Hydrocarbon fluid-water separation

Abstract

To provide a filter media including a hydrocarbon fluid-water separation filter, enabling a substrate for use in the filter media to have an improved roll off angle.SOLUTION: There is provided a filter media including a substrate. The substrate includes a surface having a roll off angle in a range of 40 degrees to 90 degrees and a contact angle in a range of 90 degrees to 180 degrees for a 50 μL droplet when the surface is immersed in toluene. The surface includes a UV-treated surface. The substrate includes one or more of an aromatic component, an unsaturated component or a UV-reactive resin.SELECTED DRAWING: None

Description

[Technical Field]

[0001] Continuing Application Data This application claims the benefit of U.S. Provisional Patent Application No. 62 / 375,768, filed August 16, 2016, and U.S. Provisional Patent Application No. 62 / 375,772, filed August 16, 2016, each of which is incorporated herein by reference. [Background technology]

[0002] Filtration of hydrocarbon fluids, including diesel fuel, for use in internal combustion engines is often essential for proper engine performance. Moisture and particulate removal may be necessary to provide favorable engine performance and to protect engine components from damage. Free water (i.e., undissolved water), present as a separate phase in hydrocarbon fluids, can cause problems, including damage to engine components due to cavitation, corrosion, or promotion of microbial growth, if not removed. Summary of the Invention [Problem to be solved by the invention]

[0003] The present disclosure describes substrates for use in filter media, including, for example, hydrocarbon fluid-water separation filters; methods for identifying substrates; methods for manufacturing substrates; methods for using substrates; and methods for improving the roll-off angle of substrates. Hydrocarbon fluids can include fuels, including, for example, diesel fuel. Substrates can be identified or modified based on the roll-off angle (i.e., adhesion) of a water droplet on a hydrophobic surface (i.e., a surface having a contact angle of at least 90 degrees) of the substrate when the surface is immersed in toluene. As described herein, the roll-off angle of a water droplet on a hydrophobic surface of the substrate when the surface is immersed in toluene correlates with the ability of the substrate to remove water from hydrocarbon fluids. [Means for solving the problem]

[0004] In one aspect, the present disclosure describes a filter medium comprising a substrate. In some embodiments, the substrate comprises a surface having a roll-off angle of 50 to 90 degrees and a contact angle of 90 to 180 degrees with a 20 microliter (μL) water droplet when immersed in toluene. In some embodiments, the surface comprises a surface having a roll-off angle of 40 to 90 degrees and a contact angle of 90 to 180 degrees with a 50 μL water droplet when immersed in toluene. In some embodiments, the surface is a UV-treated surface, including, for example, a UV-oxygen-treated surface. In some embodiments, the substrate comprises a surface having a hydrophilic group-containing polymer disposed thereon.

[0005] In a further aspect, the present disclosure describes a filter element comprising a filter medium including a substrate. In some embodiments, the substrate comprises a surface that, when immersed in toluene, has a roll-off angle in the range of 50 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet. In some embodiments, the substrate comprises a surface that, when immersed in toluene, has a roll-off angle in the range of 40 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with a 50 μL water droplet.

[0006] In another aspect, the present disclosure describes a method for treating a material, including a surface. The method includes treating the surface to form a treated surface. In some embodiments, the treated surface has a roll-off angle in the range of 50 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with a 20 μL droplet of water when the surface is immersed in toluene. In some embodiments, the treated surface has a roll-off angle in the range of 40 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with a 50 μL droplet of water when the surface is immersed in toluene. In some embodiments, the method includes exposing the surface of the substrate to UV radiation. In some embodiments, the method includes disposing a hydrophilic group-containing polymer on the surface of the substrate.

[0007] In yet another aspect, the present disclosure describes a method for identifying a material suitable for hydrocarbon fluid-water separation. The method includes determining the roll-off angle of a droplet on the surface of the material, where the material is immersed in a hydrocarbon-containing fluid and the roll-off angle is in the range of 40 degrees to 90 degrees. In some embodiments, the hydrocarbon-containing fluid includes toluene.

[0008] In further aspects, the present disclosure describes the use of UV radiation to improve the roll-off angle of a substrate, the use of a substrate obtainable by exposure of at least one of an aromatic component and an unsaturated component to UV radiation to improve the roll-off angle of a substrate, and the use of a hydrophilic group-containing polymer or a hydrophilic polymer to improve the roll-off angle of a substrate.

[0009] As used herein, the term "chemically distinct" means that two compounds have different chemical compositions.

[0010] As used herein, the term "hydrophilic" refers to the ability of a molecule or other molecular entity to dissolve in water, and the term "hydrophile" refers to a molecule or other molecular entity that is hydrophilic and / or attracted to and tends to be miscible with or soluble in water. In some embodiments, "hydrophilic" means that at least 90% of the molecule or other molecular entity, preferably at least 95%, more preferably at least 97%, and most preferably at least 99%, will dissolve in water at 25 degrees Celsius (°C), to the extent that saturation is reached. In some embodiments, "hydrophile" means that at least 90% of the molecule or other molecular entity, preferably at least 95%, more preferably at least 97%, and most preferably at least 99%, will dissolve in water at 25 degrees Celsius (°C), to the extent that saturation is reached.

[0011] A "hydrophilic surface" refers to a surface on which a water droplet has a contact angle of less than 90 degrees. In some embodiments, the surface is preferably immersed in toluene.

[0012] A "hydrophobic surface" refers to a surface on which a water droplet has a contact angle of at least 90 degrees. In some embodiments, the surface is preferably immersed in toluene.

[0013] A substrate or surface that is "stable" or has "stability" refers to a substrate or surface that has the ability to maintain a roll-off angle of at least 80 percent (%), preferably at least 85%, more preferably at least 90%, or even preferably at least 95% of the initial roll-off angle after being immersed in a hydrocarbon fluid for at least 1 hour, at least 12 hours, or at least 24 hours, and up to 10 days, up to 30 days, or up to 90 days at a temperature of at least 50° C. In some embodiments, the "initial roll-off angle" of a surface or substrate is the roll-off angle of a surface substrate that has been immersed in a hydrocarbon fluid for less than 1 hour, or more preferably less than 20 minutes.

[0014] "Polar functional group" means a functional group that possesses a net dipole as a result of the presence of an electronegative atom (eg, nitrogen, oxygen, chlorine, fluorine, etc.).

[0015] The terms "preferred" and "preferably" refer to embodiments of the invention that may afford certain benefits, under particular circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0016] The terms "comprises" and variations thereof do not have a limiting meaning where these terms appear in the description and claims.

[0017] The term "consisting of" is meant to include and be limited to everything that follows the phrase "consisting of." That is, "consisting of" indicates that the listed elements are required or mandatory, and that no other elements may be present.

[0018] The term "consisting essentially of" indicates that any elements listed after the phrase are included, and that other elements besides those listed may be included provided that those elements do not interfere with or contribute to the activity or function specified in this disclosure for the listed elements.

[0019] Unless otherwise specified, "a," "an," "the," and "at least one" are used interchangeably and mean one or more than one.

[0020] Also herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range (eg, 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0021] For any method disclosed herein that includes separate steps, the steps may be performed in any practicable order, and, where appropriate, any combination of two or more steps may be performed simultaneously.

[0022] The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The following description more particularly describes exemplary embodiments. In several places throughout the application, guidance is provided by lists of examples, which examples can be used in various combinations. In each instance, the recited list serves merely as a representative group and should not be interpreted as an exclusive list. [Brief explanation of the drawings]

[0023] [Figure 1A] 1 shows a representative arrangement of layers of a filter media including a substrate. [Figure 1B] 1 shows a representative arrangement of layers of a filter media including a substrate. [Figure 1C] 1 shows a representative arrangement of layers of a filter media including a substrate. [Figure 1D] 1 shows a representative arrangement of layers of a filter media including a substrate. [Figure 2] 10A-10C are representative images of a 50 μL water droplet on a UV oxygen-treated substrate 1 immersed in toluene at 0 degrees (0°) rotation (left) and 90° rotation (right). [Figure 3] A schematic diagram of the two-loop system used for droplet sizing tests is shown. [Figure 4] 1 shows the performance of untreated Substrate 1 (control) and UV oxygen treated Substrate 1 as measured by moisture removal efficiency. [Figure 5] Figure 1 shows the contact angle and roll-off angle of untreated Substrate 1 and UV oxygen-treated Substrate 1 without immersion or after 30 days of immersion in pump fuel. The contact angle and roll-off angle were measured using a 50 μL drop of water in toluene, and the reported values ​​are the average of independent measurements taken in different areas of the media. [Figure 6] 1 shows the contact angle (CA) and roll-off angle (RO) of the treated and untreated sides of UV / H 2 O 2 treated Substrate 1 immersed in toluene, measured using a 50 μL water droplet. [Figure 7] Representative images of a 20 μL water droplet on a PHPM-treated substrate 1 immersed in toluene at 0° rotation (left) and 60° rotation (right) are shown. [Figure 8] 1 shows the performance as measured by water removal efficiency of untreated (control) and PEI-10K coated Substrate 1. [Figure 9] 1 shows the breathability of uncoated Substrate 1 and Substrate 1 coated with 2% (w / v) PHEM, 4% (w / v) PHEM, 6% (w / v) PHEM or 8% (w / v) PHEM. [Figure 10]Figure 1 shows the contact angle and roll-off angle of a 50 μL water droplet on uncoated substrate 1 (control), PHPM-coated substrate 1, PHPM-coated substrate 1 crosslinked (CL) using 1% (w / v) N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, and PHPM-coated substrate 1 crosslinked (CL) using 1% (w / v) N-(2-aminoethyl)-3-aminopropyltrimethoxysilane and annealed after no immersion or immersion in pump fuel for the indicated period of time. [Figure 11] Figure 1 shows the contact angle and roll-off angle of a 50 μL water droplet on uncoated substrate 1 (control), PEI-10K coated substrate 1, PEI-10K coated substrate 1 crosslinked (CL) using 1% (w / v) (3-glycidyloxypropyl)trimethoxysilane, and PEI-10K coated substrate 1 crosslinked (CL) using 1% (w / v) (3-glycidyloxypropyl)trimethoxysilane and annealed after no immersion or immersion in pump fuel for the indicated period. [Figure 12] 1 shows the contact angle and roll-off angle of a 50 μL water droplet on a representative PHEM nanofiber coated substrate 6 with and without the crosslinker DAMO-T. [Figure 13] Figure 6 shows the contact angle and roll-off angle of a 50 μL water droplet on a representative PEI nanofiber coated substrate 6 without crosslinker, crosslinked with (3-glycidyloxypropyl)trimethoxysilane (crosslinker 1), or poly(ethylene glycol) diacrylate (crosslinker 2). [Figure 14] 1 shows the contact angle and roll-off angle of a 50 μL water droplet on a representative PHEM nanofiber coated DAMO-T crosslinked substrate 6 1 day, 6 days, and 32 days after formation of the coating by electrospinning. [Figure 15]The contact angle and roll-off angle of a 50 μL water droplet on a representative PEI-10K nanofiber coated crosslinked substrate 6 are shown 1, 6, and 32 days after formation of the coating by electrospinning. The PEI was crosslinked using either (3-glycidyloxypropyl)trimethoxysilane (crosslinker 1) or poly(ethylene glycol) diacrylate (PEGDA) (crosslinker 2). [Figure 16A] 1 shows a representative scanning electron microscopy (SEM) image of uncoated substrate 6 shown at 1000x magnification. [Figure 16B] 1 shows a representative scanning electron microscopy (SEM) image of substrate 6 coated by electrospinning with PHEM without a crosslinker, shown at 1000x magnification. [Figure 16C] 1 shows a representative scanning electron microscopy (SEM) image of a substrate 6 coated by electrospinning with PHEM using the crosslinker DAMO-T, shown at 1000x magnification. [Figure 17A] 1 shows a representative SEM image of Substrate 6 coated by electrospinning with PEI-10K without a cross-linker, shown at 50x magnification. [Figure 17B] 1 shows a representative SEM image of a substrate 6 coated by electrospinning with PEI-10K using the cross-linker (3-glycidyloxypropyl)trimethoxysilane, shown at 50x magnification. [Figure 17C] 1 shows a representative SEM image of a substrate 6 coated by electrospinning with PEI-10K using the cross-linker poly(ethylene glycol) diacrylate (PEGDA), shown at 50x magnification. [Figure 18A] A representative SEM image of uncoated substrate 6 is shown, shown at 200x magnification. [Figure 18B] 1 shows a representative SEM image of Substrate 6 coated by electrospinning with PEI-10K without a cross-linker, shown at 200x magnification. [Figure 18C]1 shows a representative SEM image of substrate 6 coated by electrospinning with PEI-10K and crosslinker 1 ((3-glycidyloxypropyl)trimethoxysilane) shown at 200x magnification. [Figure 18D] 1 shows a representative SEM image of substrate 6 coated by electrospinning with PEI-10K and crosslinker 2 (poly(ethylene glycol) diacrylate (PEGDA)) shown at 200x magnification. DETAILED DESCRIPTION OF THE INVENTION

[0024] A hydrocarbon fluid-water separation filter can include a filter medium including at least one layer for removing particles and / or at least one layer for coalescing water from a hydrocarbon fluid stream; the layer or layers can be a substrate or can be supported by a substrate. In some embodiments, the particle removal layer and the water-coalescing layer can be the same layer, and the layer can be a substrate or can be supported by a substrate. The present disclosure describes filter media including substrates for use in hydrocarbon fluid-water separation filters, methods for identifying substrates, methods for manufacturing substrates, methods for using substrates, and methods for improving the roll-off angle of substrates. Including a substrate in a filter medium or filter element, including, for example, a hydrocarbon fluid-water separation filter element, can provide more efficient filter manufacturing and / or improved performance characteristics of the filter medium or filter element, including, for example, improved water separation efficiency.

[0025] Hydrocarbon fluids can include, for example, diesel fuel, gasoline, hydraulic fluid, compressor oil, etc. In some embodiments, the hydrocarbon fluid preferably includes diesel fuel.

[0026] How to Identify Suitable Materials for Hydrocarbon Fluid-Water Separation In one aspect, the present disclosure describes a method for identifying materials, including, for example, filter media, having particular properties, preferably suitable for hydrocarbon fluid-water separation.

[0027] In some embodiments, the method includes determining the roll-off angle and optionally the contact angle of a droplet on the surface of the material while the material is immersed in a hydrocarbon-containing fluid. In some embodiments, the method includes identifying a material having substrate properties suitable for hydrocarbon fluid-water separation, including the roll-off angle and / or contact angle described below.

[0028] In some embodiments, the droplets comprise a hydrophilic substance. In some embodiments, the droplets preferably comprise water. In some embodiments, the droplets consist essentially of water. In some embodiments, the droplets consist of water. In some embodiments, the droplets are at least 5 μL, at least 10 μL, at least 15 μL, at least 20 μL, at least 25 μL, at least 30 μL, at least 35 μL, at least 40 μL, at least 45 μL, or at least 50 μL. In some embodiments, the droplets are at most 10 μL, at most 15 μL, at most 20 μL, at most 25 μL, at most 30 μL, at most 35 μL, at most 40 μL, at most 45 μL, at most 50 μL, at most 60 μL, at most 70 μL, or at most 100 μL. In some embodiments, the droplets are preferably 20 μL or 50 μL droplets.

[0029] In some embodiments, the hydrocarbon-containing fluid comprises toluene. In some embodiments, the hydrocarbon-containing fluid consists essentially of toluene. In some embodiments, the hydrocarbon-containing fluid consists of toluene. Without wishing to be bound by theory, it is believed that toluene acts as a surrogate for other hydrocarbon fluids, including, for example, diesel fuel, due to its surface tension with water.

[0030] In contrast to conventional methods for identifying materials suitable for use in hydrocarbon fluid-water separation, the methods described herein do not rely on the properties of a flat surface (e.g., a non-porous surface). Rather, the methods described herein provide a method for testing the properties of a porous material (e.g., including a porous substrate) or a material having a porous surface. Furthermore, the methods described herein do not rely on the properties of the material in air. Rather, materials are identified by their properties in a hydrocarbon-containing fluid, including, for example, toluene.

[0031] For example, WO 2015 / 175877 discloses that a filter medium designed to enhance fluid separation efficiency may include one or more layers with a surface modified to wet the fluid to be separated and one or more layers with a surface modified to repel the fluid to be separated. WO 2015 / 175877 also discloses that a "hydrophilic surface" may refer to a surface having a water contact angle of less than 90 degrees, and a "hydrophobic surface" may refer to a surface having a water contact angle of more than 90 degrees. However, WO 2015 / 175877 does not disclose that the contact angle should be calculated in a fluid, not in air. Indeed, the hydrophobicity of a surface in air does not predict the hydrophobicity of the surface in a hydrocarbon fluid.

[0032] Furthermore, WO 2015 / 175877 does not describe the importance of the roll-off angle of a surface, nor does it describe how to select materials to alter the roll-off angle. Rather, WO 2015 / 175877 describes that roughness or coatings can be used to modify the wettability of a layer to a particular fluid, and that the terms "wet" and "wetting" refer to the ability of a fluid to interact with a surface such that the contact angle of the fluid with the surface is less than 90 degrees.

[0033] However, the wettability or contact angle of a surface alone, whether measured in air or in a hydrocarbon fluid, does not predict the hydrocarbon-water separation ability of a surface in a hydrocarbon fluid. In contrast, and as described further below, the adhesion or roll-off angle of a water droplet on a surface in a hydrocarbon fluid, optionally in combination with the contact angle of a water droplet on the surface in a hydrocarbon fluid, can be used to predict the ability of a substrate to remove water from a hydrocarbon fluid.

[0034] Substrate surface characteristics In one aspect, the present disclosure describes a filter medium comprising a substrate suitable for hydrocarbon fluid-water separation. The substrate comprises a surface. In some embodiments, the substrate or the surface of the substrate is preferably stable.

[0035] In some embodiments, the surface has a roll-off angle of at least 30 degrees, at least 35 degrees, at least 40 degrees, at least 45 degrees, at least 50 degrees, at least 55 degrees, at least 60 degrees, at least 65 degrees, at least 70 degrees, at least 75 degrees, or at least 80 degrees with respect to a 20 μL droplet of water when the surface is immersed in toluene. In some embodiments, the surface has a roll-off angle of at least 30 degrees, at least 35 degrees, at least 40 degrees, at least 45 degrees, at least 50 degrees, at least 55 degrees, at least 60 degrees, at least 65 degrees, at least 70 degrees, or at least 80 degrees with respect to a 50 μL droplet of water when the surface is immersed in toluene.

[0036] In some embodiments, the surface has a roll-off angle of up to 60 degrees, up to 65 degrees, up to 70 degrees, up to 75 degrees, up to 80 degrees, up to 85 degrees, or up to 90 degrees with respect to a 20 μL droplet of water when the surface is immersed in toluene. In some embodiments, the surface has a roll-off angle of up to 60 degrees, up to 65 degrees, up to 70 degrees, up to 75 degrees, up to 80 degrees, up to 85 degrees, or up to 90 degrees with respect to a 50 μL droplet of water when the surface is immersed in toluene.

[0037] In some embodiments, the surface has a roll-off angle in the range of 50 degrees to 90 degrees for a 20 μL water droplet when the surface is immersed in toluene, hi some embodiments, the surface has a roll-off angle in the range of 40 degrees to 90 degrees for a 50 μL water droplet when the surface is immersed in toluene.

[0038] In some embodiments, the surface is preferably hydrophobic, i.e., the surface has a contact angle of at least 90 degrees. In some embodiments, the surface has a contact angle of at least 90 degrees, at least 100 degrees, at least 110 degrees, at least 120 degrees, at least 130 degrees, or at least 140 degrees with a 20 μL droplet of water when the surface is immersed in toluene. In some embodiments, the surface has a contact angle of at least 90 degrees, at least 100 degrees, at least 110 degrees, at least 120 degrees, at least 130 degrees, or at least 140 degrees with a 50 μL droplet of water when the surface is immersed in toluene.

[0039] In some embodiments, the surface has a contact angle of at most 150 degrees, at most 160 degrees, at most 170 degrees, or at most 180 degrees with a 20 μL droplet of water when the surface is immersed in toluene. In some embodiments, the surface has a contact angle of at most 150 degrees, at most 160 degrees, at most 170 degrees, or at most 180 degrees with a 50 μL droplet of water when the surface is immersed in toluene.

[0040] In some embodiments, the surface has a contact angle in the range of 90 degrees to 150 degrees or in the range of 90 degrees to 180 degrees with a 20 μL water droplet when the surface is immersed in toluene.

[0041] In some embodiments, the surface has a contact angle in the range of 90 degrees to 150 degrees or in the range of 90 degrees to 180 degrees with a 50 μL water droplet when the surface is immersed in toluene.

[0042] As described further below, the roll-off angle (i.e., adhesion) of water droplets on a hydrophobic surface (i.e., a surface having a contact angle of at least 90 degrees) of a substrate in a hydrocarbon fluid is related to the size of the water droplets that can coalesce or grow on the surface of the substrate in the hydrocarbon fluid. The size of the water droplets that can coalesce or grow is related to the ability of the substrate to remove water from the hydrocarbon fluid. Therefore, the ability of a substrate to remove water from a hydrocarbon fluid can be accurately predicted by determining the roll-off angle and contact angle of the droplets on the surface of the substrate in the hydrocarbon fluid.

[0043] The substrates produced by and / or identified by the methods described herein have a high contact angle and a high roll-off angle. A high contact angle indicates a low apparent drag force on a water droplet, while a high roll-off angle indicates the ability of the droplet to remain on the substrate surface. Without wishing to be bound by theory, it is believed that this combination of characteristics allows for the formation of larger droplets through coalescence, which allows the droplets to more easily separate from the hydrocarbon fluid stream and improves the overall efficiency of water separation from the hydrocarbon fluid stream.

[0044] A balance between a high contact angle and a high roll-off angle can be achieved using the methodologies disclosed herein, including, for example, modifying the substrate surface to increase the roll-off angle. Typically, these methods have little adverse effect on the contact angle. In some embodiments, a filter substrate with a high contact angle can therefore be modified to provide a substrate with the claimed combination of contact angle and roll-off angle.

[0045] Substrate materials and properties The substrate may be any substrate suitable for use in a filter medium. In some embodiments, the substrate is preferably a substrate suitable for use in a hydrocarbon fluid filter element, including, for example, a fuel filter. In some embodiments, the substrate may comprise, for example, cellulose, polyester, polyamide, polyolefin, glass, or a combination thereof (e.g., a blend, mixture, or copolymer thereof). The substrate may comprise, for example, a nonwoven web, a woven web, a porous sheet, a sintered plastic, a high-density screen, a high-density mesh, or a combination thereof. In some embodiments, the substrate may comprise a synthetic fiber, a naturally occurring fiber, or a combination thereof (e.g., a blend or mixture thereof). The substrate is typically porous and of certain definable performance characteristics, such as pore size, Frazier air permeability, and / or another suitable metric.

[0046] In some embodiments, the substrate can include thermoplastic or thermoset polymer fibers. The fiber polymer can be in a single polymer material system, a bicomponent fiber, or a combination thereof. The bicomponent fiber can include, for example, a thermoplastic polymer. In some embodiments, the bicomponent fiber can have a core-sheath structure, including a concentric or non-concentric structure. In some embodiments, the sheath of the bicomponent fiber can have a melting temperature lower than the melting temperature of the core, such that upon heating, the core maintains structural integrity while the sheath bonds to other fibers in the layer. Exemplary embodiments of bicomponent fibers include side-by-side fibers or island-in-the-sea fibers.

[0047] In some embodiments, the substrate can include cellulose fibers, including, for example, softwood fibers (such as mercerized southern pine), hardwood fibers (such as Eucalyptus fibers), regenerated cellulose fibers, mechanical pulp fibers, or combinations thereof (e.g., mixtures or blends thereof).

[0048] In some embodiments, the substrate can include glass fibers, including, for example, microfine glass, chopped glass fibers, or combinations thereof (eg, mixtures or blends thereof).

[0049] In some embodiments, the substrate comprises fibers having an average diameter of at least 0.3 microns, at least 1 micron, at least 10 microns, at least 15 microns, at least 20 microns, or at least 25 microns. In some embodiments, the substrate comprises fibers having an average diameter of up to 50 microns, up to 60 microns, up to 70 microns, up to 75 microns, up to 80 microns, or up to 100 microns. Those skilled in the art will recognize that the diameter of the fibers can vary depending on the fiber material and the method used to manufacture the fibers. The length of these fibers can also vary from a few millimeters to a continuous fiber structure. The cross-sectional shape of the fibers can also vary depending on the material or manufacturing method used.

[0050] In some embodiments, the substrate may include one or more binder materials. In some embodiments, the binder material includes a modified resin that provides additional rigidity and / or hardness to the substrate. For example, in some embodiments, the substrate may be saturated with the modified resin. The modified resin may include a UV-reactive resin or a non-UV-reactive resin described herein. In some embodiments, the modified resin may include a phenolic resin and / or an acrylic resin. In some embodiments, the non-UV-reactive resin may include an acrylic resin that does not contain aromatic and / or unsaturated components.

[0051] For example, in some embodiments where the substrate is prepared by UV treatment, the substrate preferably contains an aromatic component and / or an unsaturated component. The aromatic component and / or the unsaturated component may be present in a material contained in the substrate, or may be added to the substrate using a separate material, for example, a resin. A resin containing an aromatic component and / or an unsaturated component is referred to herein as a UV-reactive resin. The UV-reactive resin may include, for example, a phenolic resin. In some embodiments, the unsaturated component preferably contains a double bond.

[0052] In some embodiments, the substrate comprises pores having an average diameter of at most 10 microns (μm), at most 20 μm, at most 30 μm, at most 40 μm, at most 45 μm, at most 50 μm, at most 60 μm, at most 70 μm, at most 80 μm, at most 90 μm, at most 100 μm, at most 200 μm, at most 300 μm, at most 400 μm, at most 500 μm, at most 600 μm, at most 700 μm, at most 800 μm, at most 900 μm, at most 1 millimeter (mm), at most 1.5 mm, at most 2 mm, at most 2.5 mm, or at most 3 mm. In some embodiments, the substrate comprises pores having an average diameter of at least 2 μm, at least 5 μm, at least 10 μm, at least 20 μm, at least 30 μm, at least 40 μm, at least 50 μm, at least 60 μm, at least 70 μm, at least 80 μm, at least 90 μm, at least 100 μm, at least 200 μm, at least 300 μm, at least 400 μm, at least 500 μm, at least 600 μm, at least 700 μm, at least 800 μm, at least 900 μm, or at least 1 mm. In some embodiments, the substrate comprises pores having an average diameter in the range of 5 μm to 100 μm. In some embodiments, the substrate comprises pores having an average diameter in the range of 40 μm to 50 μm. In some embodiments, the pore size may be measured using a capillary flow porosimetry. In some embodiments, pore size is preferably measured by liquid extrusion porosimetry, as described in US Patent Application Publication No. 2011 / 0198280.

[0053] In some embodiments, the substrate is at least 15% porous, at least 20% porous, at least 25% porous, at least 30% porous, at least 35% porous, at least 40% porous, at least 45% porous, at least 50% porous, at least 55% porous, at least 55% porous, at least 60% porous, at least 65% porous, at least 70% porous, at least 75% porous, or at least 80% porous. In some embodiments, the substrate is at most 75% porous, at most 80% porous, at most 85% porous, at most 90% porous, at most 95% porous, at most 96% porous, at most 97% porous, at most 98% porous, or at most 99% porous. For example, the substrate can be at least 15% porous and at most 99% porous, at least 50% porous and at most 99% porous, or at least 80% porous and at most 95% porous.

[0054] In some embodiments, a filter medium can be designed for flow from "upstream" to "downstream" during use of the filter medium. In some embodiments, including, for example, when a filter medium includes a substrate located downstream of an upstream layer, the substrate can include pores having an average diameter larger than the average diameter of the pores of the upstream layer. Additionally or alternatively, the substrate can include pores having an average diameter larger than the average diameter of droplets forming on the downstream side of the upstream layer. For example, when a filter medium includes an upstream layer that is a coalesced layer including pores having an average diameter, the substrate can include pores having an average diameter larger than the average diameter of the pores of the coalesced layer.

[0055] Typically, the surface of the material (including, for example, the substrate) has a roll-off angle of less than 50 degrees, less than 40 degrees, or less than 30 degrees with respect to a 20 μL water droplet when the surface is immersed in toluene, prior to any surface modification or treatment. Typically, the surface of the material (including, for example, the substrate) has a roll-off angle of less than 30 degrees, less than 20 degrees, less than 15 degrees, or less than 12 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene, prior to any surface modification or treatment.

[0056] For example, the roll-off angle of the surface, prior to any surface modification or treatment, can range from 0 degrees to 50 degrees relative to a 20 μL water droplet when the surface is immersed in toluene.

[0057] In some embodiments, the roll-off angle of the surface, prior to any surface modification or treatment, may preferably range from 0 degrees to 40 degrees relative to a 20 μL water droplet when the surface is immersed in toluene.

[0058] For example, the roll-off angle of the surface, prior to any surface modification or treatment, can range from 0 degrees to 20 degrees relative to a 50 μL water droplet when the surface is immersed in toluene.

[0059] It is within the purview of one skilled in the art to provide a material (including, for example, a substrate) having a surface with an appropriate roll-off angle.

[0060] Typically, the surface of the material (including, for example, the substrate) prior to any surface modification or treatment has a contact angle of at least 90 degrees, at least 100 degrees, or at least 110 degrees with a 20 μL droplet of water when the surface is immersed in toluene. Typically, the surface of the material (including, for example, the substrate) prior to any surface modification or treatment has a contact angle of at least 90 degrees, at least 100 degrees, or at least 110 degrees with a 50 μL droplet of water when the surface is immersed in toluene.

[0061] For example, the contact angle of the surface, prior to any surface modification or treatment, may range from 90 degrees to 180 degrees with a 20 μL drop of water when the surface is immersed in toluene.

[0062] In some embodiments, the contact angle of the surface, prior to any surface modification or treatment, may range from 100 degrees to 150 degrees with a 20 μL drop of water when the surface is immersed in toluene.

[0063] For example, the contact angle of the surface, prior to any surface modification or treatment, may range from 90 degrees to 180 degrees with a 50 μL drop of water when the surface is immersed in toluene.

[0064] In some embodiments, the contact angle of the surface, prior to any surface modification or treatment, may range from 100 degrees to 150 degrees with a 50 μL drop of water when the surface is immersed in toluene.

[0065] In some embodiments, the surface prior to any surface modification or treatment may have a contact angle of 0 degrees, i.e., a droplet will spread completely over the surface. In some embodiments, the surface prior to any surface modification or treatment may have a contact angle of 0 degrees, and the roll-off angle prior to any surface modification or treatment may be indeterminate.

[0066] It is within the purview of one skilled in the art to provide a material (including, for example, a substrate) with a surface that has an appropriate contact angle. Typically, including a material that is generally hydrophobic will usually result in a higher contact angle.

[0067] Other factors that affect the contact angle of a surface can include pore size and porosity. For example, pores of a certain size can help hydrophobic hydrocarbon fluids to be trapped in the filter. Furthermore, the high surface tension of water prevents it from effectively penetrating pores below a certain size.

[0068] Filter media including substrate In some embodiments, a filter medium comprising the substrate is preferably used for hydrocarbon-water separation, or more preferably for fuel-water separation, and most preferably for diesel fuel-water separation.

[0069] The filter medium may include one, two, or multiple layers. In some embodiments, one or more of the layers of the filter medium may be supported by, include, or be a substrate.

[0070] In some embodiments, and as shown, for example, in FIGS. 1A-1D, a filter medium can include a layer 20 for removing particles from a hydrocarbon liquid stream and / or a layer 30 for coalescing water from the hydrocarbon liquid stream (also described as a coalescing layer). In some embodiments, the layer for removing particles from a hydrocarbon liquid stream and / or the coalescing layer may be supported by a substrate 10, as shown in the illustrative embodiments of FIGS. 1A and 1B. In some embodiments, the layer for removing particles from a hydrocarbon liquid stream and / or the coalescing layer can be located upstream of the substrate, including, for example, when the filter medium is designed to receive flow passing from "upstream" to "downstream" during use of the filter medium. In some embodiments, the layer for removing particles from a hydrocarbon liquid stream and the substrate are the same layer 40, as shown in one embodiment in FIG. 1C. In some embodiments, the coalescing layer and the substrate are the same layer 50, as shown in one embodiment in FIG. 1D. If the layer for removing particles from the substrate and the hydrocarbon liquid stream are the same layer, or if the layer for combining the substrate and the water from the hydrocarbon liquid stream are the same layer, filter media production may be more efficient because the filter media may include a reduced number of overall layers.

[0071] In some embodiments, the surface of the substrate preferably forms the downstream side of the substrate. In some embodiments, the surface of the substrate can form the downstream side, or a layer of filter media, or the downstream side of the filter media.

[0072] In some embodiments, including when the surface of a substrate forms the downstream side, or a layer of a filter medium, or the downstream side of a filter medium, the substrate can be preferably separated from another layer by sufficient space to allow for water droplet formation and / or roll-off. In some embodiments, the substrate can be separated from another layer by at least 10 μm, at least 20 μm, at least 30 μm, at least 40 μm, at least 50 μm, at least 100 μm, at least 200 μm, at least 500 μm, or at least 1 mm. In some embodiments, the substrate can be separated from another layer by up to 40 μm, up to 50 μm, up to 100 μm, up to 200 μm, up to 500 μm, up to 1 mm, up to 2 mm, up to 3 mm, up to 4 mm, or up to 5 mm.

[0073] In some embodiments, as shown in one embodiment in Figure 1A, layer 20 configured to remove particulate contaminants is located upstream of coalescing layer 30, which is located upstream of substrate 10. In some embodiments, the coalescing layer is located downstream of the substrate. In some embodiments, the filter media can include at least two coalescing layers, with one of the coalescing layers located downstream of the substrate.

[0074] In some embodiments, the substrate may be included in a flow-by structure, including, for example, the structures described in co-pending U.S. patent application Ser. No. 62 / 543,456, filed 08 / 10 / 2017, entitled "Fluid Filtration Apparatuses, Systems, and Methods," which is incorporated herein by reference for its description of media structures.

[0075] In some embodiments, the filter medium can be included in a filter element. The filter medium can have any suitable structure. In some embodiments, the filter element can include a screen. In some embodiments, the screen can be located downstream of the substrate.

[0076] The filter media can have any suitable structure. For example, the filter media can have a tubular structure. In some embodiments, the filter media can include pleats.

[0077] Manufacturing method The present disclosure further describes methods for producing materials. In some embodiments, the material can include a filter medium including a substrate. The material, filter medium, substrate, and / or its surface can be treated by any suitable method to achieve a desired roll-off angle and / or a desired contact angle. In some embodiments, treating the material, filter medium, substrate, and / or its surface includes treating only a portion of the material, filter medium, substrate, and / or its surface.

[0078] In some embodiments, the treatment to achieve the desired roll-off angle and contact angle does not change the structure of the substrate. For example, in some embodiments, the treatment does not change at least one of the average pore size of the substrate and the air permeability of the substrate. In some embodiments, the treatment does not change the appearance of the medium when viewed at 500x magnification.

[0079] hardening In some embodiments, the substrate comprises a resin (e.g., a modified resin). Resins are well known and are typically used to improve the internal bonding of filter substrates.

[0080] Any suitable resin may be used, including, for example, a UV-reactive resin or a non-UV-reactive resin. The resin may include, for example, a partially cured resin (e.g., a partially cured phenolic resin), and curing of the resin may be performed to increase the rigidity of the substrate and / or prevent the substrate from collapsing during use. Curing may be performed before or after performing treatment to achieve the desired roll-off angle and contact angle. For example, if the substrate includes a hydrophilic group-containing polymer present in a layer separate from the resin, curing of the resin may be performed before or after forming the layer including the hydrophilic group-containing polymer. In some embodiments, the resin is preferably impregnated into the substrate.

[0081] The resin can comprise polymerizable monomers, polymerizable oligomers, polymerizable polymers, or combinations thereof (e.g., blends, mixtures, or copolymers thereof). As used herein, curing refers to the solidification of the resin and can include crosslinking and / or polymerization of the resin components. In some embodiments, the resin comprises a polymer, and during curing, the molecular weight of the polymer increases due to crosslinking of the polymer.

[0082] Curing may be carried out by any suitable means, including, for example, heating the substrate. In some embodiments, curing is preferably carried out by heating the substrate at a temperature and for a time sufficient to cure the resin (including, for example, a phenolic resin). In some embodiments, the substrate may be heated to a temperature of at least 50°C, at least 75°C, at least 100°C, or at least 125°C. In some embodiments, the substrate may be heated to a temperature of up to 125°C, up to 150°C, up to 175°C, or up to 200°C. In some embodiments, the substrate may be heated to a temperature ranging from 50°C to 200°C. In some embodiments, the substrate may be heated for at least 1 minute, at least 2 minutes, at least 5 minutes, at least 7 minutes, at least 10 minutes, or at least 15 minutes. In some embodiments, the substrate may be heated for up to 8 minutes, up to 10 minutes, up to 12 minutes, up to 15 minutes, up to 20 minutes, or up to 25 minutes. In some embodiments, it may be preferable to heat the substrate at 150°C for 10 minutes.

[0083] Method for treating substrate to improve roll-off angle In some embodiments, the present disclosure relates to methods of treating a substrate to improve the roll-off angle of the surface. Without wishing to be bound by theory, it is believed that the various disclosed methods improve the roll-off angle by modifying the surface features of the substrate to make the surface microstructure more hydrophilic, while maintaining the overall hydrophobicity of the surface to water droplets.

[0084] A variety of different methods include those disclosed below.

[0085] UV In some embodiments, the substrate comprises a UV-treated surface, i.e., a surface that has been treated with UV radiation. In such embodiments, the substrate preferably comprises aromatic and / or unsaturated components.

[0086] For example, the substrate may include a fibrous material having aromatic and / or unsaturated components. In some embodiments, the substrate may include a UV-reactive resin, i.e., a resin having aromatic and / or unsaturated components. Such a UV-reactive resin may be present in addition to a fibrous material having aromatic and / or unsaturated components, or may be used in combination with a fibrous material that does not have aromatic and / or unsaturated components.

[0087] In some embodiments, the substrate preferably comprises an aromatic resin (ie, a resin containing aromatic groups), including, for example, a phenolic resin.

[0088] In some embodiments, the UV radiation is applied to the substrate at a distance from the source of at least 0.25 centimeters (cm), at least 0.5 cm, at least 0.75 cm, at least 1 cm, at least 1.25 cm, at least 2 cm, or at least 5 cm. In some embodiments, the UV radiation is applied to the substrate at a distance from the source of up to 0.5 cm, up to 1 cm, up to 2 cm, up to 3 cm, up to 5 cm, or up to 10 cm.

[0089] In some embodiments, the substrate has an electrical conductivity of at least 250 microwatts per square centimeter (μW / cm 2 ), at least 300 μW / cm 2 , at least 500 μW / cm 2 , at least 1 milliwatt per square centimeter (mW / cm 2 ), at least 5mW / cm 2 , at least 10 mW / cm 2 , at least 15mW / cm 2 , at least 20 mW / cm 2 , at least 21 mW / cm 2 or at least 25mW / cm 2 In some embodiments, the substrate is exposed to UV radiation of up to 20 mW / cm 2 , maximum 21mW / cm 2 , maximum 22mW / cm 2 , maximum 25mW / cm2 , maximum 30mW / cm 2 , up to 40mW / cm 2 , maximum 50mW / cm 2 , up to 60mW / cm 2 , up to 70mW / cm 2 , maximum 80mW / cm 2 , up to 90mW / cm 2 , maximum 100mW / cm 2 , maximum 150mW / cm 2 or up to 200mW / cm 2 is exposed to UV radiation.

[0090] In some embodiments, for example, the substrate may have a luminance of 300 μW / cm 2 ~100mW / cm 2 are exposed to UV radiation in the range of

[0091] In some embodiments, for example, the substrate may have a luminance of 300 μW / cm 2 ~200mW / cm 2 are exposed to UV radiation in the range of

[0092] In some embodiments, the substrate is exposed to (i.e., treated with) UV radiation for at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 30 seconds, at least 1 minute, at least 2 minutes, at least 3 minutes, at least 4 minutes, at least 5 minutes, at least 7 minutes, at least 9 minutes, at least 10 minutes, at least 11 minutes, at least 13 minutes, at least 15 minutes, at least 17 minutes, or at least 20 minutes. In some embodiments, the substrate is exposed to UV radiation for up to 5 seconds, up to 10 seconds, up to 30 seconds, up to 1 minute, up to 2 minutes, up to 4 minutes, up to 5 minutes, up to 6 minutes, up to 8 minutes, up to 10 minutes, up to 12 minutes, up to 14 minutes, up to 15 minutes, up to 16 minutes, up to 18 minutes, up to 20 minutes, up to 22 minutes, up to 24 minutes, up to 25 minutes, up to 26 minutes, up to 28 minutes, or up to 30 minutes.

[0093] In some embodiments, the UV radiation is applied for a time period ranging from 2 seconds to 20 minutes.

[0094] In some embodiments, UV radiation of different wavelengths may be applied sequentially. In some embodiments, it may be desirable to apply UV radiation of different wavelengths simultaneously.

[0095] While not wishing to be bound by theory, it is believed that UV radiation reacts and chemically modifies aromatic and / or unsaturated moieties, which increases the roll-off angle of the surface while still maintaining good contact angle properties.

[0096] It has been found that additional reagents, such as those disclosed below, can promote chemical reactions of aromatic and / or unsaturated components present in and / or on the substrate. These additional reagents may be used individually, sequentially, and / or simultaneously during treatment of the substrate with UV.

[0097] UV+Oxygen In some embodiments, the substrate preferably comprises a UV oxygen-treated surface, i.e., a surface treated with UV radiation in the presence of oxygen. Treatment in the presence of oxygen can include, for example, treatment in atmospheric air containing oxygen, treatment in an oxygen-containing environment, treatment in an oxygen-enriched environment, or treatment of a substrate containing oxygen in or on the substrate.

[0098] In some embodiments, the substrate is preferably treated with UV radiation under conditions sufficient to generate ozone and oxygen radicals, and at a wavelength sufficient for the treatment. In some embodiments, the UV radiation source is preferably a low-pressure mercury lamp. The UV radiation can be applied using any combination of the parameters described above for treatment with UV radiation, including distance, intensity, and time, and multiple wavelengths can be applied using sequential or simultaneous application.

[0099] In some embodiments, the UV radiation includes wavelengths capable of forming two oxygen radicals (O·) from O2. The oxygen radicals can react with O2 to form ozone (O3). In some embodiments, the UV radiation includes wavelengths of at least 165 nanometers (nm), at least 170 nm, at least 175 nm, at least 180 nm, or at least 185 nm. In some embodiments, the UV radiation includes wavelengths of up to 190 nm, up to 195 nm, up to 200 nm, up to 205 nm, up to 210 nm, up to 215 nm, up to 220 nm, up to 230 nm, or up to 240 nm. In some embodiments, the UV radiation includes wavelengths in the range of 180 nm to 210 nm. In some embodiments, the UV radiation includes a wavelength of 185 nm.

[0100] In some embodiments, the UV radiation includes wavelengths capable of dissociating ozone (O) to form O and oxygen radicals (O·). In some embodiments, the UV radiation includes wavelengths of at least 200 nm, at least 205 nm, at least 210 nm, at least 215 nm, at least 220 nm, at least 225 nm, at least 230 nm, at least 235 nm, at least 240 nm, at least 245 nm, or at least 250 nm. In some embodiments, the UV radiation includes wavelengths of up to 260 nm, up to 265 nm, up to 270 nm, up to 275 nm, up to 280 nm, up to 285 nm, up to 290 nm, up to 295 nm, up to 300 nm, up to 310 nm, or up to 320 nm. In some embodiments, the UV radiation includes wavelengths in the range of 210 nm to 280 nm. In some embodiments, the UV radiation includes a wavelength of 254 nm.

[0101] UV+Ozone In some embodiments, the substrate comprises a UV ozone treated surface, i.e., a surface treated with UV radiation in the presence of ozone (O3). The UV radiation may be applied using any combination of the parameters described above for treatment with UV radiation, including distance, intensity, and time, and multiple wavelengths may be applied using sequential or simultaneous application.

[0102] Treatment in the presence of ozone can include, for example, treatment in an ozone-containing environment or treatment while ozone is generated in the environment (e.g., by corona discharge). In some embodiments, the ozone-containing environment includes O2. In other embodiments, the ozone-containing environment includes less than 10 volume percent (vol%) O2, less than 5 vol% O2, less than 2 vol% O2, or less than 1 vol% O2. In some embodiments, the ozone-containing environment includes an inert gas, such as nitrogen, helium, argon, or a mixture thereof.

[0103] In some embodiments, the ozone-containing environment comprises at least 0.005% by volume O, at least 0.01% by volume O, at least 0.05% by volume O, at least 0.1% by volume O, at least 0.5% by volume O, at least 1% by volume O, at least 2% by volume O, at least 5% by volume O, at least 10% by volume O, or at least 15% by volume O. In some embodiments, the ozone-containing environment comprises a higher ozone concentration at the surface of the substrate. Such a concentration can be achieved, for example, by introducing ozone at the substrate surface (e.g., by allowing ozone to diffuse from the rear side of the medium). In some embodiments, the ozone concentration at or near the surface of the substrate is preferably sufficient to generate oxygen radicals from the presence of ozone in the presence of UV radiation.

[0104] In some embodiments, the UV radiation includes wavelengths capable of dissociating ozone (O) to form O and oxygen radicals (O·). In some embodiments, the UV radiation can include wavelengths of at least 165 nm, at least 170 nm, at least 175 nm, at least 180 nm, or at least 185 nm, and up to 260 nm, up to 265 nm, up to 270 nm, up to 275 nm, up to 280 nm, up to 285 nm, or up to 290 nm, including, for example, when the ozone-containing environment contains less than 10% O by volume, less than 5% O by volume, less than 2% O by volume, or 1% O by volume or less. In some embodiments, the UV radiation includes wavelengths in the range of 180 nm to 280 nm.

[0105] In some embodiments, when the ozone-containing environment includes O2, which will absorb UV radiation in the range of 180 nm to 210 nm, the UV radiation preferably includes wavelengths of at least 210 nm, at least 215 nm, at least 220 nm, at least 225 nm, at least 230 nm, at least 235 nm, at least 240 nm, at least 245 nm, or at least 250 nm. In some embodiments, the UV radiation includes wavelengths of up to 260 nm, up to 265 nm, up to 270 nm, up to 275 nm, up to 280 nm, up to 285 nm, up to 290 nm, up to 295 nm, up to 300 nm, up to 310 nm, or up to 320 nm. In some embodiments, the UV radiation includes wavelengths in the range of 210 nm to 280 nm. In some embodiments, the UV radiation includes a wavelength of 254 nm.

[0106] UV+H2O2 In some embodiments, the substrate comprises a UV-H2O2-treated surface, i.e., a surface treated with UV radiation and H2O2. In some embodiments, the surface of the substrate and / or the entire substrate may be placed in contact with (e.g., coated with and / or impregnated in) a solution comprising H2O2. In some embodiments, the solution can comprise at least 20 weight percent (wt%) H2O2, at least 25 wt% H2O2, at least 30 wt% H2O2, at least 40 wt% H2O2, at least 50 wt% H2O2, at least 60 wt% H2O2, at least 70 wt% H2O2, at least 80 wt% H2O2, or at least 90 wt% H2O2. In some embodiments, the solution can have up to 30% by weight H2O2, up to 40% by weight H2O2, up to 50% by weight H2O2, up to 60% by weight H2O2, up to 70% by weight H2O2, up to 80% by weight H2O2, up to 90% by weight H2O2, or up to 100% by weight H2O2.

[0107] In some embodiments, the substrate may be placed in contact with the solution comprising HO for at least 10 seconds, at least 30 seconds, at least 45 seconds, at least 1 minute, at least 2 minutes, at least 4 minutes, at least 6 minutes, or at least 8 minutes. In some embodiments, the substrate may be in contact with the solution comprising HO for up to 30 seconds, up to 45 seconds, up to 1 minute, up to 2 minutes, up to 4 minutes, up to 6 minutes, up to 8 minutes, up to 10 minutes, or up to 30 minutes.

[0108] In some embodiments, the substrate may be treated with UV radiation while in contact with the solution comprising HO. In some embodiments, the substrate may be treated with UV radiation after contact with the solution comprising HO. The UV radiation may be applied using any combination of the parameters described above for treatment with UV radiation, including distance, intensity, and time, and multiple wavelengths may be applied using sequential or simultaneous application.

[0109] The substrate may be treated with UV radiation sufficient to generate hydroxyl radicals (·OH). The substrate may be treated with UV radiation while contacting the surface with H2O2, after the surface has been contacted with H2O2, or both during and after contact with H2O2.

[0110] In some embodiments, the UV radiation includes wavelengths capable of forming two oxygen radicals (O·) from O2. The oxygen radicals can react with O2 to form ozone (O3). In some embodiments, the UV radiation includes wavelengths of at least 165 nm, at least 170 nm, at least 175 nm, at least 180 nm, or at least 185 nm. In some embodiments, the UV radiation includes wavelengths of up to 190 nm, up to 195 nm, up to 200 nm, up to 205 nm, up to 210 nm, up to 215 nm, up to 220 nm, up to 230 nm, or up to 240 nm. In some embodiments, the UV radiation includes wavelengths in the range of 180 nm to 210 nm. In some embodiments, the UV radiation includes a wavelength of 185 nm.

[0111] In some embodiments, the UV radiation includes wavelengths capable of dissociating ozone (O) to form O and oxygen radicals (O·). In some embodiments, the UV radiation includes wavelengths of at least 200 nm, at least 205 nm, at least 210 nm, at least 215 nm, at least 220 nm, at least 225 nm, at least 230 nm, at least 235 nm, at least 240 nm, at least 245 nm, or at least 250 nm. In some embodiments, the UV radiation includes wavelengths of up to 260 nm, up to 265 nm, up to 270 nm, up to 275 nm, up to 280 nm, up to 285 nm, up to 290 nm, up to 295 nm, up to 300 nm, up to 310 nm, or up to 320 nm. In some embodiments, the UV radiation includes wavelengths in the range of 210 nm to 280 nm. In some embodiments, the UV radiation includes a wavelength of 254 nm.

[0112] In some embodiments, the UV radiation comprises wavelengths of at least 200 nm, at least 250 nm, at least 300 nm, at least 330 nm, at least 340 nm, at least 350 nm, at least 355 nm, at least 360 nm, or at least 370 nm. In some embodiments, the UV radiation comprises wavelengths up to 350 nm, up to 360 nm, up to 370 nm, up to 375 nm, up to 380 nm, up to 385 nm, up to 390 nm, up to 395 nm, up to 400 nm, up to 410 nm, or up to 420 nm. In some embodiments, the UV radiation comprises wavelengths in the range of 350 nm to 370 nm. In some embodiments, the UV radiation comprises a wavelength of 360 nm.

[0113] In some embodiments, the substrate may be dried after being placed in contact with the solution comprising HO and before being treated with UV. In some embodiments, the substrate may be dried after being placed in contact with the solution comprising HO and after being treated with UV. In some embodiments, the substrate may be oven dried.

[0114] UV treatment (either UV alone or UV in combination with oxygen, ozone and / or hydrogen peroxide) is more effective when the substrate contains aromatic and / or unsaturated components, including, for example, when the substrate contains a UV-reactive resin, e.g., an aromatic resin (e.g., a resin containing aromatic groups), including, for example, a phenolic resin.

[0115] Substrate containing a hydrophilic group-containing polymer Alternatively, or in addition to UV treatment, the surface properties of the substrate can be modified by incorporating a hydrophilic group-containing polymer into and / or on the substrate. In some embodiments, when both UV treatment and incorporation of a hydrophilic group-containing polymer are used, it may be preferable to incorporate a hydrophilic group-containing polymer into the substrate or to modify the substrate to incorporate a hydrophilic group-containing polymer before UV treatment.

[0116] In some embodiments, the substrate comprises a hydrophilic group-containing polymer. The hydrophilic group of the hydrophilic group-containing polymer can comprise hydrophilic pendant groups, hydrophilic groups repeating in the polymer backbone, or both. As used herein, a "pendant group" refers to a group that is covalently attached to the polymer backbone but does not form part of the polymer backbone. In some embodiments, the hydrophilic group comprises at least one of hydroxy, amide, alcohol, acrylic acid, pyrrolidone, methyl ether, ethylene glycol, propylene glycol, dopamine, and ethyleneimine. In some embodiments, the hydrophilic pendant group comprises at least one of hydroxy, amide, alcohol, acrylic acid, pyrrolidone, methyl ether, and dopamine. In some embodiments, the hydrophilic group repeating in the polymer backbone comprises at least one of ethylene glycol, propylene glycol, dopamine, and ethyleneimine.

[0117] In some embodiments, a substrate comprising a hydrophilic group-containing polymer may comprise a surface having a hydrophilic group-containing polymer disposed thereon. In some embodiments, the substrate preferably comprises a layer comprising a hydrophilic group-containing polymer. In some embodiments, the surface having a hydrophilic group-containing polymer disposed thereon, or in some embodiments, the layer comprising a hydrophilic group-containing polymer, preferably forms a surface of the substrate having the desired properties described herein (including roll-off angle and contact angle).

[0118] The layer can be formed using any suitable method. For example, the layer can be formed by applying a polymer, including, for example, a prepolymerized polymer. Additionally or alternatively, the layer can be formed by applying a monomer, oligomer, polymer, or combination thereof (e.g., a blend, mixture, or copolymer thereof) and then polymerizing the monomer, oligomer, polymer, or combination thereof to form a polymer, copolymer, or combination thereof. In some embodiments, the polymer can be precipitated from solution using oxidative or reductive polymerization.

[0119] In some embodiments, the layer may be formed using any suitable coating method, including, for example, plasma deposition coating, roll-to-roll coating, dip coating, and / or spray coating. Spray coating may include, for example, pneumatic spraying, electrostatic spraying, etc. In some embodiments, the surface may be laminated. In some embodiments, the layer may be formed by spinning a polymer onto a substrate. Spinning a polymer onto a substrate may include, for example, electrospinning the polymer onto the substrate, or depositing the polymer onto the substrate by wet spinning, dry spinning, melt spinning, gel spinning, jet spinning, magnetospinning, etc. Spinning a polymer onto a substrate may, in some embodiments, form polymer nanofibers. Additionally or alternatively, spinning a polymer onto a substrate may coat fibers already present in the substrate. In some embodiments, including when the polymer is deposited onto the substrate by dry spinning a polymer solution, one or more driving forces, including air, electric field, centrifugal force, magnetic field, etc., may be used individually or in combination.

[0120] In some embodiments, the hydrophilic group-containing polymer comprises a polar functional group.

[0121] In some embodiments, the hydrophilic group-containing polymer is a hydrophilic polymer.

[0122] In some embodiments, the hydrophilic group-containing polymer is not capable of dissolving in water (e.g., it is not a hydrophilic polymer), but rather comprises at least one pendant group (e.g., a hydrophilic pendant group) or repeating group within the polymer backbone (e.g., a hydrophilic group repeating within the polymer backbone) that is capable of dissolving in water.

[0123] In some embodiments, the hydrophilic group-containing polymer comprises a hydroxylated methacrylate polymer. In some embodiments, the hydrophilic group-containing polymer does not comprise a fluorine group.

[0124] In some embodiments, the hydrophilic group-containing polymer does not include a fluoropolymer. As used herein, a fluoropolymer refers to a polymer that contains at least 5% fluorine, at least 10% fluorine, at least 15% fluorine, or at least 20% fluorine.

[0125] In some embodiments, the hydrophilic organ-containing polymer can include, for example, poly(hydroxypropyl methacrylate) (PHPM), including poly(2-hydroxypropyl methacrylate), poly(3-hydroxypropyl methacrylate), or mixtures thereof; poly(2-hydroxyethyl methacrylate) (PHEM); poly(2-ethyl-2-oxazoline) (P2E2O); polyethyleneimine (PEI); quaternized polyethyleneimine; or poly(dopamine); or combinations thereof (e.g., blends, mixtures, or copolymers thereof).

[0126] In some embodiments, the hydrophilic group-containing polymer can be dispersed and / or dissolved in the solvent during layer formation. In some embodiments, the solvent preferably dissolves the hydrophilic group-containing polymer but does not dissolve the substrate or any component of the substrate. In some embodiments, the solvent is preferably non-toxic. In some embodiments, the hydrophilic group-containing polymer is preferably insoluble in hydrocarbon fluids. In some embodiments, the hydrophilic group-containing polymer is preferably insoluble in toluene.

[0127] In some embodiments, the solvent is a solvent having a high dielectric constant, and can include, for example, methanol, ethanol, propanol, isopropanol (also known as isopropyl alcohol (IPA)), butanol (including each of its isomeric structures), butanone (including each of its isomeric structures), acetone, ethylene glycol, dimethylformamide, ethyl acetate, water, etc.

[0128] The concentration of the hydrophilic group-containing polymer in the solvent can be selected based on the molecular weight of the polymer. In some embodiments, the hydrophilic group-containing polymer can be present in the solvent at a concentration of at least 0.25 percent (%) weight / volume (w / v), at least 0.5% (w / v), at least 0.75% (w / v), at least 1.0% (w / v), at least 1.25% (w / v), at least 1.5% (w / v), at least 1.75% (w / v), at least 2.0% (w / v), at least 3% (w / v), at least 5% (w / v), at least 10% (w / v), at least 20% (w / v), at least 30% (w / v), at least 40% (w / v), or at least 50% (w / v). In some embodiments, the hydrophilic group-containing polymer may be present in the solvent at a concentration of up to 0.5% (w / v), up to 0.75% (w / v), up to 1.0% (w / v), up to 1.25% (w / v), up to 1.5% (w / v), up to 1.75% (w / v), up to 2.0% (w / v), up to 3% (w / v), up to 4% (w / v), up to 5% (w / v), up to 10% (w / v), up to 15% (w / v), up to 20% (w / v), up to 30% (w / v), up to 40% (w / v), up to 50% (w / v), or up to 60% (w / v).

[0129] In some embodiments, including deposition of the hydrophilic group-containing polymer by, for example, dip coating, the polymer may be present in a solvent at a concentration ranging from 0.5% (w / v) to 4% (w / v).

[0130] In some embodiments, including deposition of the hydrophilic group-containing polymer by, for example, dip coating, the polymer may be present in a solvent at a concentration ranging from 0.5% (w / v) to 1% (w / v).

[0131] In some embodiments, including, for example, deposition of a hydrophilic group-containing polymer by electrospinning, the polymer may be present in a solvent at a concentration ranging from 5% (w / v) to 30% (w / v).

[0132] In some embodiments, the layer can be formed using dip coating. Dip coating can be achieved, for example, by using a Chemat DipMaster 50 dip coater. In some embodiments, the layer can be formed by dip coating the substrate one, two, three, or more times. In some embodiments, the substrate can be dip coated, rotated 180 degrees, and dip coated again. In some embodiments, the substrate can be immersed in a dispersion containing a hydrophilic group-containing polymer and withdrawn at a rate of 50 millimeters per minute (mm / min). In some embodiments, the dispersion is preferably a solution.

[0133] In some embodiments, the layers may be formed using electrospinning, which may be accomplished, for example, as described in U.S. Patent No. 20160047062A1.

[0134] In some embodiments, the hydrophilic group-containing polymer may be deposited from solution using oxidative or reductive polymerization, including, for example, when the hydrophilic group-containing polymer comprises poly(dopamine). For example, a layer comprising poly(dopamine) may be prepared from the oxidative polymerization of dopamine.

[0135] In some embodiments, the layer comprising the hydrophilic group-containing polymer has a thickness of at least 0.5 angstroms (Å), at least 1 Å, at least 5 Å, at least 8 Å, at least 10 Å, at least 12 Å, at least 14 Å, at least 16 Å, at least 18 Å, at least 20 Å, at least 25 Å, at least 30 Å, or at least 50 Å.

[0136] In some embodiments, the solvent may be removed after layer formation, including, for example, after a dip-coating procedure. The solvent may be removed by evaporation, including, for example, drying using an oven.

[0137] In some embodiments, a charged coating may be formed (e.g., by quaternization, electrochemical oxidation, or reduction), and / or the coating may include a charged polymer. In some embodiments, the layer including the hydrophilic group-containing polymer may be altered after the layer is formed. For example, the hydrophilic group-containing polymer may be quaternized. In some embodiments, the hydrophilic group-containing polymer may be quaternized by treating the polymer layer with an acid. In some embodiments, the hydrophilic group-containing polymer may be quaternized by immersing the substrate including the hydrophilic group-containing polymer layer in a solution containing an acid. In some embodiments, the acid can be HCl.

[0138] In some embodiments, the hydrophilic group-containing polymer and / or coating may be treated with maleic anhydride.

[0139] In some embodiments, the substrate may include a hydrophilic group-containing polymer disposed therein. When the substrate includes a modified resin, the polymer is chemically distinct from the modified resin. In some embodiments, the hydrophilic group-containing polymer may be applied simultaneously with the modified resin. For example, the hydrophilic group-containing polymer may be mixed with the modified resin before the modified resin is applied to the substrate.

[0140] In some embodiments, the hydrophilic group-containing polymer may be crosslinked. In some embodiments, for example, when the hydrophilic group-containing polymer forms a layer on a substrate, the polymer may be crosslinked by including a crosslinking agent in the polymer dispersion used for coating or electrospinning. In some embodiments, for example, including when the polymer is dispersed in a substrate, the hydrophilic group-containing polymer may be crosslinked by including a crosslinking agent in the dispersion used to introduce the hydrophilic group-containing polymer. In some embodiments, the dispersion is preferably a solution.

[0141] Any suitable crosslinker may be selected for use with hydrophilic group-containing polymers. For example, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (DAMO-T) can be used as a crosslinker for PHEM. For example, (3-glycidyloxypropyl)trimethoxysilane or poly(ethylene glycol) diacrylate (PEGDA) can be used as a crosslinker for polyethyleneimine (PEI). Hydrophilic group-containing polymers containing primary or secondary amine groups can be crosslinked with compounds including, for example, carboxylic acids (adipic acid), aldehydes (e.g., gluteraldehyde), ketones, melamine-formaldehyde resins, phenol-formaldehyde resins, etc. In another example, hydrophilic group-containing polymers containing primary or secondary alcohol groups can be crosslinked with compounds including, for example, carboxylic acids (adipic acid), isocyanates (toluene diisocyanate), organosilanes (tetramethoxysilane), titanium (IV) complexes (tetrabutyl titanate), phenol-formaldehyde resins, melamine-formaldehyde resins, and the like.

[0142] In some embodiments, crosslinking of the hydrophilic group-containing polymer can be promoted by exposing the hydrophilic group-containing polymer and crosslinking agent to heat. Heat can be applied by any suitable method, including, for example, heating the substrate in an oven, exposing the substrate to an infrared lamp, exposing the substrate to steam, or treating the substrate with a heated roller. Any combination of time and temperature suitable for use with the hydrophilic group-containing polymer, crosslinking agent, and substrate can be used. In some embodiments, the hydrophilic group-containing polymer and crosslinking agent can be exposed to a temperature of at least 80°C, at least 90°C, at least 100°C, at least 110°C, at least 120°C, at least 130°C, at least 140°C, at least 150°C, at least 160°C, at least 170°C, at least 180°C, or at least 190°C. In some embodiments, the hydrophilic group-containing polymer and crosslinker may be exposed to temperatures of up to 140°C, up to 150°C, up to 160°C, up to 170°C, up to 180°C, up to 190°C, up to 200°C, up to 210°C, up to 220°C, up to 230°C, up to 240°C, up to 260°C, up to 280°C, or up to 300°C. In some embodiments, the hydrophilic group-containing polymer and crosslinker may be exposed to heat treatment for at least 15 seconds, at least 30 seconds, at least 60 seconds, at least 120 seconds, at least 2 minutes, at least 5 minutes, at least 10 minutes, or at least 1 hour. In some embodiments, the medium may be exposed to heat for up to 2 minutes, up to 3 minutes, up to 5 minutes, up to 10 minutes, up to 15 minutes, up to 20 minutes, up to 1 hour, up to 2 hours, up to 24 hours, or up to 2 days. For example, in some embodiments, the hydrophilic group-containing polymer may be crosslinked by heating the hydrophilic group-containing polymer and the crosslinking agent for 15 seconds to 15 minutes at a temperature of at least 100° C. and at most 150° C. In another example, in some embodiments, the hydrophilic group-containing polymer may be crosslinked by heating the hydrophilic group-containing polymer and the crosslinking agent for 15 seconds to 15 minutes at a temperature of at least 80° C. and at most 200° C.

[0143] In some embodiments, the hydrophilic group-containing polymer may be annealed. As used herein, "annealing" includes exposing the hydrophilic group-containing polymer to an environment for the purpose of reorienting functional groups in the hydrophilic group-containing polymer and / or increasing the crystallinity of the hydrophilic group-containing polymer. When crosslinking of the hydrophilic group-containing polymer is promoted by exposing the hydrophilic group-containing polymer and the crosslinking agent to heat, the hydrophilic group-containing polymer may be annealed before, during, or after crosslinking. In some embodiments, when crosslinking of the hydrophilic group-containing polymer is promoted by exposing the hydrophilic group-containing polymer and the crosslinking agent to heat, the hydrophilic group-containing polymer may preferably be annealed during or after crosslinking. In some embodiments, the hydrophilic group-containing polymer may preferably be annealed after crosslinking.

[0144] In some embodiments, annealing comprises heating a substrate containing a hydrophilic group-containing polymer in the presence of a polar solvent. For example, annealing may comprise impregnating a substrate containing a hydrophilic group-containing polymer and / or coated with a hydrophilic group-containing polymer in the presence of a polar solvent. Additionally or alternatively, annealing may comprise exposing a substrate containing a hydrophilic group-containing polymer and / or coated with a hydrophilic group-containing polymer to a polar solvent in vapor form. In some embodiments, the polymer solution may comprise a polar solvent, including, for example, when the hydrophilic group-containing polymer layer is applied by dip-coating the substrate in the polymer solution, and the polymer layer may be annealed by heating and subsequent evaporation of the polar solvent from the substrate.

[0145] Suitable polar solvents for annealing can include, for example, water or alcohols. Alcohols can include, for example, methanol, ethanol, isopropanol, t-butanol, etc. Other suitable polar solvents can include, for example, acetone, ethyl acetate, methyl ethyl ketone (MEK), dimethylformamide (DMF), etc.

[0146] In some embodiments, annealing comprises exposing the substrate to a temperature of at least the glass transition temperature (Tg) of the hydrophilic group-containing polymer, hi some embodiments, annealing comprises exposing the substrate to a solvent having a temperature of at least the Tg of the hydrophilic group-containing polymer.

[0147] In some embodiments, including for example when annealing comprises impregnating the hydrophilic group-containing polymer coated substrate in a polar solvent, the polar solvent is at least 50° C., at least 55° C., at least 60° C., at least 65° C., at least 70° C., at least 75° C., at least 80° C., at least 85° C., at least 90° C., at least 95° C., at least 100° C., at least 110° C., at least 120° C., at least 130° C., at least 140° C., or at least 150° C. In some embodiments, the polar solvent is at most 90° C., at most 95° C., at most 100° C., at most 105° C., at most 110° C., at most 115° C., at most 120° C., at most 130° C., at most 140° C., at most 150° C., or at most 200° C. In some embodiments, the medium is impregnated in the polar solvent for at least 10 seconds, at least 30 seconds, at least 60 seconds, at least 90 seconds, at least 120 seconds, at least 150 seconds, or at least 180 seconds. In some embodiments, the medium is immersed in the polar solvent for up to 60 seconds, up to 120 seconds, up to 150 seconds, up to 180 seconds, up to 3 minutes, or up to 5 minutes. In some embodiments, the polar solvent may preferably be water. For example, in some embodiments, annealing comprises immersing the hydrophilic group-containing polymer coating medium in water at 90° C. for at least 10 seconds and up to 5 minutes.

[0148] Without wishing to be bound by theory, it is believed that the surface of a substrate having a hydrophilic group-containing polymer disposed thereon or containing a hydrophilic group-containing polymer disposed therein can have the desired properties described above (including roll-off angle and contact angle) due to the discontinuities on the substrate surface. Thus, in some embodiments, the substrate can include a mixture of fibers. In some embodiments, the substrate can include both non-polymeric and polymeric fibers and / or two different types of polymeric fibers. For example, the substrate can include polyester fibers discontinuously surrounded by nylon and / or nylon fibers discontinuously surrounded by polyester. Additionally or alternatively, the substrate can include fibers that would form a hydrophilic surface if they formed the entire surface, and fibers that would form a hydrophobic surface if they formed the entire surface.

[0149] In some embodiments, substrates containing hydrophilic group-containing polymers, including substrates containing a hydrophilic group-containing polymer coating or substrates containing a hydrophilic group-containing polymer disposed thereon, are preferably stable. In some embodiments, the stability of substrates containing hydrophilic group-containing polymers can be increased by treating with maleic anhydride, annealing the hydrophilic group-containing polymer, and / or crosslinking the hydrophilic group-containing polymer. While not wishing to be bound by theory, it is believed that in some embodiments, the stability of substrates containing hydrophilic group-containing polymers is increased by reducing the solubility of the hydrophilic group-containing polymer, for example, by crosslinking. Again, while not wishing to be bound by theory, it is believed that in some embodiments, the stability of substrates is increased by increasing the accessibility of the hydrophilic pendant groups (e.g., hydroxyl groups) of the polymer on the surface of the substrate, for example, by annealing.

[0150] Treated substrates and uses In some embodiments, the present disclosure relates to a filter medium comprising a substrate obtainable by a process comprising exposing a surface of the substrate to UV radiation. The substrate comprises at least one of an aromatic component and an unsaturated component.

[0151] In some embodiments, the surface of the substrate preferably has a contact angle of at least 90 degrees, as further described herein, prior to treatment.

[0152] In some embodiments, exposing the surface of the substrate to UV radiation comprises exposing the surface to UV radiation in the presence of oxygen, as further described herein. In some embodiments, exposing the surface of the substrate to UV radiation comprises exposing the surface to UV radiation in the presence of at least one of H2O2 and ozone, as further described herein. In some embodiments, the substrate comprises a UV-reactive resin, i.e., a resin comprising at least one of an aromatic component and an unsaturated component. In some embodiments, the UV-reactive resin comprises a phenolic resin.

[0153] In some embodiments, the present disclosure relates to a filter medium comprising a substrate obtainable by a method comprising disposing a hydrophilic group-containing polymer on a surface of the substrate.

[0154] In some embodiments, the surface of the substrate preferably has a contact angle of at least 90 degrees, as further described herein, prior to treatment.

[0155] In some embodiments, the present disclosure relates to the use of UV radiation to improve the roll-off angle of a surface of a substrate comprising at least one of an aromatic component and an unsaturated component.

[0156] In some embodiments, the use is characterized by a substrate comprising an aromatic resin.

[0157] In some embodiments, the use is characterized by a substrate comprising a phenolic resin.

[0158] In some embodiments, the use is characterized by the use of UV radiation in the presence of at least one of oxygen, ozone, and H2O2.

[0159] In some embodiments, the present disclosure relates to the use of a substrate obtainable by exposure of at least one of an aromatic component and an unsaturated component to UV radiation to improve the roll-off angle of the substrate.

[0160] In some embodiments, the use relates to the use of a substrate obtainable by exposure of a UV-reactive resin to UV radiation to improve the roll-off angle of the substrate.

[0161] In some embodiments, the use relates to the use of a substrate obtainable by exposure of an aromatic resin to UV radiation to improve the roll-off angle of the substrate.

[0162] In some embodiments, the use relates to the use of a substrate obtainable by exposure of a phenolic resin to UV radiation to improve the roll-off angle of the substrate.

[0163] In some embodiments, the use is characterized by exposure to UV radiation in the presence of at least one of oxygen, ozone, and H2O2.

[0164] The present disclosure relates to the use of hydrophilic group-containing polymers to improve the roll-off angle of a substrate.

[0165] The present disclosure further relates to the use of hydrophilic polymers to improve the roll-off angle of a substrate.

[0166] In some embodiments of these uses, the substrate is preferably a filter substrate, as further described herein, including a filter substrate whose surface has a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet when immersed in toluene.

[0167] In some embodiments of these uses, the substrate is preferably a filter substrate, as further described herein, comprising a filter substrate whose surface has a contact angle in the range of 90 degrees to 180 degrees with a 50 μL water droplet when immersed in toluene.

[0168] Representative Filter Media Embodiments Embodiment 1. A filter medium comprising a substrate, the substrate comprising: A filter medium comprising a surface having a roll-off angle in the range of 50 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 20 μL water droplet when the surface is immersed in toluene.

[0169] Embodiment 2. The filter media of embodiment 1, wherein the surface has a roll-off angle in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0170] Embodiment 3. A filter medium comprising a substrate, the substrate comprising: A filter medium comprising a surface having a roll-off angle in the range of 40 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene.

[0171] Embodiment 4. The filter media of embodiment 3, wherein the surface has a roll-off angle in the range of 50 degrees to 90 degrees, in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0172] Embodiment 5. The filter media of any one of embodiments 1-4, wherein the surface comprises a UV-treated surface.

[0173] Embodiment 6. The filter media of any one of embodiments 1-5, wherein the surface comprises a UV-oxygen treated surface.

[0174] Embodiment 7. The filter media of any one of embodiments 1-6, wherein the surface comprises a UV-ozone treated surface.

[0175] Embodiment 8. The filter media of any one of embodiments 1-7, wherein the surface comprises a UV-H2O2 treated surface.

[0176] Embodiment 9. The filter medium of any one of embodiments 1-8, wherein the substrate comprises a hydrophilic group-containing polymer.

[0177] Embodiment 10. The filter medium of any one of embodiments 1-9, wherein the surface comprises a hydrophilic group-containing polymer disposed thereon.

[0178] Embodiment 11. The filter medium of either embodiment 9 or 10, wherein the hydrophilic group-containing polymer comprises hydrophilic pendant groups.

[0179] Embodiment 12. The filter medium of any one of embodiments 9-11, wherein the hydrophilic group-containing polymer comprises poly(hydroxypropyl methacrylate) (PHPM), poly(2-hydroxyethyl methacrylate) (PHEM), poly(2-ethyl-2-oxazoline) (P2E2O), polyethyleneimine (PEI), quaternized polyethyleneimine, poly(dopamine), or a combination thereof.

[0180] Embodiment 13. The filter medium of any one of embodiments 9-12, wherein the hydrophilic group-containing polymer comprises a hydrophilic polymer.

[0181] Embodiment 14. The filter medium of any one of embodiments 9-13, wherein the hydrophilic group-containing polymer comprises a charged polymer.

[0182] Embodiment 15. The filter medium of any one of embodiments 9-14, wherein the hydrophilic group-containing polymer comprises a hydroxylated methacrylate polymer.

[0183] Embodiment 16. The filter medium of any one of embodiments 9 to 15, wherein the hydrophilic group-containing polymer does not include a fluoropolymer.

[0184] Embodiment 17. A filter medium comprising a substrate, The substrate comprises a surface that has a roll-off angle in the range of 50 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 20 μL water droplet when the surface is immersed in toluene; and 1. A filter media, wherein the surface comprises poly(hydroxypropyl methacrylate) (PHPM), poly(2-hydroxyethyl methacrylate) (PHEM), poly(2-ethyl-2-oxazoline) (P2E2O), polyethyleneimine (PEI), quaternized polyethyleneimine, poly(dopamine), or a combination thereof.

[0185] Embodiment 18. The filter media of embodiment 17, wherein the surface has a roll-off angle in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0186] Embodiment 19. A filter medium comprising a substrate, The substrate comprises a surface that has a roll-off angle in the range of 40 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene; and 1. A filter media, wherein the surface comprises poly(hydroxypropyl methacrylate) (PHPM), poly(2-hydroxyethyl methacrylate) (PHEM), poly(2-ethyl-2-oxazoline) (P2E2O), polyethyleneimine (PEI), quaternized polyethyleneimine, poly(dopamine), or a combination thereof.

[0187] Embodiment 20. The filter media of embodiment 19, wherein the surface has a roll-off angle in the range of 50 degrees to 90 degrees, in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0188] Embodiment 21. The filter media of any one of embodiments 1 to 20, wherein the substrate comprises cellulose, polyester, polyamide, polyolefin, glass, or a combination thereof.

[0189] Embodiment 22. The filter medium of any one of embodiments 1 to 21, wherein the substrate comprises at least one of an aromatic component and an unsaturated component.

[0190] Embodiment 23. The filter media of any one of embodiments 1 to 22, wherein the substrate comprises a modified resin.

[0191] Embodiment 24. The filter media of any one of embodiments 1 to 23, wherein the substrate comprises a UV-reactive resin.

[0192] Embodiment 25. The filter media of any one of embodiments 1 to 24, wherein the substrate comprises a phenolic resin.

[0193] Embodiment 26. The filter medium of any one of embodiments 1 to 25, wherein the substrate comprises pores having an average diameter of at most 2 mm.

[0194] Embodiment 27. The filter medium of any one of embodiments 1 to 26, wherein the substrate comprises pores having an average diameter of up to 40 μm.

[0195] Embodiment 28. The filter medium of any one of embodiments 1 to 27, wherein the substrate is at least 15% porous and up to 99% porous.

[0196] Embodiment 29. The filter medium of any one of embodiments 1 to 28, wherein the filter medium further comprises a coalescing layer located upstream of the substrate.

[0197] Embodiment 30. The filter medium of embodiment 29, wherein the coalescing layer comprises pores having an average diameter, and the substrate comprises pores having an average diameter, and the average diameter of the pores of the substrate is larger than the average diameter of the pores of the coalescing layer.

[0198] Embodiment 31. The filter medium of either embodiment 29 or 30, wherein the substrate comprises pores having an average diameter, and droplets having an average diameter form on the upstream side of the coalescence layer, and further wherein the average diameter of the pores of the substrate is greater than the average diameter of the droplets.

[0199] Embodiment 32. The filter medium of any one of embodiments 1 to 31, wherein the substrate is stable.

[0200] Representative Processing Method Embodiments Embodiment 1. A method for treating a material comprising a surface, comprising: Treating a surface to form a treated surface Including, A method wherein the treated surface has a roll-off angle in the range of 50 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 20 μL water droplet when the surface is immersed in toluene.

[0201] Embodiment 2. The method of embodiment 1, wherein the treated surface has a roll-off angle in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0202] Embodiment 3. A method for treating a material comprising a surface, comprising: Treating a surface to form a treated surface Including, A method wherein the treated surface has a roll-off angle in the range of 40 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene.

[0203] Embodiment 4. The method of embodiment 3, wherein the treated surface has a roll-off angle in the range of 50 degrees to 90 degrees, in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0204] Embodiment 5. The method of any one of embodiments 1-4, wherein treating the surface comprises exposing the surface to ultraviolet (UV) radiation.

[0205] Embodiment 6. The method of embodiment 5, wherein treating the surface comprises exposing the surface to ultraviolet (UV) radiation in the presence of oxygen, and wherein the UV radiation comprises a first wavelength in the range of 180 nm to 210 nm and a second wavelength in the range of 210 nm to 280 nm.

[0206] Embodiment 7. The method of any one of embodiments 1-6, wherein the UV radiation comprises a wavelength of 185 nm.

[0207] Embodiment 8. The method of any one of embodiments 1-7, wherein the UV radiation comprises a wavelength of 254 nm.

[0208] Embodiment 9. The method of any one of embodiments 1-8, wherein treating the surface comprises exposing the surface to H2O2.

[0209] Embodiment 10. The method of any one of embodiments 1 to 9, wherein treating the surface comprises exposing the surface to ultraviolet (UV) radiation comprising wavelengths in the range of 350 nm to 370 nm.

[0210] Embodiment 11. The method of any one of embodiments 1 to 10, wherein treating the surface comprises exposing the surface to ultraviolet (UV) radiation in the presence of ozone.

[0211] Embodiment 12. The surface treatment is 300 μW / cm 2 ~200mW / cm 2 12. The method of any one of embodiments 1-11, comprising exposing the surface to UV radiation in the range of

[0212] Embodiment 13. The method of any one of embodiments 1 to 12, wherein treating the surface comprises exposing the surface to UV radiation for a time period ranging from 2 seconds to 20 minutes.

[0213] Embodiment 14. The method of any one of embodiments 1 to 13, wherein treating the surface comprises forming a layer comprising a hydrophilic group-containing polymer on the surface.

[0214] Embodiment 15. The method of embodiment 14, wherein the hydrophilic group-containing polymer comprises poly(hydroxypropyl methacrylate) (PHPM), poly(2-hydroxyethyl methacrylate) (PHEM), poly(2-ethyl-2-oxazoline) (P2E2O), polyethyleneimine (PEI), quaternized polyethyleneimine, poly(dopamine), or a combination thereof.

[0215] Embodiment 16 The method of any of embodiments 14 or 15, wherein the hydrophilic group-containing polymer comprises a hydrophilic polymer.

[0216] Embodiment 17. The method of any one of embodiments 14-16, wherein the hydrophilic group-containing polymer comprises hydrophilic pendant groups.

[0217] Embodiment 18 The method of any one of embodiments 14-17, wherein the hydrophilic group-containing polymer comprises a hydroxylated methacrylate polymer.

[0218] Embodiment 19. The method of any one of embodiments 14-18, wherein the hydrophilic group-containing polymer does not comprise a fluoropolymer.

[0219] Embodiment 20. The method of any one of embodiments 14-19, wherein the layer comprises an electrostatically charged layer.

[0220] Embodiment 21 The method of any one of embodiments 14 to 20, wherein forming the layer comprising the hydrophilic group-containing polymer comprises dip-coating the material in a solution comprising the hydrophilic group-containing polymer.

[0221] Embodiment 22 The method of embodiment 21, wherein the solution comprising the hydrophilic group-containing polymer further comprises a crosslinker.

[0222] Embodiment 23. The method of embodiment 22, wherein the crosslinker comprises at least one of N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (DAMO-T), 3-glycidyloxypropyl)trimethoxysilane, and poly(ethylene glycol) diacrylate (PEGDA).

[0223] Embodiment 24 The method of any one of embodiments 14 to 20, wherein forming a layer comprising a hydrophilic group-containing polymer on the surface comprises electrospinning a solution comprising a hydrophilic group-containing polymer onto the surface.

[0224] Embodiment 25 The method of embodiment 24, further comprising forming nanofibers comprising the hydrophilic group-containing polymer on the surface.

[0225] Embodiment 26 The method of any of embodiments 24 or 25, wherein the solution comprising the hydrophilic group-containing polymer further comprises a crosslinker.

[0226] Embodiment 27. The method of embodiment 26, wherein the crosslinker comprises at least one of N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (DAMO-T), 3-glycidyloxypropyl)trimethoxysilane, and poly(ethylene glycol) diacrylate (PEGDA).

[0227] Embodiment 28 The method of any one of embodiments 14 to 27, further comprising crosslinking the hydrophilic group-containing polymer.

[0228] Embodiment 29. The method of embodiment 28, wherein crosslinking the hydrophilic group-containing polymer comprises heating the material coated with the hydrophilic group-containing polymer at a temperature in the range of 80°C to 200°C for 30 seconds to 15 minutes.

[0229] Embodiment 30. The method of any one of embodiments 14 to 29, further comprising annealing the hydrophilic group-containing polymer.

[0230] Embodiment 31. The method of embodiment 30, wherein annealing the hydrophilic group-containing polymer comprises immersing the material coated with the hydrophilic group-containing polymer in a solvent for at least 10 seconds, and the temperature of the solvent is at least the glass transition temperature of the hydrophilic group-containing polymer.

[0231] Embodiment 32. The method of any one of embodiments 1 to 31, wherein the material comprises a filter medium.

[0232] Embodiment 33 The method of embodiment 32, wherein the filter medium comprises a substrate.

[0233] Embodiment 34. The method of any one of embodiments 1 to 33, wherein the material comprises cellulose, polyester, polyamide, polyolefin, glass, or a combination thereof.

[0234] Embodiment 35. The method of any one of embodiments 1 to 34, wherein the material comprises at least one of an aromatic component and an unsaturated component.

[0235] Embodiment 36. The method of any one of embodiments 1 to 35, wherein the material comprises a modified resin.

[0236] Embodiment 37. The method of any one of embodiments 1 to 36, wherein the material comprises a UV-reactive resin.

[0237] Embodiment 38. The method of any one of embodiments 1 to 37, wherein the material comprises a phenolic resin.

[0238] Embodiment 39. The method of any one of embodiments 1 to 38, wherein the material comprises pores having an average diameter of up to 2 mm.

[0239] Embodiment 40. The method of any one of embodiments 1 to 39, wherein the material comprises pores having an average diameter in the range of 40 μm to 50 μm.

[0240] Embodiment 41. The method of any one of embodiments 1 to 40, wherein the material is at least 15% porous and up to 99% porous.

[0241] Embodiment 42. The method of any one of embodiments 1 to 41, wherein the treated surface is stable.

[0242] Embodiment 43. The method of any one of embodiments 1 to 42, wherein the surface of the material has a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0243] Embodiment 44. The method of any one of embodiments 1 to 43, wherein the surface of the material has a contact angle in the range of 100 degrees to 150 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0244] Embodiment 45. The method of any one of embodiments 1 to 44, wherein the surface of the material has a roll-off angle in the range of 0 degrees to 50 degrees relative to a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0245] Embodiment 46. The method of any one of embodiments 1 to 42, wherein the surface of the material has a contact angle in the range of 90 degrees to 180 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0246] Embodiment 47. The method of any one of embodiments 1 to 42 or 46, wherein the surface of the material has a contact angle in the range of 100 degrees to 150 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0247] Embodiment 48. The method of any one of embodiments 1 to 42, 46, or 47, wherein the surface of the material has a roll-off angle in the range of 0 degrees to 40 degrees relative to a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0248] Representative Filter Element Embodiments Embodiment 1. A filter medium comprising a substrate comprising a surface having a roll-off angle in the range of 50 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 20 μL water droplet when the surface is immersed in toluene. A filter element comprising:

[0249] Embodiment 2. The filter element of embodiment 1, wherein the surface has a roll-off angle in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0250] Embodiment 3. A filter medium comprising a substrate comprising a surface having a roll-off angle in the range of 40 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene. A filter element comprising:

[0251] Embodiment 4. The filter element of embodiment 3, wherein the surface has a roll-off angle in the range of 50 degrees to 90 degrees, in the range of 60 degrees to 90 degrees, in the range of 70 degrees to 90 degrees, or in the range of 80 degrees to 90 degrees.

[0252] Embodiment 5. The filter element of any one of embodiments 1-4, wherein the surface defines a downstream side of the filter media.

[0253] Embodiment 6. The filter element of any one of embodiments 1-5, wherein the filter media comprises a layer configured to remove particulate contaminants.

[0254] Embodiment 7. The filter element of embodiment 6, wherein the layer configured to remove particulate contaminants is upstream of the substrate.

[0255] Embodiment 8. The filter element of any one of embodiments 1 to 7, wherein the filter media comprises a coalescing layer.

[0256] Embodiment 9. The filter element of embodiment 8, wherein the coalescing layer is upstream of the substrate.

[0257] Embodiment 10. The filter element of any one of embodiments 1 to 9, wherein the filter media comprises a layer configured to remove particulate contaminants and a coalescing layer, and the layer configured to remove particulate contaminants is upstream of the coalescing layer, and the coalescing layer is upstream of the substrate.

[0258] Embodiment 11. The filter element of any one of embodiments 1 to 10, wherein the filter element further comprises a screen.

[0259] Embodiment 12. The filter element of embodiment 11, wherein the screen is downstream of the substrate.

[0260] Embodiment 13. The filter element of any one of embodiments 1 to 12, wherein the filter element further comprises a second coalescing layer downstream of the substrate.

[0261] Embodiment 14. The filter element of any one of embodiments 1 to 13, wherein the filter medium has a tubular structure.

[0262] Embodiment 15. The filter element of any one of embodiments 1 to 14, wherein the filter medium comprises pleats.

[0263] Embodiment 16. The filter element of any one of embodiments 1 to 15, wherein the filter element is configured for removing water from hydrocarbon fluids.

[0264] Embodiment 17. The filter element of embodiment 16, wherein the hydrocarbon fluid comprises diesel fuel.

[0265] Embodiment 18. The filter element of any one of embodiments 1 to 17, wherein the surface is stable.

[0266] Identification of suitable materials for typical hydrocarbon fluid-water separations Embodiment 1. A method for identifying a material suitable for hydrocarbon fluid-water separation, comprising determining the roll-off angle, in the range of 40 degrees to 90 degrees, of a droplet on the surface of the material immersed in a hydrocarbon-containing fluid.

[0267] Embodiment 2. The method of embodiment 1, wherein the droplets comprise a hydrophilic material.

[0268] Embodiment 3. The method of embodiment 1 or 2, wherein the droplets comprise water.

[0269] Embodiment 4. The method of any one of embodiments 1-3, wherein the hydrocarbon-containing fluid comprises toluene.

[0270] Embodiment 5. The method of any one of embodiments 1-4, wherein the droplets are 20 μL droplets.

[0271] Embodiment 6. The method of any one of embodiments 1-4, wherein the droplets are 50 μL droplets.

[0272] Embodiment 7. The method of any one of embodiments 1-6, further comprising determining the contact angle of the liquid droplet on the surface of the material.

[0273] Embodiment 8. The method of embodiment 7, wherein the contact angle is in the range of 90 degrees to 180 degrees.

[0274] Embodiment 9. The method of any one of embodiments 1-8, wherein the material comprises a hydrophilic group-containing polymer disposed thereon.

[0275] Embodiment 10. The method of embodiment 10, wherein the hydrophilic group-containing polymer comprises a hydrophilic polymer.

[0276] Embodiment 11. The method of any one of embodiments 1 to 10, wherein the surface of the material is stable.

[0277] Embodiment 12. The method of any one of embodiments 1 to 11, wherein the material comprises pores having an average diameter of up to 2 mm.

[0278] Embodiment 13. The method of any one of embodiments 1 to 12, wherein the material comprises pores having an average diameter in the range of 40 μm to 50 μm.

[0279] Embodiment 14. The method of any one of embodiments 1-13, wherein the material is at least 15% porous and up to 99% porous.

[0280] Representative UV Radiation Treated Substrate Embodiments Embodiment 1. A filter medium comprising a substrate obtainable by a process comprising exposing a surface of a substrate comprising at least one of an aromatic component and an unsaturated component to ultraviolet (UV) radiation.

[0281] Embodiment 2. The filter media of embodiment 1, wherein the surface of the material has a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0282] Embodiment 3. The method of any of embodiments 1 or 2, wherein the surface of the material has a contact angle in the range of 100 degrees to 150 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0283] Embodiment 4. The filter media of embodiment 1, wherein the surface of the material has a contact angle in the range of 90 degrees to 180 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0284] Embodiment 5. The filter medium of any one of embodiments 1-4, wherein the surface of the material has a contact angle in the range of 100 degrees to 150 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0285] Embodiment 6. A filter medium comprising a substrate comprising at least one of an aromatic component and an unsaturated component, the substrate being obtainable by a method comprising: providing a substrate having a surface that, when immersed in toluene, has a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet; and exposing the surface of the substrate to ultraviolet (UV) radiation.

[0286] Embodiment 7. The filter media of embodiment 6, wherein the surface of the material has a contact angle in the range of 100 degrees to 150 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0287] Embodiment 8. A filter medium comprising a substrate comprising at least one of an aromatic component and an unsaturated component, the substrate being obtainable by a method comprising: providing a substrate having a surface that, prior to treatment, has a contact angle in the range of 90 degrees to 180 degrees with a 50 μL water droplet when the surface is immersed in toluene; and exposing the surface of the substrate to ultraviolet (UV) radiation.

[0288] Embodiment 9. The filter media of embodiment 8, wherein the surface of the material has a contact angle in the range of 100 degrees to 150 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0289] Embodiment 10. The filter media of any one of embodiments 1-9, wherein exposing the surface of the substrate to UV radiation comprises exposing the surface to UV radiation in the presence of oxygen, and the UV radiation comprises a first wavelength in the range of 180 nm to 210 nm and a second wavelength in the range of 210 nm to 280 nm.

[0290] Embodiment 11. The filter medium of any one of embodiments 1-10, wherein the UV radiation comprises a wavelength of 185 nm.

[0291] Embodiment 12. The filter medium of any one of embodiments 1 to 11, wherein the UV radiation comprises a wavelength of 254 nm.

[0292] Embodiment 13. The filter medium of any one of embodiments 1 to 12, wherein exposing the surface comprises exposing the surface to H2O2.

[0293] Embodiment 14. The filter medium of any one of embodiments 1 to 13, wherein exposing the surface comprises exposing the surface to UV radiation comprising wavelengths in the range of 350 nm to 370 nm.

[0294] Embodiment 15. The filter media of any one of embodiments 1 to 14, wherein exposing the surface comprises exposing the surface to UV radiation in the presence of ozone.

[0295] Embodiment 16. The exposure of the surface is 300 μW / cm 2 ~200mW / cm 2 16. The filter medium of any one of embodiments 1-15, comprising exposing the surface to UV radiation in the range of

[0296] Embodiment 17. The filter medium of any one of embodiments 1 to 16, wherein exposing the surface comprises exposing the surface to UV radiation for a time period ranging from 2 seconds to 20 minutes.

[0297] Embodiment 18. The filter medium of any one of embodiments 1 to 17, wherein the substrate comprises an aromatic component and an unsaturated component.

[0298] Embodiment 19. The filter media of embodiment 18, wherein the substrate comprises a UV-reactive resin.

[0299] Embodiment 20. The filter media of either embodiment 18 or 19, wherein the UV-reactive resin comprises a phenolic resin.

[0300] Embodiment 21. The filter medium of any one of embodiments 1 to 20, wherein the substrate comprises pores having an average diameter of at most 2 mm.

[0301] Embodiment 22. The filter medium of any one of embodiments 1 to 21, wherein the substrate comprises pores having an average diameter in the range of 40 μm to 50 μm.

[0302] Embodiment 23. The filter medium of any one of embodiments 1 to 22, wherein the substrate is at least 15% porous and up to 99% porous.

[0303] Embodiment 24. The filter media of any one of embodiments 1 to 22, wherein the substrate, prior to treatment, has a roll-off angle in the range of 0 degrees to 50 degrees relative to a 20 μL water droplet when the surface is immersed in toluene.

[0304] Embodiment 25. The filter media of any one of embodiments 1 to 22, wherein the substrate, prior to treatment, has a roll-off angle in the range of 0 degrees to 40 degrees relative to a 50 μL water droplet when the surface is immersed in toluene.

[0305] Representative embodiments of hydrophilic group-containing polymer-treated substrates Embodiment 1. A filter medium comprising a substrate obtainable by a method comprising disposing a hydrophilic group-containing polymer on a surface of the substrate.

[0306] Embodiment 2. The filter media of embodiment 1, wherein the surface of the substrate has a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0307] Embodiment 3. The filter media of embodiment 1 or 2, wherein the surface of the substrate has a contact angle in the range of 100 degrees to 150 degrees with a 20 μL water droplet when the surface is immersed in toluene prior to treatment.

[0308] Embodiment 4. The filter media of embodiment 1, wherein the surface of the substrate has a contact angle in the range of 90 degrees to 180 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0309] Embodiment 5. The filter media of embodiment 1 or 4, wherein the surface of the substrate has a contact angle in the range of 100 degrees to 150 degrees with a 50 μL water droplet when the surface is immersed in toluene prior to treatment.

[0310] Embodiment 6. The filter medium of any one of embodiments 1-5, wherein the hydrophilic group-containing polymer comprises poly(hydroxypropyl methacrylate) (PHPM), poly(2-hydroxyethyl methacrylate) (PHEM), poly(2-ethyl-2-oxazoline) (P2E2O), polyethyleneimine (PEI), quaternized polyethyleneimine, poly(dopamine), or a combination thereof.

[0311] Embodiment 7. The filter medium of any one of embodiments 1-6, wherein the hydrophilic group-containing polymer comprises a hydrophilic polymer.

[0312] Embodiment 8. The filter medium of any one of embodiments 1-7, wherein the hydrophilic group-containing polymer comprises hydrophilic pendant groups.

[0313] Embodiment 9. The filter medium of any one of embodiments 1-8, wherein the hydrophilic group-containing polymer comprises a hydroxylated methacrylate polymer.

[0314] Embodiment 10. The filter medium of any one of embodiments 1-9, wherein the hydrophilic group-containing polymer does not comprise a fluoropolymer.

[0315] Embodiment 11. The filter medium of any one of embodiments 1 to 10, wherein disposing the hydrophilic group-containing polymer on the surface of the substrate comprises forming a layer comprising the hydrophilic group-containing polymer on the surface.

[0316] Embodiment 12. The filter media of embodiment 11, wherein the layer comprises an electrostatically charged layer.

[0317] Embodiment 13. The filter medium of any one of embodiments 1 to 12, wherein disposing the hydrophilic group-containing polymer on the surface of the substrate comprises dip-coating the substrate in a solution comprising the hydrophilic group-containing polymer.

[0318] Embodiment 14. The filter medium of embodiment 13, wherein the solution comprising the hydrophilic group-containing polymer further comprises a cross-linking agent.

[0319] Embodiment 15. The filter media of embodiment 14, wherein the cross-linking agent comprises at least one of N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (DAMO-T), 3-glycidyloxypropyl)trimethoxysilane, and poly(ethylene glycol) diacrylate (PEGDA).

[0320] Embodiment 16. The filter medium of any one of embodiments 1 to 12, wherein disposing the hydrophilic group-containing polymer on the surface of the substrate comprises electrospinning a solution comprising the hydrophilic group-containing polymer onto the surface.

[0321] Embodiment 17. The filter medium of embodiment 16, wherein electrospinning the solution comprising the hydrophilic group-containing polymer onto the surface comprises forming nanofibers comprising the hydrophilic group-containing polymer on the surface.

[0322] Embodiment 18 The filter medium of either embodiment 16 or 17, wherein the solution comprising the hydrophilic group-containing polymer further comprises a cross-linking agent.

[0323] Embodiment 19. The filter media of embodiment 18, wherein the cross-linking agent comprises at least one of N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (DAMO-T), 3-glycidyloxypropyl)trimethoxysilane, and poly(ethylene glycol) diacrylate (PEGDA).

[0324] Embodiment 20. The filter medium of any one of embodiments 1 to 20, wherein the method further comprises crosslinking the hydrophilic group-containing polymer.

[0325] Embodiment 21. The filter medium of embodiment 20, wherein crosslinking the hydrophilic group-containing polymer comprises heating the material coated with the hydrophilic group-containing polymer at a temperature in the range of 80°C to 200°C for 30 seconds to 15 minutes.

[0326] Embodiment 22. The filter medium of any one of embodiments 1 to 21, wherein the method further comprises annealing the hydrophilic group-containing polymer.

[0327] Embodiment 23. The filter medium of embodiment 22, wherein annealing the hydrophilic group-containing polymer comprises immersing the hydrophilic group-containing polymer-coated material in a solvent for at least 10 seconds, the solvent having a temperature at least equal to the glass transition temperature of the hydrophilic group-containing polymer.

[0328] Embodiment 24. The filter medium of any one of embodiments 1 to 23, wherein the substrate comprises pores having an average diameter of at most 2 mm.

[0329] Embodiment 25. The filter medium of any one of embodiments 1 to 24, wherein the substrate comprises pores having an average diameter in the range of 40 μm to 50 μm.

[0330] Embodiment 26. The filter medium of any one of embodiments 1 to 25, wherein the substrate is at least 15% porous and up to 99% porous.

[0331] Embodiment 27. The filter media of any one of embodiments 1 to 26, wherein the substrate, prior to treatment, has a roll-off angle in the range of 0 degrees to 50 degrees relative to a 20 μL water droplet when the surface is immersed in toluene.

[0332] Embodiment 28. The filter media of any one of embodiments 1 to 26, wherein the substrate, prior to treatment, has a roll-off angle in the range of 0 degrees to 40 degrees relative to a 50 μL water droplet when the surface is immersed in toluene.

[0333] Representative Use Embodiments Embodiment 1. Use of ultraviolet (UV) radiation to improve the roll-off angle of a surface of a substrate comprising at least one of an aromatic component and an unsaturated component.

[0334] Embodiment 2. The use of embodiment 1, characterized in that the substrate comprises an aromatic resin.

[0335] Embodiment 3. The use of any of embodiments 1 or 2, characterized in that the substrate comprises a phenolic resin.

[0336] Embodiment 4. The use of any one of embodiments 1 to 3, characterized by the use of UV radiation in the presence of oxygen to improve the roll-off angle.

[0337] Embodiment 5. The use of any one of embodiments 1 to 4, characterized by the use of UV radiation in the presence of ozone to improve the roll-off angle.

[0338] Embodiment 6. The use of any one of embodiments 1 to 5, characterized by the use of UV radiation in the presence of H2O2 to improve the roll-off angle.

[0339] Embodiment 7. Use of a material obtainable by exposure of at least one of an aromatic component and an unsaturated component to UV radiation to improve the roll-off angle of a substrate.

[0340] Embodiment 8. The use of embodiment 7, relating to the use of a material obtainable by exposure of a UV-reactive resin to UV radiation to improve the roll-off angle of a substrate.

[0341] Embodiment 9. The use of any of embodiments 7 or 8 relating to the use of a material obtainable by exposure of a phenolic resin to UV radiation to improve the roll-off angle of a substrate.

[0342] Embodiment 10. The use of any one of embodiments 7 to 9, characterized by exposing at least one of the aromatic component and the unsaturated component to UV radiation in the presence of oxygen.

[0343] Embodiment 11. The use of any one of embodiments 7 to 9, characterized by exposing at least one of the aromatic component and the unsaturated component to UV radiation in the presence of ozone.

[0344] Embodiment 12. The use of any one of embodiments 7 to 9, characterized by exposing at least one of the aromatic and unsaturated components to UV radiation in the presence of H2O2.

[0345] Embodiment 13. Use of a hydrophilic group-containing polymer to improve the roll-off angle of a substrate.

[0346] Embodiment 14. Use of a hydrophilic polymer to improve the roll-off angle of a substrate.

[0347] Embodiment 15. The use of any one of embodiments 1 to 14, wherein the substrate is a filter substrate.

[0348] Embodiment 16. The use of embodiment 15, wherein the filter substrate has a contact angle in the range of 90 degrees to 180 degrees with a 20 μL water droplet when the surface is immersed in toluene.

[0349] Embodiment 17. The use of embodiment 15, wherein the filter substrate has a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene.

[0350] The present invention is illustrated by the following examples, it being understood that the particular examples, materials, amounts and procedures are to be interpreted broadly in accordance with the scope and spirit of the invention as set forth herein. [Example]

[0351] material All purchased materials were used as received (i.e., without further purification). Unless otherwise specified, materials were purchased from Sigma Aldrich (St. Louis, MO). CHROMASOLV Isopropyl Alcohol (IPA) - 99.9% CHROMASOLV Toluene - 99.9% CHROMASOLV Ethyl Acetate - 99.9% Methyl alcohol-ACS Reagent-99.8% Ethyl alcohol (EtOH) Maleic anhydride - 99% H2O2 - 30% or 50% NH4OH-ACS Reagent-50% N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (also known as DYNASYLAN DAMO-T or DAMO-T) - Evonik Industries AG (Essen, Germany) ·DYNASYLAN SIVO 203-Evonik Industries AG(Essen,Germany) Tyzor 131 (Tyzor) HCl in isopropyl alcohol (IPA) - 0.05M Poly(2-hydroxyethyl methacrylate) (PHEM) - Scientific Polymer Products (Ontario, NY) - Mw = 20,000 Poly(2-ethyl-2-oxazoline) (P2E2O) - Mw = 50,000 Polyethyleneimine, branched (PEI-10K or PEI 10000) - Mw=25,000 - Mn=10,000 Polyethyleneimine, branched (PEI-600) - Mw=600 Poly(hydroxypropyl methacrylate) (PHPM) - Scientific Polymer Products (Ontario, NY) - Granular Poly(ethylene oxide) diamine terminated (PEO-NH2) - Scientific Polymer Products (Ontario, NY) - Mw=2000 Polystyrene-co-allyl alcohol (PS-co-AA) - 40 mol% Poly(acrylic acid) (PAA) ·Acrodur 950L-BASF Corporation(Florham Park, NJ) 3-Glycidyloxypropyl)trimethoxysilane Poly(ethylene glycol) diacrylate (PEGDA) Ultrapure water was produced by treating tap water with Millipore Elix 10UV and Millipore Milli-Q A10 modules, and had a resistance of 18.2 MΩ. * cm resistance. Diesel Fuel or Pump Fuel = Ultra-Low Sulfur Diesel (ULSD) meeting ASTM-D975. "Pump Fuel" indicates that the source ULSD was used as received from the fuel pump. Biodiesel = Soy-based biodiesel meeting ASTM-D6751 (Renewable Energy Group (REG), Inc., Mason City, IA).

[0352] Test Procedure Contact angle and roll-off angle The contact angle and roll-off angle of the substrate were measured using a DropMaster DM-701 contact angle meter (Kyowa Interface Science Co., Ltd.; Niiza, Japan) equipped with a tilt stage. Measurements were performed using a wide camera lens setting and calibrated using a 6 millimeter (mm) calibration standard with the FAMAS software package (Kyowa Interface Science Co., Ltd.; Niiza, Japan). Measurements were performed immediately after the droplet reached equilibrium on the surface (i.e., the contact angle and exposed droplet volume were constant for 1 minute). Measurements were performed with the droplet in contact with the substrate only; i.e., the droplet was not in contact with the surface supporting the substrate.

[0353] Water contact angles in toluene were measured using a 20 μL or 50 μL droplet of ultrapure water placed on a substrate sample immersed in toluene. Contact angles were measured using a tangent fit and calculated from the average of five independent measurements performed on different areas of the substrate.

[0354] The water roll-off angle in toluene was measured using a 20 μL or 50 μL droplet of ultrapure water placed on a substrate sample immersed in toluene. The stage was set to rotate through 90° at a rotation speed of 2 degrees per second (° / s). Rotation was stopped when the water droplet freely rotated away or when the rear contact line moved at least 0.4 millimeters (mm) relative to the media surface. The angle and time at which rotation stopped were measured; this angle is defined as the roll-off angle. If the droplet did not roll off before 90°, the value is reported as 90°. If the droplet rotated away during the deposition process, the value is reported as 1°. A representative image of a water droplet on a substrate sample immersed in toluene is shown in Figure 2. Reported values ​​were calculated from the average of five independent measurements performed on different areas of the media. Intentional depressions in the substrate (e.g., point-bonded depressions) were avoided. If the substrate had directional macrostructure (eg, roughness), the roll-off angle was measured in the direction that minimized the effect of the macrostructure.

[0355] Droplet Sizing Test A modified version of ISO 16332 was used to determine droplet sizing. A 10 liter (L) tank was used to feed a two-loop system in a multi-pass fashion, as shown in Figure 3. The main loop handled the majority of the flow, and the test loop, including the media holder, provided a slipstream away from the main loop. A manual backpressure valve was used to adjust the flow through the test media to a face velocity of 0.07 feet per minute (ft / min) for the duration of the test. This face velocity is typical for field applications.

[0356] Two-inch by two-inch square samples of each layer were cut and then packed into a multilayer media composite containing a loading layer, an efficiency layer, and a substrate sample. The substrate sample to be tested was positioned downstream of the efficiency layer, and the efficiency layer was positioned downstream of the loading layer. The loading and efficiency layers were thermally bonded sheets containing 20% ​​to 80% bicomponent binder fibers with fiber diameters of 5 μm to 50 μm and fiber lengths of 0.1 cm to 15 cm, glass fibers with fiber diameters of 0.1 microns to 30 microns and aspect ratios of 10 to 10,000, and pore sizes of 0.5 μm to 100 μm.

[0357] Once the multilayer media composite was filled, the media layers were held in a custom-made clear acrylic holder. Stainless steel 1 / 4-inch outside diameter (OD) tubing with National Pipe Thread Taper (NPT) fittings was used to deliver fuel into and out of the test loop. The holder was 6 inches by 4 inches, with a 1-inch by 1-inch sample window and a 1-inch by 4-inch by 3 / 4-inch channel on the downstream side of the media to allow coalesced droplets to exit the fuel fluid. As the droplets exited the fuel stream, they passed through a zone where a charge-coupled device (CCD) camera captured an image of the droplets. Image analysis software (Image J 1.47T, available on the World Wide Web at imagej.nih.gov) was used to analyze the captured images and determine droplet diameter. The measured droplet size was used for statistical analysis. The reported average droplet diameter was volume-weighted. D10 represents 10% of the droplets containing a total water volume less than D10 and 90% of the droplets containing a total water volume greater than D10. D50 represents 50% of the droplets containing a total water volume less than D50 and 50% of the droplets containing a total water volume greater than D50. D90 represents 90% of the droplets containing a total water volume less than D90 and 10% of the droplets containing a total water volume greater than D90.

[0358] Ultra-low sulfur diesel from Chevron Phillips Chemical (The Woodlands, TX) was used as the base fuel. Five percent (volume %) soybean biodiesel (Renewable Energy Group (REG), Inc., Mason City, IA) was added to the base fuel to form a fuel mixture. The surface tension of the fuel mixture was determined by the pendant drop method to be 21 ± 2 dynes per centimeter. The same batch of fuel mixture was used for all tests.

[0359] To test, the multilayer media composite was placed in a holder and the holder was filled with a fuel mixture. A face velocity of 0.07 ft / min was set and manually maintained for 10 minutes before introducing water.

[0360] A water-in-fuel emulsion was created by injecting water into the main fuel loop and forcing it through an orifice plate. A 1.8 mm plate was used to achieve the desired average 20 μm emulsion. The flow rate of the main loop was adjusted to achieve a differential pressure across the orifice plate of 5.0 pounds per square inch (psi) (approximately 1.2 liters per minute (Lpm)). Water was injected at a rate of 0.3 milliliters per minute (mL / min) with an initial target challenge of 2500 parts per million (ppm) of water. Fuel not carried into the test loop was sent through a cleanup filter before being directed back to the main tank, where it was again allowed to pass through the orifice. The system provided a consistent emulsion challenge to the multi-media composite over the 20-minute test period.

[0361] Fuel-water separation efficiency test Fuel-water separation efficiency testing was performed using the ISO / TS 16332 laboratory test method, modified as described herein.

[0362] To test flat sheets of media, an aluminum holder was used to hold a 7" x 7" sheet of filter media (effective diameter 6" x 6") sheet. On the downstream side of the filter media, a 100 μm polyester screen (effective diameter 6" x 6") was placed to ensure that coalesced water droplets larger than 100 μm in diameter were not carried downstream with the fuel flow.

[0363] The upstream water concentration in the fuel was set at 5000 ppm and assumed to be constant throughout the duration of the test. Such water concentration was determined by measuring the known flow rates of both the water injection pump and the fuel flow rate. The downstream water concentration was recorded at predetermined intervals. The water concentration was measured using the Karl-Fischer volumetric titration method using a commercially available Metrohm AG (Herisau, Switzerland) 841 Titrando titrator.

[0364] The droplet size distribution of the upstream free water was determined using a commercially available Malvern Instruments (Malvern, United Kingdom) Insitec SX droplet size analyzer equipped with a flow cell. For emulsified water tests, the droplet size distribution typically has a D50 of 10 μm±1 μm, and D10 and D90 of 3 μm and 25 μm, respectively.

[0365] Unless otherwise specified, the face velocity through the media was fixed at 0.05 feet per minute (fpm or ft / min) for all tests. The total test time was 15 minutes unless otherwise specified.

[0366] The percent separation efficiency of the media during the test was calculated as the ratio of the downstream water concentration to the upstream water concentration.

[0367] Breathability Test At least 38cm 2Samples were cut from the media and tested. The samples were placed on a TEXTEST® FX3310 (obtained from Textest AG, Schwerzenbach, Switzerland). The breathability through the media was measured using air, expressed in cubic feet (ft ) of air per square foot of media per minute at a pressure drop of 0.5 inches (1.27 cm) of water. 3 air / ft 2 cubic meters of air per square meter of medium per minute (m 3 air / m 2 The media / min) was measured.

[0368] Preparation method Example 1 - UV Treatment The UV-treated media layer was produced by exposing the downstream (wire-side) surface of the substrate to UV radiation. The UV source was a low-pressure mercury lamp (4" x 4" Standard Mercury Grid Lamp, BHK, Inc., Ontario, Canada). The low-pressure mercury lamp produces UV light at the following discrete wavelengths: 185 nm, 254 nm, 297 nm, 302 nm, 313 nm, 365 nm, and 366 nm. 4" x 4" samples were exposed to the lamp for 1 to 20 minutes. The sample shown in Figure 2 was exposed to the lamp for 20 minutes; samples used for water droplet sizing experiments were treated for 8 minutes. Samples were positioned approximately 1 cm below the lamp during treatment.

[0369] Samples of each substrate listed in Table 1 were UV treated with a low-pressure mercury lamp in the presence of atmospheric oxygen. Using the same batch of fuel, the D10, D50, and D90 of each substrate were measured before and after treatment. The results are shown in Table 2. The contact angles and roll-off angles (for 20 μL and 50 μL droplets in toluene) of each substrate before and after treatment are shown in Table 3.

[0370] UV-oxygen treatment with a low-pressure mercury lamp resulted in substrates that exhibited increased roll-off angles compared to untreated substrates. Enhancement of the D50 mean droplet size by at least two-fold was also observed, with the exception of Substrate 6, as shown in Table 2. Higher roll-off angles, measured using water droplets placed on substrate samples immersed in toluene (Table 3), correlate with the coalescence of larger droplets (D50 enhancement) by the substrate in diesel fuel (Tables 2 and 3). Because the roll-off angle correlates with the diameter of droplets that coalesce on the surface of the substrate, the roll-off angle can be used to identify substrates that have the ability to coalesce larger droplets that can exit the fuel stream.

[0371] Without wishing to be bound by theory, it is believed that the acrylic-based resin system of Substrate 6 does not allow for the necessary modification of the surface during exposure to UV radiation. Considering the ability of UV-oxygen treatment to enhance adhesion and droplet growth in 100% polyester and phenolic resin-containing media (Substrate 7 and Substrates 1-5, respectively), it is believed that aromatic moieties or other forms of carbon-carbon bond unsaturation may enhance the effect of UV-oxygen treatment of the substrate.

[0372] In contrast, when the low-pressure mercury lamp was equipped with either a UV bandpass filter (FSQ-UG5, Newport Corp., Irving, CA) that blocked wavelengths below about 220 nm and above about 400 nm, treated substrate 1 showed little or no change in roll-off angle or average droplet size compared to the untreated media.

[0373] Similarly, when substrates 1 and 7 were treated with a lamp emitting UV at wavelengths greater than 360 nm (Model F300S, Heraeus Noblelight Fusion UV Inc., Gaithersburg, MD), the treated substrates showed little or no change in average droplet size and a slight increase in roll-off angle compared to the untreated media.

[0374] [Table 1]

[0375] [Table 2]

[0376] [Table 3]

[0377] The ability of the (untreated and UV-oxygen treated) Substrate 1 samples to remove water from the fuel (i.e., media performance) was determined by measuring the downstream water content after 15 minutes. The results are shown in Figure 4. As can be seen from Figure 4, compared to the untreated Substrate 1, the UV-oxygen treated Substrate 1 demonstrated a significantly improved ability to remove water from the fuel and maintain a low downstream water content. This is consistent with the increased roll-off angle and enhanced D50 observed compared to the untreated substrate.

[0378] Substrate 1 samples (untreated and UV-oxygen treated) were immersed in 200 milliliters (mL) of pump fuel at 55°C for 30 days. Prior to testing, the control (unimmersed) and treated samples were washed with hexane and then heated in an oven at 80°C for 5 minutes to evaporate the hexane. Contact angles in toluene and roll-off angles in toluene were measured using 50 μL of ultrapure water placed on the toluene-immersed substrate samples. Measurements were performed as described above. Results are shown in Figure 5 and Table 4. The average roll-off and contact angles, as well as the corresponding ability to remove water from fuel, were maintained for the UV-oxygen treated substrates even after immersion in fuel for 30 days at 55°C, conditions that are encountered in some field applications and can accelerate substrate aging.

[0379] [Table 4]

[0380] Example 2 - UV / H2O2 Treatment Substrate 1 was cured by heating in a medium at 150°C for 10 minutes. The substrate was then immersed in a 50% HO solution contained in a shallow Petri dish (1 cm deep) and UV-treated with a low-pressure mercury lamp (4" x 4" Standard Mercury Grid Lamp, BHK, Inc., Ontario, Canada) for 0, 2, 4, 6, or 8 minutes. The substrate was then oven-dried at 80°C for 5 minutes.

[0381] The contact angle (CA) and roll-off angle (RO) in toluene of the treated and untreated sides of each substrate were measured using a 50 μL droplet of ultrapure water in toluene. The results are shown in Table 4 and Figure 6.

[0382] Example 3 - Comparative Example The contact angle and roll-off angle of a Cummins MO-608 fuel-water separating filter in toluene were tested using a 20 μL water droplet. The upstream side of the filter media had a contact angle of 143° and a roll-off angle of 19°. The downstream side of the filter media had a contact angle of 146° and a roll-off angle of 24°.

[0383] The contact angle and roll-off angle of an ACDelco TP3018 fuel-water separating filter in toluene were tested using a 20 μL water droplet. The upstream side of the filter media had a contact angle of 146° and a roll-off angle of 28°. The downstream side of the filter media had a reported roll-off angle of 1° (i.e., the droplet rolled off during the deposition process).

[0384] The contact angle and roll-off angle of a Ford F150 FD4615 fuel-water separating filter in toluene were tested using a 20 μL water droplet. The upstream side of the filter media had a contact angle of 149° and a roll-off angle of 10°. The downstream side of the filter media had a contact angle of 137° and a roll-off angle of 9°.

[0385] The contact angle and roll-off angle of a Donaldson P551063 fuel-water separating filter in toluene were tested using a 20 μL water droplet. The upstream side of the filter media had a contact angle of 157° and a roll-off angle of 22°. The downstream side of the filter media had a contact angle of 125° and a roll-off angle of 11°.

[0386] The contact angle and roll-off angle of polytetrafluoroethylene (PTFE) membranes in toluene were tested using a 50 μL water droplet. The membrane had a reported roll-off angle of 1° (i.e., the droplet rolled away during the deposition process), and it was not possible to stabilize the droplet to measure the contact angle. The contact angle was estimated to be at least 165°.

[0387] The contact angle and roll-off angle of a Komatsu 600-319-5611 fuel filter in toluene were tested using a 20 μL water droplet. The upstream side of the filter media had a contact angle of 150° and a roll-off angle of 3°. The downstream side of the filter media had a contact angle of 145° and a roll-off angle of 32°.

[0388] Example 4 - Polymer Coating by Dip Coating Substrate 1 (20% polyester / 80% cellulose media with a partially cured phenolic resin component) was coated with polymer using the polymer, concentration, and solvent shown in Table 5. Samples were dip-coated using a Chemat DipMaster 50 dip coater (Chemat Technology, Inc., Northridge, CA). The media was completely immersed in the polymer-containing solution and withdrawn at a rate of 50 mm / min. To ensure coating uniformity, the media was dip-coated, rotated 180 degrees, and dip-coated again (a total of two dip coats). The non-aqueous solvent was removed by oven drying at 80°C for 5 minutes, and the water was removed by oven drying at 100°C for 5 minutes.

[0389] To prepare a charged coating of PEI-600 (by quaternization) (see Table 5 (PEI-600 HCl)), Substrate 1 pre-coated with PEI-600 was dip-coated in HCl (0.05 M in IPA) using the dip-coating procedure described above. To prepare a PEI-10K + maleic anhydride coating (see Table 5), Substrate 1 pre-coated with PEI-10K was dip-coated with maleic anhydride using the dip-coating procedure described above.

[0390] After the dip-coating procedure was completed, a curing treatment was applied at 150°C for 10 minutes, followed by drying at 80°C for 5 minutes, to increase the stiffness of the medium and harden the partially cured phenolic resin.

[0391] The results are shown in Table 5 and Figure 8. Figure 2 shows representative images of a 20 μL water droplet on a PHPM-treated substrate (see Table 5) immersed in toluene at 0 degrees (0°) rotation (left) and 60° rotation (right).

[0392] As shown in Table 4, higher roll-off angles measured using water droplets deposited on substrate samples impregnated in toluene are associated with the coalescence of larger droplets (enhanced D50) by the substrate in diesel fuel. Because roll-off angle is related to the diameter of droplets that coalesce on the surface of the substrate, roll-off angle can be used to identify substrates with the ability to coalesce larger droplets that can exit the fuel stream. As shown in Figure 8, increased fuel-water separation efficiency was observed for PEI-10K coated substrates compared to untreated substrates, which is consistent with the observed increased roll-off angle and enhanced D50.

[0393] [Table 5]

[0394] [Table 6]

[0395] [Table 7]

[0396] [Table 8]

[0397] Example 5 - Effect of polymer coating on breathability Substrate 1 (20% polyester / 80% cellulose media with a partially cured phenolic resin component) was dip-coated with 2% (w / v) PHEM, 4% (w / v) PHEM, 6% (w / v) PHEM, or 8% (w / v) PHEM in methanol using a Chemat DipMaster 50 dip coater (Chemat Technology, Inc., Northridge, CA). The media was completely submerged in the polymer-containing solution and withdrawn at a speed of 50 mm / min. To ensure coating uniformity, the media was dip-coated, rotated 180 degrees, and dip-coated again (a total of two dip coats). The non-aqueous solvent was removed by oven drying at 80°C for 5 minutes, and the water was removed by oven drying at 100°C for 5 minutes.

[0398] After the dip coating procedure was completed and after drying at 80°C for 5 minutes, a curing treatment was applied at 150°C for 10 minutes.

[0399] Breathability was tested as described above, and the results are shown in Figure 9.

[0400] Example 6 - Polymer Coating by Dip Coating, Crosslinking and Annealing Substrate 1 (20% polyester / 80% cellulose media with a partially cured phenolic resin component, see Table 1) was coated with polymer using the polymers, concentrations, and solvents shown in Tables 6 and 7. Samples were dip-coated using a Chemat DipMaster 50 dip coater (Chemat Technology, Inc., Northridge, CA). The media was completely immersed in the polymer-containing solution and withdrawn at a rate of 50 mm / min. To ensure coating uniformity, the media was dip-coated, rotated 180 degrees, and dip-coated again (a total of two dip coats). The non-aqueous solvent was removed by oven drying at 80°C for 5 minutes, and the water was removed by oven drying at 100°C for 5 minutes.

[0401] After dip coating and / or before annealing, if performed, the media was oven dried at 80° C. for 5 minutes and then exposed to 150° C. for 5 minutes. Heating is believed to increase the stiffness of the media, harden the partially cured phenolic resin, and promote cross-linking of the cross-linking agent, if present.

[0402] If the polymer coating was to be annealed, after completion of the dip-coating procedure and heating, the media was immersed in hot (90°C) water for 1-2 minutes. After annealing, the media was oven dried at 100°C for 5 minutes.

[0403] Substrate 1 samples (untreated and polymer-coated) were immersed in 200 milliliters (mL) of pump fuel at 55°C for 13, 30, or 39 days (as shown in Figure 10 or Figure 11). Prior to testing, the control (unimmersed) and treated samples were washed with hexane and then heated in an oven at 80°C for 5 minutes to evaporate the hexane. Contact angles in toluene and roll-off angles in toluene were measured using 50 μL of ultrapure water placed on the substrate samples immersed in toluene. Measurements were performed as described above.

[0404] The results are shown in Figures 10 and 11. The average roll-off and contact angles, and the corresponding ability to remove water from fuel, were maintained for the crosslinked polymer-coated substrate and the crosslinked and annealed polymer-coated substrate even after immersion in fuel for 39 days at 55°C, conditions that are found in some field applications and can accelerate aging of the substrate.

[0405] [Table 9]

[0406] [Table 10]

[0407] Example 7 - Electrospun polymer coating Coatings were formed on Substrate 6 (see Table 1) by electrospinning a 10% polymer (w / v) solution using the conditions shown in Table 8. A methanol solution was used for poly(2-hydroxyethyl methacrylate) (PHEM), and an isopropyl alcohol (IPA) solution was used for PEI-10K. Coatings were formed with and without the presence of a crosslinker in the spinning solution. 0.5% (w / v) N-(2-aminoethyl)-3-aminopropyltrimethoxysilane (also referred to herein as DAMO-T) was used as the crosslinker for PHEM; 0.5% (w / v) (3-glycidyloxypropyl)trimethoxysilane (also referred to herein as crosslinker 1) or 0.5% (w / v) poly(ethylene glycol) diacrylate (PEGDA) (also referred to herein as crosslinker 2) was used as the crosslinker for PEI-10K.

[0408] The results are shown in Figures 12-15. The contact angle and roll-off angle of a 50 μL water droplet on PHEM-coated substrates with and without crosslinker were measured immediately after electrospinning and are shown in Figure 12. The contact angle and roll-off angle of a 50 μL water droplet on PEI-coated substrates with and without crosslinker were measured immediately after electrospinning and are shown in Figure 13.

[0409] Figure 14 shows the contact angle and roll-off angle of a 50 μL water droplet on a representative PHEM nanofiber-coated DAMO-T crosslinked substrate 6 1, 6, and 32 days after the electrospun coating was formed. The contact angle and roll-off angle 52 days after the electrospun coating was formed were similar to those observed 32 days after the electrospun coating was formed.

[0410] Figure 15 shows the contact angle and roll-off angle of a 50 μL water droplet on a representative PEI-10K nanofiber coated cross-linked substrate 6 1, 6, and 32 days after the electrospun coating was formed. The PEI was cross-linked using (3-glycidyloxypropyl)trimethoxysilane (cross-linker 1) or poly(ethylene glycol) diacrylate (PEGDA) (cross-linker 2). The contact angle and roll-off angle 52 days after the electrospun coating was formed were similar to those observed 32 days after the electrospun coating was formed.

[0411] Scanning electron microscopy (SEM) images of electrospun polymer-coated substrate 6 are shown in Figures 16, 17, and 18. As shown in Figure 16, electrospinning of PHEM results in the formation of PHEM nanofibers that coat the cellulose substrate. In contrast, as shown in Figures 17 and 18, PEI-10K does not form nanofibers on the substrate, but rather directly coats the cellulose fibers present on the substrate. These results indicate that the polymer coating created using electrospinning techniques can exist in the form of nanofibers or it can exist as a solid polymer coat on the substrate.

[0412] [Table 11]

[0413] The entire disclosures of all patents, patent applications, and publications cited herein, as well as electronically available materials, are incorporated by reference. In the event of any inconsistency between the disclosure of this application and the disclosure of any document incorporated herein by reference, the disclosure of this application shall control. The above detailed description and examples are given solely for clarity of understanding. No unnecessary limitations should be understood therefrom. The invention is not limited to the exact details shown and described; variations obvious to those skilled in the art will be within the scope of the invention as defined by the claims.

[0414] Unless otherwise indicated, all numerical values ​​expressing quantities of ingredients, molecular weights, and the like used in the specification and claims are to be understood as being modified in all instances by the term "about." Accordingly, unless otherwise indicated, the numerical parameters set forth in the specification and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of at least the number of reported significant digits and by applying ordinary rounding techniques.

[0415] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible, however, all numerical values ​​inherently contain ranges necessarily resulting from the standard deviation found in their respective testing measurements.

[0416] All headings are for the convenience of the reader and should not be used to limit the meaning of the text that follows the heading, unless so specified.

Claims

1. 1. A filter medium comprising a substrate, the substrate comprising: a surface having a roll-off angle in the range of 30 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene; The filter media, wherein the substrate comprises a UV-reactive resin that includes one or more of an aromatic component and an unsaturated component.

2. 10. The filter media of claim 1, wherein the surface has a roll-off angle in the range of 40 degrees to 90 degrees for a 50 μL water droplet when immersed in toluene.

3. 10. The filter media of claim 1, wherein the substrate comprises pores having an average diameter of up to 2 mm.

4. 1. A filter medium comprising a substrate, the substrate comprising: a surface having a roll-off angle in the range of 30 degrees to 90 degrees and a contact angle in the range of 90 degrees to 180 degrees with respect to a 50 μL water droplet when the surface is immersed in toluene; the substrate comprises a UV-reactive resin that includes an aromatic component, an unsaturated component, or both; A filter medium wherein the substrate comprises pores having an average diameter of at least 20 μm.

5. 5. The filter media of claim 4, wherein the UV-reactive resin comprises a phenolic resin, an acrylic resin, or both.

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