Pulse cleanable deep pleated industrial filter

Patent metadata

Field	Value
Publication number	US-11794142-B2
Application number	US-202017087980-A
Country	US
Kind code	B2
Filing date	Nov 3, 2020
Priority date	Nov 5, 2019
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

A filter media pack with pleat folds, pleat panels and a plurality of glue bead sections is provided. The glue bead sections provide increased rigidity, dimensional stability and maintain spacing between adjacent pleat panels. Methods of manufacturing the filter media packs are provided. Filter elements including the filter media packs are contemplated.

First claim

What is claimed is:

1. A filter element comprising:
a pleated media pack formed from a continuous sheet of filter media having opposed surfaces with a thickness therebetween, the pleated filter media having:
a plurality of pleat panels, each pleat panel of the plurality of pleat panels having a height;
a plurality of pleat folds, each pleat fold of the plurality of pleat folds interconnecting a corresponding pair of adjacent pleat panels of the plurality of pleat panels, each pleat fold having a fold inner side and a fold outer side, the height of each pleat panel being defined between the pleat folds associated with each pleat panel;
at each pleat fold, there is:
an outer glue bead section on the fold outer side extending across the pleat fold with the pleat fold interposed between opposed first and second ends of the outer glue bead section, the outer glue bead section having a first portion between the first end and the pleat fold and a second portion between the second end and the pleat fold;
a first inner glue bead section extending between first and second ends on the fold inner side overlapped with the first portion of the outer glue bead section, the first inner glue bead section is spaced away from the pleat fold and does not extend across the pleat fold;
a second inner glue bead section extending between first and second ends on the fold inner side overlapped with the second portion of the outer glue bead section, the second inner glue bead section is spaced away from the pleat fold and does not extend across the pleat fold;
when folded, the first and second inner glue bead sections at each pleat fold contact one another to secure the adjacent pleat panels interconnected by the pleat fold relative to one another.

2. The filter element of claim 1 , wherein:
a first distance is defined between the second end of the first inner glue bead section and the pleat fold;
a second distance is defined between the first end of the second inner glue bead section and the pleat fold; and
the second distance is different than the first distance.

3. The filter element of claim 1 , wherein a thickness of the first and second inner glue bead sections at each pleat fold measured perpendicular to the surfaces of the sheet of filter media are substantially the same.

4. The filter element of claim 1 , wherein the outer glue bead section at one pleat fold is on an opposite surface of the sheet of filter media as the outer glue bead section at another immediately adjacent pleat fold.

5. The filter element of claim 1 , wherein when the sheet of filter media is folded, the first portion of an outer glue bead at a first fold contacts the second portion of an outer glue bead at a second fold, the first and second folds not being connected to a same pleat panel.

6. The filter element of claim 2 , wherein:
at each pleat fold, each pleat panel interconnected by the pleat fold has a tapered portion extending outward from the pleat fold less than or equal to the second distance, the tapered portions tapering away from one another when moving away from the pleat fold.

7. The filter element of claim 6 , wherein the first distance is less than 10% of the height of the pleat panels.

8. The filter element of claim 6 , wherein:
each pleat panel has:
two tapered portions, one tapered portion associated with each pleat fold connected to the pleat panel;
a parallel portion formed between the tapered portions;

the parallel portions of adjacent pleat panels being parallel with one another, when the filter media sheet is folded about the pleat folds.

9. The filter element of claim 8 , wherein each parallel portion has a length that is at least 80% of the height of the pleat panel.

10. The filter element of claim 6 , wherein a thickness of any glue forming any glue bead or beads between adjacent tapered portions proximate each pleat fold is less than twice a thickness of any one of the outer glue bead section, the first inner glue bead section or the second inner glue bead section.

11. The filter element of claim 1 , wherein no glue bead extends across the pleat fold on the inner side of the pleat folds.

12. The filter element of claim 1 , wherein:
the plurality of pleat folds alternate between being folded in a first fold direction and a second fold direction that is opposite the first fold direction; and
for each pleat fold, the fold inner side is positioned between the corresponding pair of adjacent pleat panels that are interconnected by the pleat fold formed by one of the opposed surfaces of the filter media and the fold outer side is formed by the other one of the opposed surfaces of the filter media.

13. The filter element of claim 1 , wherein there are at each pleat fold:
a plurality of outer glue bead sections that are laterally spaced apart along the pleat fold;
a plurality of first inner glue bead sections that are laterally spaced apart along the pleat fold; and
a plurality of second inner glue bead sections that are laterally spaced apart along the pleat fold.

14. The filter element of claim 13 , wherein:
the lateral spacing between adjacent ones of the outer glue bead sections of the plurality of outer glue bead sections is no greater than 2″;
the lateral spacing between adjacent ones of the first inner glue bead sections of the plurality of first inner glue bead sections is no greater than 2″; and
the lateral spacing between adjacent ones of the second inner glue bead sections of the plurality of second inner glue bead sections is no greater than 2″.

15. The filter element of claim 1 further comprising:
an external cover surrounding the pleated media pack; and
a reinforcing grid extending across at least one flow face defined by a plurality of the pleat folds, the reinforcing grid including a support flange that extends outboard of the filter media pack; and
a seal member carried by the support flange.

16. The filter element of claim 1 , wherein the filter media includes a gradient density layer including a layer of coarse nanofibers layered over a layer of finer nanofibers, the coarse nanofibers being upstream of the finer nanofibers.

17. The filter element of claim 16 , wherein the filter media includes a base layer of filter media, the layer of finer nanofibers being positioned between the coarse nanofibers and the base layer of filter media.

18. A filter arrangement comprising:
a filter element according to claim 1 , the filter element including:
a support grid mounted to an outlet face of the filter media pack, the support grid including a plurality of grid bars that extend outward from the outlet face at a non-perpendicular, non-parallel angle relative to the outlet face.

19. A method of forming a filter element according to claim 1 , the method comprising;
forming a pleated media pack from continuous sheet of filter media having opposed surfaces with a thickness therebetween, forming the pleated filter media pack includes:
folding the continuous sheet of filter media to form a plurality of pleat panels interconnected by a plurality of pleat folds, each pleat panel of the plurality of pleat panels having a height, the height of each pleat panel being defined between the pleat folds associated with each pleat panel, each pleat fold of the plurality of pleat folds interconnecting a corresponding pair of adjacent pleat panels of the plurality of pleat panels, each pleat fold having a fold inner side and a fold outer side;
at each pleat fold, further comprising:
applying an outer glue bead section on the fold

Assignees

• Canfield Jeff A
• Ladwig Jeffery M
• Kadavy Dale R
• Parker Hannifin Corp

Inventors

• Canfield Jeff A
• Ladwig Jeffery M
• Kadavy Dale R

Classifications

• B01D46/523 Primary

  with means for maintaining spacing between the pleats or folds · CPC title

• B01D46/0001

  Making filtering elements · CPC title

• B01D46/0002

  Casings; Housings; Frame constructions · CPC title

• B01D46/522 Primary

  with specific folds, e.g. having different lengths · CPC title

• B01D46/546

  using nano- or microfibres · CPC title