Surface coated filter method

Patent metadata

Field	Value
Publication number	US-2019105593-A1
Application number	US-201715999284-A
Country	US
Kind code	A1
Filing date	Feb 9, 2017
Priority date	Feb 19, 2016
Publication date	Apr 11, 2019
Grant date	—

Abstract

A filter element is provided. The filter element includes a filter media pack including an outer surface. The outer surface extending between a first flow face and a second flow face. The filter element also includes a polymeric coating applied to the outer surface of the filter media pack, wherein the polymeric coating is not a molded structure. In embodiments, the polymeric coating covers at least 25% of a span between the first flow face and the second flow face and has an average thickness of between 0.005 and 0.100 in. In other embodiments, the polymeric coating has a surface roughness of at least 50 μin to provide an outer gripping surface. A method and system for applying the polymeric coating to the filter element are also provided.

First claim

1 . A filter element, comprising:
a filter media pack including an outer surface, the outer surface extending between a first flow face and a second flow face; and a polymeric coating applied to the outer surface of the filter media pack, wherein the polymeric coating is not a molded structure.

2 . The filter element of claim 1 , wherein the polymeric coating has a surface roughness of between about 50 and about 10,000 μin.

3 . The filter element of claim 1 , wherein the polymeric coating penetrates the filter media pack to a depth of at least 9,000 μin.

4 . The filter element of claim 1 , wherein the polymeric coating comprises a spray coating layer.

5 . The filter element of claim 1 , wherein the polymeric coating is a roll coating layer.

6 . The filter element of claim 1 , wherein the polymeric coating has a Shore A Durometer hardness of between about 60 and about 95.

7 . The filter element of claim 1 , wherein the coating is comprised of at least two layers.

8 . The filter element of claim 7 , wherein at least one layer is a polyurea material.

9 . The filter element of claim 1 , wherein the polymeric coating is selected from the group consisting of urethane, acrylic, epoxy, silicone, polyurethane, polyurea, polyaspartic, polymer, aliphatic polyurea, polystyrene, polyethylene, ethylene-vinyl acetate, polyethylene-vinyl acetate, ethylene propylene diene monomer, polyurea/polyurethane hybrid, and combinations thereof and wherein the polymeric coating optionally includes fiberglass, roughening agents, or other fillers.

10 . The filter element of claim 1 , wherein the filter media pack is constructed of a filter media and comprises a fluted filter media filter pack comprising a face sheet and a fluted sheet in a wound or stacked configuration for form a plurality of layers such that unfiltered fluid must pass through the face sheet or the fluted sheet to pass from the first flow face to the second flow face.

11 . The filter element of claim 10 , wherein a span from the first flow face to the second flow face is at least 8 centimeters.

12 . The filter element of claim 10 , wherein the fluted filter media filter pack is a wound pack having an annular shape, a leading edge of the wound pack being in a radial center of a pack and a trailing edge of the wound pack being along the outer surface forming a step, the polymeric coating filling in and sealing the step and preventing unfiltered fluid flow leakage from the first flow face to the second flow face, without any additional materials applied along the step between the polymeric coating and the fluted filter media filter pack.

13 . The filter element of claim 1 , wherein the filter element is a pleated filter element constructed of a filter media and comprising a plurality of pleat flanks extending between pleat tips at the first flow face and pleat tips at the second flow face, wherein fluid must pass through the filter media to pass from the first flow face to the second flow face, the polymeric coating applied to a leading-most pleat flank and a trailing-most pleat flank.

14 . The filter element of claim 13 , wherein the polymeric coating is also applied along edges of the pleat flanks that extend transverse to the leading-most pleat flank and the trailing-most pleat flank.

15 . The filter element of claim 1 , wherein the filter media pack first flow face and the second flow face are free of the polymeric coating.

16 . The filter element of claim 1 , wherein the polymeric coating has been applied to at least 25% of a surface area of the outer surface between the first and second flow faces.

17 . The filter element of claim 16 , wherein a seal is attached to the polymeric coating.

18 . The filter element of claim 1 , wherein the filter media pack maintains its volume during a storage period after the polymeric coating has been applied, the polymeric coating restraining the media pack from expanding and limiting any expansion in perimeter of the outer surface to less than 5%, when subjected to 100% humidity for a period of 48 hours.

19 . The filter element of claim 1 , further comprising a border gasket having housing sealing surface, the border gasket secured to the polymeric coating in surrounding relation to the filter media pack.

20 . The filter element of claim 19 , wherein the border gasket is molded in place and integrally bonded to the polymeric coating.

21 . The filter element of claim 20 , wherein the border gasket is formed from a seal material being of a compatible bonding material to the polymeric coating and comprising at least one of polyurethane, urethane, and silicone.

22 . The filter element of claim 1 , wherein the polymeric coating is impermeable to air and moisture.

23 . The filter element according to claim 1 , wherein filter media pack comprises a filter media having the following properties:
a basis weight of between 2 and 4 ounces/square yard;
an air permeability of between 5 and 20 [email protected] inch of water gauge pressure, measured according to ASTM F778-88 (2014); and
a Mullen burst strength of at least 15 PSI.

24 . The filter element according to claim 1 , wherein the filter media is an air filtration media having an initial efficiency of at least 99.6% at removing ISO 12103-1 A2 Fine Test Dust, measured according to ISO 5011 test standard, and wherein the air filtration media comprises a layer containing at least one of cellulose, polymer, or glass fibers having an average diameter of between 1 and 200 micron.

25 . The filter element according to claim 1 , wherein said filter media forms the outer surface of the filter media pack.

26 . The filter element according to claim 1 , wherein the filter element is free of metal or plastic preformed component parts.

27 . The filter element according to claim 1 , wherein the polymeric coating provides a complete surrounding seal between the filter media pack and at least one of housing gasket or a metal or plastic preformed component part.

28 . The filter element according to claim 1 , further comprising a metal or plastic preformed component part attached to the filter media pack, wherein the polymeric coating overlaps an outward facing exterior surface portion of the metal or plastic preformed component part.

29 . The filter element according to claim 1 , wherein the polymeric coating has an average thickness of between 0.005 and 0.100 in.

30 . A filter element comprising:
a filter media pack including an outer surface, the outer surface extending between a first flow face and a second flow face; a layer applied to the outer surface and in surrounding relation of a filtering region of the filter media pack, the layer has a surface roughness of at least 50 μin to provide an outer gripping surface.

31 . The filter element of claim 30 , wherein the layer is a polymeric coating comprising a material that is integrally bonded to and penetrates into the outer surface of the filter media pack.

32 . The filter element of claim 31 , wherein the material penetrates to a depth of at least 9,000 μin into the outer surface of the filter media pack.

33 . The filter element of claim 30 , wherein the surface roughness is up to 10,000 μin.

34 . A filter element comprising:
a filter media p

Assignees

• Krull Timothy L
• Epperson Matthew K
• Pokorney Daniel P
• Von Seggern Michael J
• Baldwin Filters Inc

Inventors

• Krull Timothy L
• Epperson Matthew K
• Pokorney Daniel P
• Von Seggern Michael J

Classifications

• B01D25/001

  Making filtering elements not provided for elsewhere · CPC title

• B01D46/525 Primary

  which comprises flutes · CPC title

• B01D46/0004

  Details of removable closures, lids, caps or filter heads · CPC title

• B01D46/0002

  Casings; Housings; Frame constructions · CPC title

• B01D46/52

  Particle separators, e.g. dust precipitators, using filters embodying folded {corrugated or wound sheet} material · CPC title