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Thermoplastic bicomponent binder fiber can be combined with other media, fibers and other filtration components to form a thermally bonded filtration media. The filtration media can be used in filter units. Such filter units can be placed in the stream of a mobile fluid and can remove a particulate

Thermoplastic bicomponent binder fiber can be combined with other media, fibers and other filtration components to form a thermally bonded filtration media. The filtration media can be used in filter units. Such filter units can be placed in the stream of a mobile fluid and can remove a particulate load from the mobile stream. The unique combination of media fiber, bicomponent binder fiber and other filtration additives and components provide a filtration media having unique properties in filtration applications.

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We claim: 1. A filtration medium comprising a thermally bonded sheet, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and (b) an effective amount of a glass fiber having a fibe

We claim: 1. A filtration medium comprising a thermally bonded sheet, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and (b) an effective amount of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers, an aspect ratio of about 10 to 10,000 to obtain a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min-1; wherein the media has a thickness of about 0.2 to 50 mm, a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m-2. 2. The medium of claim 1 wherein the media comprises about 0.1 to 10 wt % of a binder resin. 3. The medium of claim 1 wherein the media comprises about 0.5 to 15 wt % of a secondary fiber. 4. The medium of claim 3 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 5. The medium of claim 1 comprising two or more layers. 6. The medium of claim 1 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 7. The medium of claim 1, wherein the bicomponent binder fiber comprises a blend of two or more fibers having different average diameters. 8. The medium of claim 1, wherein the bicomponent binder fiber comprises a blend of two or more fibers comprising different materials. 9. The medium of claim 8 wherein the different materials comprise two or more of a vinyl acetate polymer, poly(vinyl chloride), polyvinyl alcohol, polyvinyl acetate, polyvinyl acetyl, acrylic polymer, methacrylic polymer, polyamide, polyethylene vinyl acetate copolymer, urea phenol resin, urea formaldehyde resin, a polyolefin, a polyester, a nylon, polytetrafluoroethylene, polyvinyl chloride acetate, polyvinyl butyral, polyvinylidene chloride, polystyrene, a cellulosic resin, or blends or copolymers thereof. 10. A liquid filtration medium comprising a thermally bonded sheet, the sheet comprising: (a) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and (b) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m-2, a pore size of about 0.2 to 50 micrometers and a permeability of about 2 to 200 ft-min-1. 11. The medium of claim 10 wherein the media comprises a secondary fiber. 12. The medium of claim 10 wherein the media fiber comprises a glass fiber. 13. The medium of claim 12 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 14. The medium of claim 10 also comprising a 0.1 to 25 wt % of a binder resin. 15. The medium of claim 10 comprising two or more layers. 16. The medium of claim 10 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 17. A method of filtering a liquid stream, the method comprising: (a) placing a filter unit into the stream and (b) retaining particulate entrained in the filter in the stream using filter media within the filter unit, the filter media comprising a thermally bonded sheet comprising: (i) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and (ii) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; wherein the medium has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m-2, a pore size of about 0.2 to 50 micrometers and a permeability of about 2 to 200 ft-min-1. 18. The method of claim 17 wherein the liquid is an aqueous liquid. 19. The method of claim 17 wherein the liquid is a non-aqueous liquid. 20. The method of claim 19 wherein the medium also comprises 0.1 to 25 wt % of a binder resin. 21. The method of claim 17 comprising two or more layers. 22. A gaseous filtration medium for removing mist from air comprising a thermally bonded sheet, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; (b) about 20 to 80 wt % of a media fiber a fiber diameter of about 0.1 to 20 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 20 to 200 grams-m-2, a pore size of about 5 to 100 micrometers and a permeability of about 5 to 500 ft-min-1. 23. The medium of claim 22 wherein the media comprises about 0.1 to 10 wt % of a secondary fiber having a fiber diameter of 0.1 to 15 microns. 24. The medium of claim 22 wherein the media fiber comprises a glass fiber. 25. The medium of claim 24 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 26. The medium of claim 22 comprising two or more layers. 27. The medium of claim 22 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 28. A gaseous filtration medium for removing particulate from air comprising a thermally bonded sheet, the sheet comprising: (a) about 80 to 98 wt % of a bicomponent binder fiber having a fiber diameter of about 10 to 15 micrometers and a fiber length of about 0.1 to 15 cm; (b) about 2 to 20 wt % of a media fiber a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 10 to 25%, a basis weight of about 40 to 400 grams-m-2, a pore size of about 10 to 30 micrometers and a permeability of about 20 to 200 ft-min-1. 29. The medium of claim 28 wherein the media comprises a secondary fiber. 30. The medium of claim 28 wherein the media fiber comprises a glass fiber. 31. The medium of claim 30 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 32. The medium of claim 28 comprising two or more layers. 33. The medium of claim 30 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 34. A gaseous filtration medium for removing an entrained liquid from blow-by gases comprising a thermally bonded sheet, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 5 to 15 cm; (b) about 0.5 to 15 wt % of a media fiber or a secondary fiber having a fiber diameter of about 0.5 to 15 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 1 to 10%, a basis weight of about 20 to 80 grams-m-2, a pore size of about 5 to 50 micrometers and a permeability of about 50 to 500 ft-min-1. 35. The medium of claim 34 wherein the media comprises a secondary fiber. 36. The medium of claim 34 wherein the media fiber comprises a glass fiber. 37. The medium of claim 36 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 38. The medium of claim 34 comprising two or more layers. 39. The medium of claim 37 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 40. A filtration medium for filtering a lubricant oil comprising a thermally bonded sheet, the sheet comprising: (a) about 1 to 40 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 0.1 to 15 cm; and (b) about 60 to 99 wt % of a glass fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.2 to 2 mm, a solidity of about 2 to 10%, a basis weight of about 10 to 50 g-m-2, a pore size of about 0.5 to 10 micrometers and a permeability of about 0.1 to 30 ft-min-1. 41. The medium of claim 40 wherein the media comprises a binder resin. 42. The medium of claim 40 wherein the media fiber comprises a glass fiber. 43. The medium of claim 42 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 44. The medium of claim 40 comprising two or more layers. 45. The medium of claim 44 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 46. A filtration medium for filtering a hydraulic oil comprising a thermally bonded sheet, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 15 micrometers and a fiber length of about 0.1 to 15 cm; and (b) about 80 to 20 wt % of a media fiber having a fiber diameter of about 0.1 to 2 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.2 to 2 mm, a basis weight of about 40 to 350 g-m-2, a pore size of about 0.5 to 30 micrometers and a permeability of about 5 to 200 ft-min-1. 47. The medium of claim 46 wherein the media comprises a binder resin. 48. The medium of claim 46 wherein the media fiber comprises a glass fiber. 49. The medium of claim 48 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 50. The medium of claim 46 comprising two or more layers. 51. The medium of claim 46 wherein the media contains a secondary thermoplastic binder fiber and is substantially free of a residue from an aqueous binder resin. 52. A method of filtering a heated fluid, the method comprises the steps of: (a) passing a mobile fluid phase containing a contaminant through a filter medium, the medium having a thickness of about 0.2 to 50 mm, the medium comprising a thermally bonded sheet, the sheet comprising: (i) about 20 to 80 wt % of a bicomponent binder fiber having a first component with a melting point and a second component with a lower melting point, the fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; and (ii) about 20 to 80 wt % of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m-2, a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min-1, the mobile fluid phase having a temperature greater than the melting point of the second component; and (b) removing the contaminant. 53. The method of claim 52 wherein the fluid is a gas. 54. The method of claim 52 wherein the contaminant is a liquid. 55. The method of claim 52 wherein the contaminant is a solid. 56. The method of claim 52 wherein the fluid is a liquid. 57. The method of claim 52 wherein the liquid is an aqueous liquid. 58. The method of claim 52 wherein the liquid is a fuel. 59. The method of claim 52 wherein the liquid is a lubricant oil. 60. The method of claim 52 wherein the liquid is a hydraulic fluid. 61. A filtration medium comprising a thermally bonded sheet, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm: (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and (c) about 20 to 80 wt % of a glass fiber having a fiber diameter of about 0.1 to 30 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.2 to 50 mm, a solidity of about 2 to 25%, a basis weight of about 10 to 1000 g-m-2, a pore size of about 0.5 to 100 micrometers and a permeability of about 5 to 500 ft-min-1. 62. The medium of claim 61 wherein the media comprises about 0.1 to 10 wt % of a binder resin. 63. The medium of claim 61 wherein the media comprises an effective amount of the secondary binder fiber to bind the sheet and the media is substantially free of a residue from an aqueous binder resin. 64. The medium of claim 61 wherein the media comprises 0.5 to 15 wt % of the secondary binder fiber and the media is substantially free of a residue from an aqueous binder resin. 65. The medium of claim 63 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 3 to 30 micrometers and combinations of two or more sources thereof. 66. The medium of claim 61 comprising two or more layers. 67. A liquid filtration medium comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising: (a) about 10 to 90 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; (b) an effective medium binding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and (c) about 10 to 90 wt % of a media fiber having a fiber diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 2 to 200 g-m-2, a pore size of about 0.2 to 50 micrometers and a permeability of about 1 to 200 ft-min-1. 68. The medium of claim 67 wherein the media comprises about 0.5 to 15 wt % of the secondary binder fiber and the media fiber comprises a glass fiber. 69. The medium of claim 68 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 70. The medium of claim 67 comprising two or more layers. 71. A method of filtering a liquid stream, the method comprising: (a) placing a filter unit comprising the medium of claim 67 into the stream; and (b) retaining particulate entrained within the filter from the stream using filter media within the filter unit. 72. A gaseous filtration medium for removing mist from air comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising: (a) about 20 to 80 wt % of a bicomponent binder fiber having a fiber diameter of about 5 to 50 micrometers and a fiber length of about 0.1 to 15 cm; (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and (c) about 20 to 80 wt % of a media fiber with a diameter of about 0.1 to 20 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 2 to 25%, a basis weight of about 20 to 200 g-m-2, a pore size of about 5 to 20 micrometers and a permeability of about 5 to 500 ft-min-1. 73. The medium of claim 72 wherein the secondary binder fiber is present in an effective amount to bind the sheet and the fiber has a fiber diameter of about 0.1 to 15 microns. 74. The medium of claim 72 wherein the media comprises about 0.5 to 15 wt % of the secondary binder fiber having a diameter of about 0.1 to 15 microns and the media fiber comprises a glass fiber. 75. The medium of claim 74 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 76. A method of filtering a gaseous stream, the method comprising: (a) placing a filter unit comprising the medium of claim 72 into the stream; and (b) retaining particulate entrained within the filter from the stream using filter media within the filter unit. 77. A gaseous filtration medium for removing particulate from air comprising a thermally bonded sheet, the sheet substantially free of a residue from an aqueous binder resin, the sheet comprising: (a) about 80 to 98 wt % of a bicomponent binder fiber having a fiber diameter of about 10 to 15 micrometers and a fiber length of about 0.1 to 15cm; (b) an effective medium bonding amount of a secondary binder fiber, the fiber comprising a thermoplastic resin; and (c) about 2 to 20 wt % of a media fiber with a diameter of about 0.1 to 5 micrometers and an aspect ratio of about 10 to 10,000; wherein the media has a thickness of about 0.1 to 2 mm, a solidity of about 10 to 25%, a basis weight of about 40 to 400 g-m-2, a pore size of about 10 to 30 micrometers and a permeability of about 20 to 200 ft-min-1. 78. The medium of claim 77 wherein the secondary binder fiber is present in an effective amount to bind the sheet and the fiber has a fiber diameter of 0.1 to 15 microns. 79. The medium of claim 77 wherein the secondary binder fiber is present in an amount of about 0.01 to 10 wt % and the fiber has a fiber diameter of 0.1 to 15 microns. 80. The medium of claim 79 wherein the glass fiber is selected from the sources comprising an average fiber diameter of about 0.1 to 1 micrometer, 0.3 to 2 micrometers, 0.5 to 5 micrometers, 0.75 to 7 micrometers, 1 to 10 micrometers, 10 to 50 micrometers and combinations of two or more sources thereof. 81. The medium of claim 77 comprising two or more layers. 82. A method of filtering a gaseous stream, the method comprising: (a) placing a filter unit comprising the medium of claim 77 into the stream and (b) retaining particulate entrained within the filter from the stream using filter media within the filter unit.