrous groupings.    
     
     
         2 . The apparatus of  claim 1  wherein the at least two different component materials include a polyester inner core and polypropylene sheath.  
     
     
         3 . The apparatus of  claim 1  wherein the at least two component materials include a nylon inner core and a polypropylene sheath.  
     
     
         4 . The apparatus of  claim 1  wherein each of the at least two different component materials is selected from the group consisting of polyester, copolyester, polyactic acid, polytrimethylene terephtalate, polycyclohexanediol, terephthalate, polyethylene napthalate, high density polyethylene, linear low density polyethylene, polyethylene, polypropylene, nylon, polyvinylidene fluoride, polytetrafluoroethylene and polyurethane.  
     
     
         5 . The apparatus of  claim 1  wherein the filter media includes a plurality of compressible fibrous bundles with at least one bundle including at least one fiber comprising at least two different component materials.  
     
     
         6 . The apparatus of  claim 5  wherein each of the at least two different component materials is selected from the group consisting of polyester, copolyester, polyactic acid, polytrimethylene terephtalate, polycyclohexanediol, terephthalate, polyethylene napthalate, high density polyethylene, linear low density polyethylene, polyethylene, polypropylene, nylon, polyvinylidene fluoride, polytetrafluoroethylene and polyurethane.  
     
     
         7 . The apparatus of  claim 5  wherein the at least two different component materials include a polyester inner core and polypropylene sheath.  
     
     
         8 . The apparatus of  claim 5  wherein the at least two component materials include a nylon inner core and a polypropylene sheath.  
     
     
         9 . The apparatus of  claim 1 , wherein the at least one fiber comprising at least two different component materials includes a sheath of one component material surrounding a core of at least a different component material.  
     
     
         10 . The apparatus of  claim 9 , further comprising two or more component materials within the sheath.  
     
     
         11 . The apparatus of  claim 1 , wherein the at least one fiber is crimped.  
     
     
         12 . The apparatus of  claim 5 , wherein the at least one bundle includes crimped fibers.  
     
     
         13 . A method for filtering fluids comprising filtering a fluid through a dispersed, compressible fibrous filter media, wherein the filter media includes at least one fiber comprising at least two different component materials, and wherein the filter media includes one or more detached fibrous groupings.  
     
     
         14 . The filtering method of  claim 13  wherein the filter media includes a plurality of compressible fibrous bundles with at least one bundle including at least one fiber comprising at least two different component materials.  
     
     
         15 . The filtering method of  claim 14  wherein each of the at least two different component materials is selected from the group consisting of polyester, copolyester, polyactic acid, polytrimethylene terephtalate, polycyclohexanediol, terephthalate, polyethylene napthalate, high density polyethylene, linear low density polyethylene, polyethylene, polypropylene, nylon, polyvinylidene fluoride, polytetrafluoroethylene and polyurethane.  
     
     
         16 . The filtering method of  claim 15  wherein the at least two component materials include a nylon inner core and a polypropylene sheath.  
     
     
         17 . The filtering method of  claim 15  wherein the at least two different component materials include a polyester inner core and polypropylene sheath.  
     
     
         18 . The filtering method of  claim 15  wherein the at least one fiber comprising at least two different component materials includes one or more component materials within a sheath.  
     
     
         19 . The filtering method of  claim 14  wherein the at least one fibrous bundle includes crimped fibers.  
     
     
         20 . The filtering method of  claim 13  wherein each of the at least two different component materials is selected from the group consisting of polyester, copolyester, polyactic acid, polytrimethylene terephtalate, polycyclohexanediol, terephthalate, polyethylene napthalate, high density polyethylene, linear low density polyethylene, polyethylene, polypropylene, nylon, polyvinylidene fluoride, polytetrafluoroethylene and polyurethane.  
     
     
         21 . The filtering method of  claim 20  wherein the at least one fiber comprising at least two different component materials includes one or more component materials within a sheath.  
     
     
         22 . The filtering method of  claim 20  wherein the at least one fiber comprising at least two different component materials is crimped.