WO2008039377A1 - Filter media arrangement, filter cartridge, and methods - Google Patents

Filter media arrangement, filter cartridge, and methods Download PDF

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Publication number
WO2008039377A1
WO2008039377A1 PCT/US2007/020500 US2007020500W WO2008039377A1 WO 2008039377 A1 WO2008039377 A1 WO 2008039377A1 US 2007020500 W US2007020500 W US 2007020500W WO 2008039377 A1 WO2008039377 A1 WO 2008039377A1
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WO
WIPO (PCT)
Prior art keywords
media
filter
screen
inch
corrugations
Prior art date
Application number
PCT/US2007/020500
Other languages
French (fr)
Inventor
Reynold Frederick Durre
Prosper Ngwerume
Original Assignee
Donaldson Company, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Donaldson Company, Inc. filed Critical Donaldson Company, Inc.
Publication of WO2008039377A1 publication Critical patent/WO2008039377A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
    • B01D29/13—Supported filter elements
    • B01D29/15—Supported filter elements arranged for inward flow filtration
    • B01D29/21—Supported filter elements arranged for inward flow filtration with corrugated, folded or wound sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/62—Regenerating the filter material in the filter
    • B01D29/66—Regenerating the filter material in the filter by flushing, e.g. counter-current air-bumps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2201/00—Details relating to filtering apparatus
    • B01D2201/12—Pleated filters

Definitions

  • This disclosure concerns filter media, filter cartridges, and methods.
  • this disclosure relates to filter media, methods for making the media, and filter cartridges which utilize the media, the filtration being used mainly for liquids such as liquids for hydraulic systems, engine lubrication systems, and fuel systems.
  • Filters have been employed in a variety of applications including hydraulic systems, engine lubrication systems, and fuel systems.
  • Such filter assemblies generally include a tubular or cylindrical filter element within a can or housing. Liquid to be filtered flows into the housing, through the filter media in the element, and then exits the housing.
  • a filter media arrangement including a layer of filter media and a layer of woven wire screen secured together into a media/screen construction.
  • the media/screen construction has first and second opposite ends. At least the screen includes corrugations.
  • the media/screen construction includes pleats. The pleats run generally between the first and second ends and are angled relative to the corrugations. The pleats are generally 90° relative to the first and second ends.
  • This filter media arrangement can then be formed into a filter element by, for example, forming the construction into a tubular or cylindrical shape with the wire screen along the interior, for forward flow systems (that is, the wire screen is on the downstream side of the media construction).
  • the wire screen would preferably be oriented along the outside of the tubular or cylindrical construction, again, being on the downstream side of the flow path of the fluid.
  • the tubular construction of media can be mounted or secured between two opposite end caps and then mounted within a filter housing. In many arrangements, no hot melt beads are needed to support the pleats, i.e., the element is bead-free.
  • a method of making a filter media arrangement includes providing a sheet of flat filter media; securing a wire screen to the filter media to create a media/screen construction; corrugating at least the screen; and then pleating the corrugated media/screen construction angled to a direction of corrugations.
  • the media/screen construction is corrugated.
  • FIG. 1 is a schematic, side elevational view of a first step in a method of making filter media, in accordance with principles of this disclosure
  • FIG. 2 is a schematic, side elevational view of another step in a method of making filter media, in accordance with principles of this disclosure
  • FIG. 3 is a schematic, side elevational view of another step of making filter media, in accordance with principles of this disclosure.
  • FIG. 4 is a schematic, perspective view of another step of making filter media, according to principles of this disclosure.
  • FIG. 4A is a perspective photograph of the filter media depicted in FIG. 4, constructed according to principles of this disclosure
  • FIG. 5 is a schematic, cross-sectional view of a filter cartridge having a filter element constructed from filter media of the type depicted in FIGS. 4 and 4 A;
  • FIG. 6 is a schematic, cross-sectional view of a pleat of an alternate embodiment of the filter media, constructed according to principles of this disclosure
  • FIG. 7 is a schematic, cross-sectional view of a pair of pleats of the embodiment of the filter media depicted in FIG. 6.
  • DETAILED DESCRIPTION A Some Problems With Existinfi Arrangements
  • U.S. Patent No. 4,102,792 to Harris also describes, among other things, filter material with continuous lines of corrugations at right angles to the pleats.
  • a media support such as a wire screen
  • the flow channels on the wire screen side can have higher restriction than desired because the wire screen does not conform closely with the corrugated media. Recognition of this problem has led to the solution shown in FIGS. 1 - 7.
  • FIG. 5 illustrates a filter cartridge 10.
  • the filter cartridge 10 includes a housing 14 defining an interior volume 18. Within the interior volume 18 of the housing 14 is mounted a filter element 20.
  • the filter element 20 includes a filter media arrangement 22 constructed according to principles of this disclosure.
  • the filter element 20 is a tubular construction 26 defining an open interior 28.
  • the tubular construction 26 is cylindrical. Still in reference to FIG. 5, in this embodiment, the tubular construction 26 is illustrated as being pleated media 32 with the pleat length extending between a first end cap 36 and a second end cap 38. Still in reference to FIG. 5, in this particular illustration, the filter cartridge
  • spin-on cartridge 40 is depicted as a spin-on cartridge 40. It should be understood that the media arrangement 22 can be made into elements 20 that are useable in other types of arrangements such as bowl-cartridge filters.
  • Spin-on cartridges 40 are disposable units, which include a single-use housing holding a permanently mounted, non- replaceable filter element 20. The housing 14 or canister is typically spun onto a filter head by threaded engagement.
  • the spin- on cartridge 40 includes a baffle plate 42 secured to the housing 14.
  • the baffle plate 42 defines a central hub 44, which includes threads 46 for engagement with a suitably threaded filter head.
  • the baffle plate 42 further includes an inlet arrangement 48, typically embodied by a plurality of inlet apertures or holes through the baffle plate 42, and an outlet arrangement 50, embodied in FIG. 5 as a central aperture defined by the hub 44.
  • forward flow it is meant that the fluid to be filtered enters the cartridge 10 through the inlet arrangement 48, flows into the volume 52 between the housing 14 and the tubular construction 26, then flows through the pleated media 32, flows into the open interior 28, and then exits the filter cartridge 10 through the outlet arrangement 50. It is possible to operate the filter cartridge 10 in a reverse-flow manner, in which the arrangement 50 operates as an inlet, and the arrangement 48 operates as an outlet.
  • the filter element 20 defines an upstream side at 54 and a downstream side at 56.
  • the downstream side 56 in this embodiment, forms a boundary to the open interior 28.
  • the downstream side 56 is also the side depicted as having a wire screen 58 circumscribing and defining the open interior 28.
  • the downstream side would be at 54, while the upstream would be at 56.
  • the media arrangement 22 and wire screen 58 can be supported by an inner filter support or liner 59.
  • the inner liner 59 can be perforated or expanded metal.
  • the inner liner 59 extends between the first end cap 36 and second end 38 and is downstream of the wire screen 58.
  • the media arrangement 22 includes pleats that run the length between the first end cap 36 and the second end cap 38. Angled relative to the pleat lengths, the media arrangement 22 is corrugated. The combined corrugation and pleating of the media arrangement 22 results in flow channels on both the upstream side 54 and the downstream side 56 that have less restriction than prior art arrangements in which the wire screen 58 is not corrugated. There is improved utilization of the media arrangement 22 for dirt loading, and the pleats are less likely to bunch up or collapse than with prior arrangements.
  • FIGS. 1 - 3 a method for making the media arrangement 22 is illustrated.
  • a layer or sheet of filter media 60 is provided.
  • the filter media 60 can be many types of media, such as cellulose, synthetic, or blends thereof.
  • One useable type of media 60 includes the following synthetic media, available from, for example, Hollingsworth and Vose Company, East Walpole, MA: Efficiency Ratings Per ISO 16889 Test Standards
  • Beta 4 ( C ) 200 signifies that there are 200 times as many particles that are 4 ⁇ m and larger upstream as downstream. This is 99.5% efficiency.
  • a wire screen 62 is secured to the media 60 to create a media/screen construction 64.
  • the wire screen 62 is illustrated as being a woven wire screen.
  • a variety of types of screen 62 are useable, and one useable woven wire screen includes: a wire having a diameter of 0.010 in. with a pattern of 10 wires/in, by 12-18 wires/in., available from, for example, New York Wire, Mount Wolf, PA.
  • the wire screen 62 can be secured to the media 60 in a variety of manners.
  • the wire screen 62 can be glued to the media 60 using paste or adhesive or otherwise mechanically or ultrasonically secured.
  • the construction 64 is corrugated. This can be done by placing the media/screen construction 64 between a pair of corrugation rollers, for example.
  • the wire screen 62 can be corrugated alone and then secured to the media 60.
  • the media/screen construction 64 is transformed into a corrugated media/screen construction 66, illustrated at FIG. 3.
  • the corrugations are shown as a plurality of generally smooth waves 68 having a height h, which can vary depending upon the application.
  • the corrugation waves 68 have a height of 0.02 inch to 0.10 inch.
  • the corrugation waves are of uniform size, including both uniform height h and length. In such constructions, there can be, for example, 3 - 7 corrugation waves 68 per inch, although other sizes are useable.
  • FIGS. 6 and 7 illustrate alternative corrugation patterns for the corrugated media/screen construction 66'.
  • the corrugation waves 68' have varying wave lengths.
  • FIG. 6 also illustrates the waves 68' as having varying heights.
  • the corrugation waves can have uniform heights and varying lengths; in some arrangements, the corrugation waves can have varying heights and uniform lengths; and in some arrangements, such as the particular one shown in FIG. 6, the corrugation waves 68' can have both varying heights and varying lengths.
  • the corrugation waves 68' can have both varying heights and varying lengths.
  • the wave pattern is "regular” in that there is a repeating pattern, but it is "non-uniform” in that the height and length of each wave is not equal to each other.
  • the FIG. 6 embodiment shows a regular non-uniform wave pattern 168.
  • the regular non-uniform wave pattern 168 is two alternating sizes of waves, a first wave being tall in height and short in length, while the second wave being short in height and long in length — with the terms short, tall, and long being relative as measured against the other wave size.
  • the first wave has a first height greater than a height of the second wave; the first wave has a first length less than a length of the second wave; the second wave has a height less than the first height of the first wave; and the second wave has a length greater than the first length of the first wave.
  • FIG. 6 embodiment illustrates a single pleat and how, in this embodiment, the corrugation waves 68' are aligned.
  • the corrugation waves 68' are aligned with the matching pattern of the wave along the line of symmetry "x" that corresponds to the pleat.
  • FIG. 7 shows two pleats 201, 202 and their alignment. Again, there is a line of symmetry x' between the two pleats 201, 202.
  • the particular wave pattern of FIGS. 6 and 7 can result in advantages. For example, on the upstream side of the media/screen construction 66, there is fewer contact points (i.e. media blinding that blocks throughflow) than the prior art configuration. On the downstream side of the media/screen construction 66, there is increased contact points leading to stiffness, than the prior art configuration.
  • both the media 60 and the wire screen 62 are corrugated together. This is what is illustrated in FIG. 3 at 66.
  • the corrugated media/screen construction 66 is then pleated in a direction angled relative to the direction of corrugation. In the embodiment illustrated, the corrugated media/screen construction 66 is pleated such that the pleats run 90° relative to the direction of corrugation.
  • the wire screen 62 can be corrugated alone, and then secured to the media 60.
  • FIG. 4 shows the pleated construction 70.
  • the pleated construction 70 defines first and second opposite ends 74, 76.
  • the pleats 72 have a length 1 running from the first end 74 to the second end 76.
  • the corrugation waves can be angled relative to the first and second ends 74, 76, in the embodiment illustrated in FIG. 4, the corrugation waves run generally parallel to the first and second ends 74, 76.
  • the pleated construction 70 includes a plurality of pleats 72 having a length 1.
  • the pleat length 1 is generally angled relative to the corrugated media waves 68.
  • the pleats are perpendicular (90°) relative to the first and second ends 74, 76 and the corrugated media waves 68.
  • the pleats 72 also define a pleat height or depth d.
  • each pleat has a depth or height of 0.25 inch to 2 inch, for example, about 0.4 -1.0 inch.
  • the pleat density will be about 5 - 12 pleats per inch, for example, about 8 - 9 pleats/inch.
  • each pleat may have a height that is at least 20 times larger than each corrugation height.
  • FIG. 4A depicts a photograph of the schematic depiction of the pleated construction 70 of FIG. 4.
  • the pleated construction 70 is then formed into the tubular construction 26 illustrated in FIG. 5. Because the embodiment in FIG. 5 is shown in a forward flow arrangement, the wire screen 58 is shown adjacent to the open interior 28.
  • the wire screen 62 in FIGS. 2 and 3 would correspond to the wire screen 58 in FIG. 5.

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

Abstract

A filter arrangement includes a layer of media and a layer of woven wire screen secured together into a media/screen construction, in which there are corrugations and pleats angled relative to the corrugations. Either only the screen is corrugated, or both the media and screen are corrugated. The filter media arrangement is useable in a filter cartridge. A method of making a filter media arrangement includes providing a sheet of flat filter media; securing a wire screen to the filter media to create a media/screen construction; corrugating the at least the wire screen; and pleating the media/screen construction angled to a direction of the corrugations.

Description

FILTER MEDIA ARRANGEMENT. FILTER CARTRIDGE, AND METHODS
This application is being filed on 21 September 2007 as a PCT International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and
Reynold Frederick Durre, a citizen of the U.S., and Prosper Ngwerume, a citizen of Zimbabwe, applicants for the designation of the US only, and claims priority to U.S. Provisional Patent Application No. 60/827,157, filed September 27, 2006.
TECHNICAL FIELD
This disclosure concerns filter media, filter cartridges, and methods. In particular, this disclosure relates to filter media, methods for making the media, and filter cartridges which utilize the media, the filtration being used mainly for liquids such as liquids for hydraulic systems, engine lubrication systems, and fuel systems.
BACKGROUND
Filters have been employed in a variety of applications including hydraulic systems, engine lubrication systems, and fuel systems. Such filter assemblies generally include a tubular or cylindrical filter element within a can or housing. Liquid to be filtered flows into the housing, through the filter media in the element, and then exits the housing.
Various models and designs of filter media, filters, and methods of making have been known over the years. Many designs improve on various aspects. Continued improvements are desired.
SUMMARY OF THE DISCLOSURE
A filter media arrangement is provided including a layer of filter media and a layer of woven wire screen secured together into a media/screen construction. The media/screen construction has first and second opposite ends. At least the screen includes corrugations. The media/screen construction includes pleats. The pleats run generally between the first and second ends and are angled relative to the corrugations. The pleats are generally 90° relative to the first and second ends.
This filter media arrangement can then be formed into a filter element by, for example, forming the construction into a tubular or cylindrical shape with the wire screen along the interior, for forward flow systems (that is, the wire screen is on the downstream side of the media construction). In reverse-flow systems, the wire screen would preferably be oriented along the outside of the tubular or cylindrical construction, again, being on the downstream side of the flow path of the fluid. The tubular construction of media can be mounted or secured between two opposite end caps and then mounted within a filter housing. In many arrangements, no hot melt beads are needed to support the pleats, i.e., the element is bead-free.
A method of making a filter media arrangement includes providing a sheet of flat filter media; securing a wire screen to the filter media to create a media/screen construction; corrugating at least the screen; and then pleating the corrugated media/screen construction angled to a direction of corrugations. In some implementations, the media/screen construction is corrugated.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic, side elevational view of a first step in a method of making filter media, in accordance with principles of this disclosure;
FIG. 2 is a schematic, side elevational view of another step in a method of making filter media, in accordance with principles of this disclosure;
FIG. 3 is a schematic, side elevational view of another step of making filter media, in accordance with principles of this disclosure;
FIG. 4 is a schematic, perspective view of another step of making filter media, according to principles of this disclosure;
FIG. 4A is a perspective photograph of the filter media depicted in FIG. 4, constructed according to principles of this disclosure; FIG. 5 is a schematic, cross-sectional view of a filter cartridge having a filter element constructed from filter media of the type depicted in FIGS. 4 and 4 A;
FIG. 6 is a schematic, cross-sectional view of a pleat of an alternate embodiment of the filter media, constructed according to principles of this disclosure; and FIG. 7 is a schematic, cross-sectional view of a pair of pleats of the embodiment of the filter media depicted in FIG. 6. DETAILED DESCRIPTION A. Some Problems With Existinfi Arrangements U.S. Patent No. 3,062,378 to Briggs, incorporated herein by reference, discloses, among other things, taking a fibrous sheet paper stock, forming corrugations, and then forming pleats 90° relative to the direction of corrugation. U.S. Patent No. 4,102,792 to Harris also describes, among other things, filter material with continuous lines of corrugations at right angles to the pleats.
In these types of constructions, and in other types of prior art constructions, a media support such as a wire screen, can be secured to the corrugated media before providing pleats. In these types of arrangements, the flow channels on the wire screen side can have higher restriction than desired because the wire screen does not conform closely with the corrugated media. Recognition of this problem has led to the solution shown in FIGS. 1 - 7.
B. The Embodiment of FIGS. 1 - 7
FIG. 5 illustrates a filter cartridge 10. The filter cartridge 10 includes a housing 14 defining an interior volume 18. Within the interior volume 18 of the housing 14 is mounted a filter element 20. The filter element 20 includes a filter media arrangement 22 constructed according to principles of this disclosure. In the embodiment shown, the filter element 20 is a tubular construction 26 defining an open interior 28. In the particular embodiment shown, the tubular construction 26 is cylindrical. Still in reference to FIG. 5, in this embodiment, the tubular construction 26 is illustrated as being pleated media 32 with the pleat length extending between a first end cap 36 and a second end cap 38. Still in reference to FIG. 5, in this particular illustration, the filter cartridge
10 is depicted as a spin-on cartridge 40. It should be understood that the media arrangement 22 can be made into elements 20 that are useable in other types of arrangements such as bowl-cartridge filters. Spin-on cartridges 40 are disposable units, which include a single-use housing holding a permanently mounted, non- replaceable filter element 20. The housing 14 or canister is typically spun onto a filter head by threaded engagement. In the embodiment shown in FIG. 5, the spin- on cartridge 40 includes a baffle plate 42 secured to the housing 14. The baffle plate 42 defines a central hub 44, which includes threads 46 for engagement with a suitably threaded filter head. The baffle plate 42 further includes an inlet arrangement 48, typically embodied by a plurality of inlet apertures or holes through the baffle plate 42, and an outlet arrangement 50, embodied in FIG. 5 as a central aperture defined by the hub 44. When the inlet arrangement is at 48 and the outlet arrangement is at 50, the filter cartridge 10 operates in a forward flow operation. By forward flow, it is meant that the fluid to be filtered enters the cartridge 10 through the inlet arrangement 48, flows into the volume 52 between the housing 14 and the tubular construction 26, then flows through the pleated media 32, flows into the open interior 28, and then exits the filter cartridge 10 through the outlet arrangement 50. It is possible to operate the filter cartridge 10 in a reverse-flow manner, in which the arrangement 50 operates as an inlet, and the arrangement 48 operates as an outlet.
Still in reference to FIG. 5, when the filter cartridge 10 is arranged in a forward-flow manner, the filter element 20 defines an upstream side at 54 and a downstream side at 56. The downstream side 56, in this embodiment, forms a boundary to the open interior 28. In such a system, the downstream side 56 is also the side depicted as having a wire screen 58 circumscribing and defining the open interior 28. In reverse-flow systems, the downstream side would be at 54, while the upstream would be at 56. In a reverse-flow system, it would be desirable to have the wire screen 58 at the downstream side, which, in a reverse-flow system, would correspond to the side opposite of the open interior 28, this being side 54. The embodiment of FIG. 5 additionally shows the media arrangement 22 and wire screen 58 can be supported by an inner filter support or liner 59. The inner liner 59 can be perforated or expanded metal. In the FIG. 5 embodiment, the inner liner 59 extends between the first end cap 36 and second end 38 and is downstream of the wire screen 58.
In FIG. 5, the media arrangement 22 includes pleats that run the length between the first end cap 36 and the second end cap 38. Angled relative to the pleat lengths, the media arrangement 22 is corrugated. The combined corrugation and pleating of the media arrangement 22 results in flow channels on both the upstream side 54 and the downstream side 56 that have less restriction than prior art arrangements in which the wire screen 58 is not corrugated. There is improved utilization of the media arrangement 22 for dirt loading, and the pleats are less likely to bunch up or collapse than with prior arrangements. Turning now to FIGS. 1 - 3, a method for making the media arrangement 22 is illustrated. In FIG. 1, a layer or sheet of filter media 60 is provided. The filter media 60 can be many types of media, such as cellulose, synthetic, or blends thereof.
One useable type of media 60 includes the following synthetic media, available from, for example, Hollingsworth and Vose Company, East Walpole, MA: Efficiency Ratings Per ISO 16889 Test Standards
Media Number Betax(c)=200 Betax(c)=1000
No. V2 <3μm(c) <3μm(c)
No. 1 4μm(c) 6μm(c)
No. 2 5μm(c) 9μm(c)
No. 2'/2 8μm(C) 10μm(c)
No. 3 12μm(c) 14μm(c)
No. 4 15μm(c) 20μm(c)
No. 6 10μm(c) 13μm(c)
No.9 18μm(c) 23μm(c)
No. 16 16μm(c) 22μm(c)
No.20 >50μni(C) >50μm(C)
For ISO 16889, the beta ratings for 200 is an efficiency of 99.5%; and for 1000, an efficiency at 99.9%. For example, a Beta4(C) = 200 signifies that there are 200 times as many particles that are 4μm and larger upstream as downstream. This is 99.5% efficiency.
In FIG. 2, a wire screen 62 is secured to the media 60 to create a media/screen construction 64. The wire screen 62 is illustrated as being a woven wire screen. A variety of types of screen 62 are useable, and one useable woven wire screen includes: a wire having a diameter of 0.010 in. with a pattern of 10 wires/in, by 12-18 wires/in., available from, for example, New York Wire, Mount Wolf, PA.
The wire screen 62 can be secured to the media 60 in a variety of manners. For example, the wire screen 62 can be glued to the media 60 using paste or adhesive or otherwise mechanically or ultrasonically secured.
In this particular embodiment, after the media/screen construction 64 is created, the construction 64 is corrugated. This can be done by placing the media/screen construction 64 between a pair of corrugation rollers, for example. In other implementations, the wire screen 62 can be corrugated alone and then secured to the media 60.
After corrugation, the media/screen construction 64 is transformed into a corrugated media/screen construction 66, illustrated at FIG. 3. In FIG. 3, the corrugations are shown as a plurality of generally smooth waves 68 having a height h, which can vary depending upon the application. In many typical embodiments, the corrugation waves 68 have a height of 0.02 inch to 0.10 inch. In some constructions, as the particular one shown in FIG. 3, the corrugation waves are of uniform size, including both uniform height h and length. In such constructions, there can be, for example, 3 - 7 corrugation waves 68 per inch, although other sizes are useable.
The embodiment of FIGS. 6 and 7 illustrate alternative corrugation patterns for the corrugated media/screen construction 66'. In FIG. 6, the corrugation waves 68' have varying wave lengths. FIG. 6 also illustrates the waves 68' as having varying heights. In some arrangements, the corrugation waves can have uniform heights and varying lengths; in some arrangements, the corrugation waves can have varying heights and uniform lengths; and in some arrangements, such as the particular one shown in FIG. 6, the corrugation waves 68' can have both varying heights and varying lengths. In the FIG. 6 arrangement, the wave pattern is "regular" in that there is a repeating pattern, but it is "non-uniform" in that the height and length of each wave is not equal to each other. As such, the FIG. 6 embodiment shows a regular non-uniform wave pattern 168.
In the particular illustration, the regular non-uniform wave pattern 168 is two alternating sizes of waves, a first wave being tall in height and short in length, while the second wave being short in height and long in length — with the terms short, tall, and long being relative as measured against the other wave size. In other words, the first wave has a first height greater than a height of the second wave; the first wave has a first length less than a length of the second wave; the second wave has a height less than the first height of the first wave; and the second wave has a length greater than the first length of the first wave.
The FIG. 6 embodiment illustrates a single pleat and how, in this embodiment, the corrugation waves 68' are aligned. The corrugation waves 68' are aligned with the matching pattern of the wave along the line of symmetry "x" that corresponds to the pleat. FIG. 7 shows two pleats 201, 202 and their alignment. Again, there is a line of symmetry x' between the two pleats 201, 202.
The particular wave pattern of FIGS. 6 and 7 can result in advantages. For example, on the upstream side of the media/screen construction 66, there is fewer contact points (i.e. media blinding that blocks throughflow) than the prior art configuration. On the downstream side of the media/screen construction 66, there is increased contact points leading to stiffness, than the prior art configuration.
Because the wire screen 62 is secured to the media 60 before placing the media/screen construction 64 between the corrugation rollers, both the media 60 and the wire screen 62 are corrugated together. This is what is illustrated in FIG. 3 at 66. The corrugated media/screen construction 66 is then pleated in a direction angled relative to the direction of corrugation. In the embodiment illustrated, the corrugated media/screen construction 66 is pleated such that the pleats run 90° relative to the direction of corrugation. Alternatively, the wire screen 62 can be corrugated alone, and then secured to the media 60.
FIG. 4 shows the pleated construction 70. The pleated construction 70 defines first and second opposite ends 74, 76. In the embodiment illustrated, the pleats 72 have a length 1 running from the first end 74 to the second end 76. Although in other embodiments, the corrugation waves can be angled relative to the first and second ends 74, 76, in the embodiment illustrated in FIG. 4, the corrugation waves run generally parallel to the first and second ends 74, 76. The pleated construction 70 includes a plurality of pleats 72 having a length 1. The pleat length 1 is generally angled relative to the corrugated media waves 68. In the particular example illustrated, the pleats are perpendicular (90°) relative to the first and second ends 74, 76 and the corrugated media waves 68. The pleats 72 also define a pleat height or depth d. Typically, each pleat has a depth or height of 0.25 inch to 2 inch, for example, about 0.4 -1.0 inch. Typically, the pleat density will be about 5 - 12 pleats per inch, for example, about 8 - 9 pleats/inch. In some embodiments, each pleat may have a height that is at least 20 times larger than each corrugation height.
FIG. 4A depicts a photograph of the schematic depiction of the pleated construction 70 of FIG. 4. The pleated construction 70 is then formed into the tubular construction 26 illustrated in FIG. 5. Because the embodiment in FIG. 5 is shown in a forward flow arrangement, the wire screen 58 is shown adjacent to the open interior 28. The wire screen 62 in FIGS. 2 and 3 would correspond to the wire screen 58 in FIG. 5.

Claims

What is claimed is:
1. A filter media arrangement comprising:
(a) a layer of filter media and a layer of wire screen secured together into a media/screen construction;
(b) the media/screen construction having first and second opposite ends; the filter media arrangement characterized in that:
(c) at least the wire screen includes corrugations; and
(d) the media/screen construction includes pleats angled relative to the corrugations and extending between the first and second ends; the pleats being 90° relative to the first and second ends.
2. A filter media arrangement according to claim 1 wherein:
(a) the media/screen construction has a pleat density of 5-10 pleats per inch.
3. A filter media arrangement according to any one of claims 1 and 2 wherein: (a) the wire screen has 3-7 corrugations per inch.
4. A filter media arrangement according to any one of claims 1-3 wherein: (a) each pleat has a height of 0.25 inch to 1 inch.
5. A filter media arrangement according to any one of claims 1-4 wherein: (a) each corrugation has a height of 0.02 inch to 0.08 inch.
6. A filter media arrangement according to any one of claims 1-5 wherein: (a) each pleat has a height that is at least 20 times larger than each corrugation height.
7. A filter media arrangement according to any one of claims 1-6 wherein:
(a) the layer of filter media comprises cellulose, synthetic, or blends thereof; and
(b) the woven wire screen comprises a wire having a pattern of 10 wires/in, by 12-18 wires/in.
8. A filter media arrangement according to any one of claims 1-7 wherein:
(a) the media/screen construction includes corrugations generally parallel to the first and second ends.
9. A filter media arrangement according to any one of claims 1-7 wherein:
(a) at least the wire screen includes corrugations generally parallel to the first and second ends.
10. A filter media arrangement according to any one of claims 1-9 wherein: (a) the pleats are generally 90° relative to the corrugations.
11. A filter cartridge comprising a filter element having first and second opposite ends and comprising a pleated, tubular media arrangement including a layer of filter media and a layer of woven wire screen secured together into a media/screen construction; the media/screen construction including pleats extending between the first and second ends; the filter cartridge being characterized in that:
(a) at least the screen includes corrugations angled relative to the pleats.
12. A filter cartridge according to claim 11 wherein:
(a) the media/screen construction has a pleat density of 5- 10 pleats per inch.
(b) the screen construction has 3-7 corrugations per inch;
(c) each pleat has a height of 0.25 inch to 1 inch; and
(d) each corrugation has a height of 0.02 inch to 0.08 inch.
13. A filter cartridge according to any one of claims 1 1 and 12 wherein:
(a) the media/screen construction includes corrugations 90° to the pleats.
14. A filter cartridge according to any one of claims 1 1 and 12 wherein: (a) the screen includes corrugations 90° to the pleats.
15. A filter cartridge according to any one of claims 1 1-14 wherein:
(a) the filter element includes first and second end caps; the pleated, tubular media extending between the first and second end caps.
16. A filter cartridge according to any one of claims 1 1-15 further comprising: (a) a housing defining an interior volume;
(i) the filter element being operable mounted within the interior volume.
17. A filter cartridge according to claim 16 further including:
(a) a baffle plate including an inlet arrangement, an outlet arrangement, and a threaded hub to permit the filter cartridge to be threadably mounted onto a filter head.
18. A method of making a filter media arrangement; the method comprising providing a sheet of flat filter media; securing a wire screen to the filter media to create a media/screen construction; the method further characterizing:
(a) corrugating at least the wire screen; and
(b) after the step of corrugating, pleating the media/screen construction angled relative to a direction of corrugations.
19. A method according to claim 18 wherein:
(a) the step of corrugating includes corrugating only the wire screen and is done before the step of securing.
20. A method according to claim 18 wherein:
(a) the step of corrugating includes corrugating both the wire screen and the media and is done after the step of securing.
21. A method according to any one of claims 18-20 wherein:
(a) the step of corrugating includes providing 3-7 corrugations per inch, with each corrugation having a height of 0.02 inch to 0.08 inch.
22. A method according to any one of claims 18-21 wherein:
(a) the step of pleating includes providing 5-10 pleats per inch, with each pleat having a height of 0.25 inch to 1 inch.
23. A method according to any one of claims 18-22 further comprising:
(a) after the step of pleating, forming a tubular construction of media.
24. A method according to any one of claims 18-23 wherein:
(a) the step of pleating includes pleating the media/screen construction angled 90° relative to a direction of corrugations.
PCT/US2007/020500 2006-09-27 2007-09-21 Filter media arrangement, filter cartridge, and methods WO2008039377A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US82715706P 2006-09-27 2006-09-27
US60/827,157 2006-09-27

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ITMO20130153A1 (en) * 2013-05-30 2014-12-01 Rand Srl FILTER FOR THE FILTRATION OF ORGANIC FLUIDS
US9579592B2 (en) 2015-04-06 2017-02-28 Pall Corporation Filter elements
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WO2018177618A1 (en) * 2017-03-29 2018-10-04 Mahle International Gmbh Filter element for a fluid filter, fluid filter and method for producing a filter element
US10357729B2 (en) 2012-03-09 2019-07-23 Ahlstrom-Munksjö Oyj High efficiency and high capacity glass-free fuel filtration media and fuel filters and methods employing the same
JP2021090955A (en) * 2019-12-09 2021-06-17 ポール・コーポレーションＰａｌｌ Ｃｏｒｐｏｒａｔｉｏｎ Filter element, filter, filter device and using method

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US9662600B2 (en) 2012-03-09 2017-05-30 Ahlstrom Corporation High efficiency and high capacity glass-free fuel filtration media and fuel filters and methods employing the same
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ITMO20130153A1 (en) * 2013-05-30 2014-12-01 Rand Srl FILTER FOR THE FILTRATION OF ORGANIC FLUIDS
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JP2021090955A (en) * 2019-12-09 2021-06-17 ポール・コーポレーションＰａｌｌ Ｃｏｒｐｏｒａｔｉｏｎ Filter element, filter, filter device and using method
JP7259166B2 (en) 2019-12-09 2023-04-18 ポール・コーポレーション Filter element, filter, filter device and method of use

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