Filter media including oriented fibers

Abstract

Filter media incorporating one or more filtration layers that include fibers including fiber portions orientated at a non-zero angle with respect to a surface of the filtration layer are provided. In some embodiments, at least a part of the fiber portions are positioned at an angle of at least 20 degrees (e.g., between 46 degrees and 90 degrees, or between 61 degrees and 90 degrees) with respect to a surface of the filtration layer or an outer or cover layer of the media. This orientation of fiber portions may result in an increased efficiency (e.g., average efficiency and/or initial efficiency) compared to similar filter media that do not include such oriented fiber portions.

What is claimed is: 
     
         1 . (canceled) 
     
     
         2 . A filter media, comprising:
 a first filtration layer comprising a plurality of fibers including fiber portions, the plurality of fibers having an average fiber diameter of at least 5 microns and less than or equal to 60 microns, the first filtration layer having a first surface,   a second filtration layer comprising a plurality of fiber portions having an average fiber diameter of at least 5 microns and less than or equal to 40 microns,   wherein the first and second filtration layers are directly adjacent one another,   wherein each of the first and second filtration layers comprises fiber portions that are positioned at an angle of between 46 degrees and 90 degrees with respect to the first surface,   wherein at least 25% of the combined fiber portions of the first and second filtration layers are positioned at an angle of between 46 degrees and 90 degrees with respect to the first surface,   wherein the first and second filtration layers have a combined basis weight of at least 40 gsm,   wherein the filter media has an thickness of at least 0.035 inches,   
       wherein the filter media has an average filtration efficiency of at least 40% for 0.4 micron or greater particles. 
     
     
         3 . The filter media of  claim 1 , wherein the basis weight of the first and/or second filtration layer is between about 80 gsm and 200 gsm. 
     
     
         4 . The filter media of  claim 1 , wherein the first and/or second filtration layer has a thickness of between about 80 mil and about 230 mil. 
     
     
         5 . The filter media of  claim 1 , wherein the first and/or second filtration layer has a mean pore flow size of between about 5 microns and about 80 microns. 
     
     
         6 . The filter media of  claim 1 , wherein the first and/or second filtration layer has an air permeability of between about 350 cfm and about 600 cfm. 
     
     
         7 . The filter media of  claim 1 , wherein the first filtration layer has an average fiber diameter that is different from an average fiber diameter of the second filtration layer. 
     
     
         8 . The filter media of  claim 1 , wherein the plurality of fibers are comprised of a synthetic polymer. 
     
     
         9 . The filter media of  claim 8 , wherein the synthetic polymer is selected from the group consisting of polyesters, acrylics, polyolefins, nylons, rayons, and polyvinyl derivatives. 
     
     
         10 . The filter media of  claim 1 , wherein the first and/or second filtration layer comprises staple fibers. 
     
     
         11 . The filter media of  claim 1 , wherein the first and/or second filtration layer comprises between about 20 wt % and about 70 wt % of binder fibers. 
     
     
         12 . The filter media of  claim 1 , wherein the first and/or second filtration layer has a pressure drop across the filtration layer of between about 7 Pa and about 15 Pa. 
     
     
         13 . The filter media of  claim 1 , wherein the first and/or second filtration layer has an average efficiency for 0.4 micron or larger particles of between about 30% and about 80%, as determined according to standard EN779-2012 using a final pressure drop of 450 Pa. 
     
     
         14 . The filter media of  claim 1 , wherein the filter media has a mean flow pore size of between about 5 microns and about 80 microns. 
     
     
         15 . The filter media of  claim 1 , wherein the first and/or second filtration layer has an initial efficiency for 3.0-10.0 micron-sized particles of between about 20% to about 90% as determined according to the standard ASHRAE 52.2. 
     
     
         16 . The filter media of  claim 1 , wherein the first and/or second filtration layer has a dust holding capacity of between about 100 g/m2 and about 160 g/m2. 
     
     
         17 . The filter media of  claim 1 , wherein the filter media is classified as an M5 filter media. 
     
     
         18 . The filter media of  claim 1 , wherein the filter media has an overall thickness of between about 80 mil and about 230 mil. 
     
     
         19 . The filter media of  claim 1 , wherein at least 10% of the fiber portions of the first and/or second filtration layer are positioned at an angle of between 0 degrees and 30 degrees with respect to the first surface, at least 25% of the fiber portions of the filtration layer are positioned at an angle of between 31 degrees and 60 degrees with respect to the first surface, and at least 40% of the fiber portions of the filtration layer are positioned at an angle of between 61 degrees and 90 degrees with respect to the first surface. 
     
     
         20 . The filter media of  claim 1 , wherein the plurality of fibers comprise a waved configuration including a plurality of peaks and troughs. 
     
     
         21 . The filter media of  claim 20 , wherein the fiber density and/or fiber mass at the peaks is higher than the fiber density and/or fiber mass at the troughs.