Pleated fluid filter element and methods

Patent metadata

Field	Value
Publication number	US-10653979-B2
Application number	US-201514682898-A
Country	US
Kind code	B2
Filing date	Apr 9, 2015
Priority date	Apr 10, 2014
Publication date	May 19, 2020
Grant date	May 19, 2020

Abstract

A filter element has an upstream and downstream side. A filter media assembly of the filter element has an upstream side and a downstream side and has a first filter media layer and a second filter media layer that is adjacent to the first media layer. A substantial portion of the first layer and second layer are uncoupled, and at least one of the first media layer and second media layer comprises binder fiber. The second media layer has a mean flow pore size equal to or smaller than the first media layer. A support layer system is adjacent to the downstream side of the filter media assembly, and a first wire mesh layer is adjacent to the support layer system. At least the first media layer, second media layer, support layer system, and first wire mesh cooperatively define pleats at a pleat packing density of greater than 125%.

First claim

We claim:

1. A filter element having an upstream side and a downstream side, the filter element comprising: a filter media assembly comprising a first layer of filter media and a second layer of filter media adjacent to the first media layer, wherein each of the first and second layers of filter media comprises a bicomponent fiber, wherein the first layer of filter media and the second layer of filter media has polyester fibers and glass fibers, wherein a portion of the first media layer and second media layer are uncoupled, and wherein the second media layer has a mean flow pore size equal to or smaller than the first media layer, wherein the filter media assembly comprises an upstream side and a downstream side; a support layer system adjacent to the downstream side of the filter media assembly; and a first wire mesh layer adjacent to the support layer system; wherein at least the first media layer, second media layer, support layer system, and first wire mesh layer cooperatively define pleats having a pleat packing density of greater than 125%, wherein each of the pleats have an equal pleat height wherein the first and second wire mesh layers each define a pattern of open areas, wherein the first wire mesh layer defines smaller open areas than the second wire mesh layer.

2. The filter element of claim 1 , wherein the pleats have a linear pleat density of no less than 16 pleats per inch.

3. The filter element of claim 1 , wherein a ratio of the β 200 particle efficiency rating of the first media layer to the second media layer is greater than 2.

4. The filter element of claim 1 , further comprising a second wire mesh layer positioned on the upstream side of the filter media assembly.

5. The filter element of claim 1 wherein the pleats defined by the first media layer, second media layer, support layer system, and first wire mesh layer have a pleat packing density of at least 130%.

6. The filter element of claim 1 having a particle efficiency of greater than 99.5% for 10 micron particles.

7. The filter element of claim 1 , having a clean pressure drop of less than 7 psid.

8. The filter element of claim 1 , wherein the filter media assembly is chemically compatible with phosphate-ester hydraulic fluids.

9. The filter element of claim 1 , wherein the ratio of the mean flow pore size of the first media layer to the second media layer is greater than 3.7.

10. The filter element of claim 1 , wherein the ratio of the maximum pore size of the first media layer to the second media layer is greater than 3.0.

11. A method of forming a filter element comprising: providing a first layer of filter media, a second layer of filter media adjacent to the first media layer, a support layer system, and a first wire mesh layer, wherein the second media layer has a mean flow pore size equal to or smaller than the first media layer, wherein each of the first and second layers of filter media comprises a bicomponent fiber, wherein the first layer of filter media and the second layer of filter media has polyester fibers and glass fibers, wherein a portion of the first media layer and second media layer are uncoupled; folding each of the first media layer, the second media layer, the support layer system, and the first wire mesh layer to form pleats at a linear pleat density of at least about 8 pleats per inch, and compressing the pleats of the first media layer, the second media layer, the support layer system, and the first wire mesh layer to a linear pleat density of at least about 17 pleats per inch and a pleat packing density of greater than 125%, whereby the pleats are under compression; wherein the filter element comprises an upstream side and a downstream side and the support layer system is adjacent to the downstream side and the first wire mesh layer is adjacent to the support layer system, and wherein each of the pleats have an equal pleat height, wherein the first and second wire mesh layers each define a pattern of open areas, wherein the first wire mesh layer defines smaller open areas than the second wire mesh layer.

12. The method of claim 11 , further comprising layering each of the first media layer, the second media layer, the support layer system, and the first wire mesh layer before folding, wherein folding comprises co-pleating the layers.

13. The method of claim 11 further comprising layering the first media layer, the second media layer, the support layer system, and the first wire mesh layer to form a filter element having an upstream side and a downstream side.

14. The method of claim 13 , wherein compressing occurs after layering the first media layer, the second media layer, the support layer system, and the first wire mesh layer.

15. The method of claim 11 , further comprising cutting the first media layer, the second media layer, the support layer system, and the first wire mesh layer into a segment.

16. The method of claim 15 , wherein the cutting occurs after folding and before compressing.

17. The method of claim 11 , further comprising providing a second wire mesh layer; folding the second wire mesh layer; and compressing the second wire mesh layer to a linear pleat density of at least about 17 pleats per inch.

18. The filter element of claim 1 wherein the pleats defined by the first media layer, second media layer, support layer system, and first wire mesh layer have a pleat packing density of up to 138%.

Assignees

• Donaldson Co Inc

Inventors

• Barsness James P
• Jones Derek O

Classifications

• B01D39/2024

  otherwise bonded, e.g. by resins · CPC title

• B01D29/21

  with corrugated, folded or wound sheets · CPC title

• B01D29/07 Primary

  with corrugated, folded or wound filtering sheets · CPC title

• B01D29/58

  arranged concentrically or coaxially · CPC title

• B01D2201/291

  End caps · CPC title